SPICE PACKAGING SYSTEM

Abstract

A spice packaging system is provided that includes a plurality of packets for one or more spices, herbs or spice blends. Each packet includes a flexible packaging material that is impervious to light, gas and moisture. The packet has an exterior and a single or segmented enclosed and sealed interior space. A known volume of a single certified organic spice or herb is contained with the interior space of each packet, and an inert gas surrounds each known volume of the single certified organic spice or herb within the interior space.

Description

FIELD OF THE INVENTION

The present invention relates to flexible packaging and in particular to flexible packaging of known volumes of herbs, spices and other seasonings.

BACKGROUND OF THE INVENTION

Spices, both whole and ground spices and herbs, are provided in relatively large containers. These containers can be used multiple times and include a volume of spice or spice blend that is suitable for such a large number of recipes that the container would last for years. These containers, however, are not made of materials that are light, air and moisture resistant and do not contain seals that are capable of maintaining these spices in a fresh state for extended periods of time. This results in a substantial degradation in the flavor and aroma of these spices. Typically, a bulk spice in a large container will lose 10% of the aromatic oils per month. Ultimately, the spice will be discarded even after using only a small portion of the total volume in the container. In addition, it may be desired to purchase or carry only enough spice for a single use or two, for example when camping or on vacation. Currently, even the smallest available volumes of spices are not suitable for these uses.

SUMMARY OF THE INVENTION

The present invention is directed to a spice packaging system in which each spice is provided in multiple small packets, preferably single-use packets of 1-teaspoon size. Each packet keeps the spice fresh and protects the spice from light, air and moisture.

In one embodiment, a spice packaging system is provided that includes a plurality of packets such that each packet includes a flexible packaging material impervious to light, gas and moisture, an exterior surface, and an enclosed and sealed interior space. The flexible packaging material can include polyethylene terephthalate or can be a biodegradable material. A known volume of a single certified organic spice, for example one teaspoon or one tablespoon, is contained with the interior space of each packet. This spice can be whole or ground, for example to a grind size of about 1 mm to about 1.5 mm. In addition, an inert gas surrounds each known volume of the single certified organic spice with the interior space. This inert gas is preferably nitrogen. In one embodiment, the interior space includes two opposing sides, two opposing ends spanning between the sides, and a seal on one of the ends that is capable of being opened to access the interior space and subsequently closed to seal the interior space from light, gas and moisture intrusion.

In one embodiment, the interior space includes two opposing sides, two opposing ends, a primary seal on one of the ends capable of being opened to access the interior space and sealing the interior space from light, gas and moisture intrusion, and a secondary seal spanning across the interior space from one side to the other and disposed between the two ends, the secondary seal dividing the interior space into two chambers such that an equal portion of the known volume of spice is disposed in each chamber, the secondary seal capable of being selectively ruptured to reunite the two chambers without rupturing the primary seal. In one embodiment, the known volume is about 1 tablespoon, and the interior space further includes two secondary seals dividing the interior space into three chambers, each chamber comprising about 1 teaspoon of the spice. If desired, a grinder capable of grinding the spice and of holding an amount of spice to be ground substantially equivalent to the known volume of spice can be provided in the packaging system.

The packaging system also includes a method for packaging spices. This method includes, forming a sheet of flexible packaging material into a tube or any other desired shape. In one embodiment, a first end of the tube is sealed, and a desired quantity, e.g., one teaspoon, of a single certified organic spice is measured volumetrically. The desired measured volume of spice is introduced into the tube, and a short burst of inert gas is introduced into the tube following the introduced volume of spice. The short burst of inert gas has a pressure, flow and duration sufficient to ensure that the entire introduced volume of spice passes into the tube. The second end of the tube opposite the first end is then sealed. The end seals and flexible material are impervious to light, gas and moisture.

The measured volume of spice or herb can be a whole spice or a ground spice having a grind size of about 1 to about 1.5 mm. Therefore, the method can also include grinding the spice to the desired grind size prior to measuring and introduction into the packet. In one embodiment, introduction of the spice into the packet includes introducing separately each one of a plurality of discrete portions of the desired measured volume, and the short burst of inert gas is directed into the tube following the introduction of each one of the discrete portions of the desired measured volume. Secondary seals are established in the tube between any two portions of the spice in the tube. In one embodiment, the desired measured volume is about 1 tablespoon, and the plurality of discrete portions includes three discreet portions each comprising about 1 teaspoon. In one embodiment, each secondary seal is capable of being selectively ruptured to combine two adjacent portions without rupturing the seals located at the end of the tube. In one embodiment, the tube or other filling components can be vibrated or the electrostatic properties of the tube, the filling components or the desired measured volume of spice can be adjusted to facilitate introduction of the desired measured volume into the tube.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a first side of an embodiment of a spice packet for use in accordance with the present invention;

FIG. 2 is a plan view of a second side of the spice packet of FIG. 1;

FIG. 3 is a plan view of a first side of another embodiment of a spice packet in accordance with the present invention;

FIG. 4 is a view through line 4-4 of FIG. 3;

FIG. 5 is a plan view of one embodiment of multiple spice packets;

FIG. 6 is view through line 6-6 of FIG. 1; and

FIG. 7 is a schematic representation of an embodiment of a method for filling a spice packet in accordance with the present invention.

DETAILED DESCRIPTION

The present invention is directed to systems and methods for packaging spices, spice blends, herbs and seasonings. Any type of spice used as a flavor enhancer or garnish for food can be used in this system. Suitable spices include, but are not limited to, basil, dill, oregano, tarragon, salt, pepper, sugar, thyme, marjoram, mint, sage, lemon zest, orange zest, chile pepper, coriander, cumin, fennel seed, ginger, turmeric, all spice, anise seed, cardamom, cinnamon, cloves, nutmeg, ancho chile pepper, bay leaves, peppercorns true cinnamon, cocoa, vanilla and blends of these herbs and spices. These spices can be processed and packaged as whole, i.e., uncut, spices or can be ground or chopped. For example, the spices can be subjected to a “tea bag” grind, having a ground size of about 1 mm to about 1.5 mm. This size is particularly advantageous for the processing and packaging of spices that are sticky or tacky. The spices can be processed and packaged as single spices or as spice blends. Examples of blends include cinnamon sugar and cinnamon cocoa. In addition to dry spices, packaging systems and methods in accordance with exemplary embodiments of the present invention are used to package wet or liquid substances including oils, flavor infused oils, vinegar and personal hygiene items such as mouthwash and toothpaste.

In general, all of the spices processed and packaged in accordance with the present invention are certified organic. As used herein, a certified organic spice is a spice that meets the United States Department of Agriculture (USDA) requirements for an organic spice as defined in the appropriate rules and regulations and as certified by a competent federal or state level enforcement agency. Organic certification also includes any applicable foreign or international certification. The spices are certified organic from the beginning of the process through the final packaging. Therefore, no foreign substances, additives or preservatives are used, including anti-caking agents and flow agents that would enhance the processing of the spices. In addition, the spices are not irradiated.

Referring initially to FIGS. 1 and 2, an exemplary embodiment of a spice packaging system 100 in accordance with the present invention is illustrated. The system includes a plurality of packets containing the desired spice or spices. One such packet is illustrated. As illustrated, the packet is generally rectangular or elongated in appearance and has a length from about 3″ to about 5″ and a width up to about 1″. Since the package is made of flexible material, the elongated shape can be formed into a generally tubular or cylindrical shape for the purposes of filling the packet with a single spice, a spice blend or a liquid. Other suitable shapes for the packet include spherical shapes, conical or circular shaped and rectangular box shapes.

Each packet in the plurality of packets is formed from a flexible packaging material impervious to light, gas and moisture. Therefore, spices contained within the package will have a long shelf life of up to ten years or more. Suitable flexible packaging materials include single layer materials and laminates of multiple materials such that each layer in the laminate provides a given type of protection to the contents in the packet. In addition, the layers can be either partially or completely transparent or translucent. Suitable materials for the flexible packaging include, but are not limited to, polyethylene, polystyrene, polyvinyl chloride, polyamides, polycarbonates, cellulose acetate, coated cellophane, rubber hydrochloride, paper and metal foils such as aluminum foil. In one embodiment, the flexible packaging material includes polyethylene terephthalate. For example, the flexible packaging can have an inner layer of polyethylene terephthalate (PET) that is in direct contact with the spices and an outer layer of PET or of a material such as cellulose acetate or another layer of polyethylene terephthalate. In addition, an intermediate metal foil layer is disposed between the inner and outer layer.

In one embodiment, a poly/foil/poly laminate is used with the specification “48 Ga PET/0.00035. Therefore, an intermediate foil layer having a thickness of 0.00035 is sandwiched between two PET layers. The inner PET layer can be transparent, and the outer PET layer can be opaque and can include colors or other graphics. If desired, the inner PET layer can be omitted. The thickness of the foil layer is the minimum thickness necessary to provide the desired level of protection to the spice contents from air, light or moisture. In another embodiment, the packaging material is paper coated, i.e., has an exterior paper mat finish. A suitable specification for this embodiment is 25#paper/9#PI/0.00035Foil/0.00015CoexLDPE, which is a 25# paper exterior outer wrap surrounding a 9# PI layer and a 0.00015 thick coextruded low density polyethylene interior layer with the 0.00035 foil layer sandwiched between the inner and outer layers. In another embodiment, the packaging material is a brown plastic film laminate with the specification 48gaugePET/10#tan/0.00035Foil/0.0002 metalycine. A 48 gauge PET, tan, outer layer and a 0.0002 outer metalycine inner layer, which is similar to surlyn, surround the 0.00035 foil intermediate layer. A paper layer can also be included to give the packaging a mat appearance and to facilitate the addition of printing or graphics. In one embodiment, the packaging material includes a biodegradable material such as a corn starch based polymer. The overall thickness of the packaging material is up to about 100 μm and preferably from about 20 μm to about 50 μm.

As is best shown in FIG. 6, the packet 102 includes an exterior 602 and an enclosed and sealed interior space 604. A known volume of a single certified organic spice 606 is contained with the interior space of each packet. The spice volume can completely or partially fill the interior space of the packet. In order to preserve the freshness of the spices, any voids between the spice granules as well as any interior space not filled with spice is filled with an inert gas. Therefore, the inert gas surrounds each known volume of the single certified organic spice with the interior space. Preferably, this inert gas is nitrogen.

Although the packet, being made of flexible packaging, can be shaped into a generally cylindrical tube, the packet once filled with spice has a generally rectangular appearance. In this appearance, the packet and therefore the interior space or pocket, defined by the packet, includes two opposing sides 104 running the length of the interior space. These sides can be formed from bends, folds or creases in the flexile material or from heat seals or adhesive bonds. In one embodiment, the flexible packaging material is a single sheet of material that is formed into a tubular shape. A lengthwise bond 108, for example a heat seal, adhesive bond or physical fold or crimp bond, is provided to form the tube. In general, suitable methods and materials for bonding the flexible material are known and available in the art. The interior space also includes two opposing ends 106. These ends can be formed from folds in the material. In addition, one or both ends are initially open, for example to permit filling of the interior space with the single spice or spices and are subsequently sealed using any suitable sealing process. In one embodiment, a seal 110 is provided on at least one of the ends. Suitable seals protect the enclosed spices from light, gas and moisture that can degrade the enclosed spices. A wide variety of seals are available in the art. As illustrated, a seal is provided on both ends of the interior space or packet. In one embodiment, the seal is re-sealable in that the seal is capable of being opened to access the interior space and subsequently closed to seal the interior space from light, gas and moisture intrusion. Suitable reclosable seals include a semi-adhesive pressure seal or a “zip-lock” type seal.

In one embodiment, the end seals include mechanisms to facilitate the opening of the ends to expose the interior space and to access the spice. For example, each seal can contain a perforated line 112 running generally parallel to the end to facilitate tearing off a portion of the end to expose the interior space. Alternatively, each end can include a plurality of notches 114 that are used to start a tear in a direction generally parallel to the sides of the packet, exposing the interior space. Other methods to facilitate tearing the packet open are known and available in the art. In one embodiment, the packet includes different seals and tear mechanisms on either end to provide a different type of dispensing, either controlled or bulk. Alternatively, both ends of the packet have the same or similar seals and tearing mechanisms. In one embodiment, a spout 116 is provided at one of the ends in communication with the interior space. The tearing mechanism opens the spout, which provides flow control when emptying the contents of the interior space. Each packet can also contain markings including a volume marking 118 to indicate the volume of the spices or contents of the interior space, a identification 120 of the contents of the interior space, e.g., the name of the spice or spice blend, and organic certifications 122 among other markings.

The known volume contained within the interior space is chosen in accordance with the contents and the uses to which those contents are put. These volumes can be in English or Metric, i.e., SI, units, including liters, milliliters, cups, cubic centimeters (cc's), tablespoons, teaspoons and fraction thereof. These measurements are provided, however, in volumes as opposed to weights, as that is how the contents, for example spices, are used in recipes. Although larger volumes are possible, the packaging system of the present invention is particularly well suited for use with smaller volumes, for example fractions of a tablespoon, teaspoons and fractions of a teaspoon. A preferred volume is one teaspoon, as this is a convenient and common volume used in cooking. In addition, this is a small size that minimizes waste. Freshness is preserved since only one packet has to be opened for each teaspoon required. Therefore, other teaspoon packets are not opened, retaining freshness. Freshness contributes to enhanced spice flavor and aroma, improving the quality and taste of the foods prepared using these spices.

In order to provide for larger overall quantities of spices, multiple packets are provided. For example, a plurality of single packets, e.g., three one-teaspoon packets for a total of one tablespoon, are provided in a large package such as a box or carton. These multiple packets can be separate and grouped together or can be joined together as shown, for example, in FIG. 5. When joined together, the plurality of packets can be used together or can be separately, for example by tearing perforations located at different points or along the entire length of two adjacent packets. These packets can be joined along the sides or along the ends. Although illustrated as three packets groups together along the sides, a larger number of packets can also be grouped together. In addition, the grouping of packets, since the packaging material is flexible, can be formed into a roll, and can be placed in a dispenser that allows one packet to be dispensed at a time. In one embodiment, a plurality of one-teaspoon packets is provided in a box or metal tin, appropriately labeled. The metal tins are stackable and provide additional light and moisture protection for the spices contained in the packets. Each grouping of a plurality of packets can contain the same spice or spice blend. Therefore, different groupings of packets are provided, for example each in its own tin, each having a given spice. Therefore, an assortment of different spices is provided, and any given spice is available in a packet of a given small size, for example one teaspoon.

Referring to FIGS. 3 and 4, in one embodiment, the packet is a segmented package 300. In one embodiment, the materials and general shape of the segmented packet is the same as for the packet containing a single interior space. The segmented packet and, therefore, the interior space of the segmented packet include two opposing sides 302 and two opposing ends 304. At least one of the ends, and preferably both ends, includes a seal 306. In one embodiment, each end seal is a primary seal that is capable of being opened to access the interior space and sealing the interior space from light, gas and moisture intrusion. The primary seals can be re-sealable. In one embodiment, at least one secondary seal 308 is provided that crosses the packet and the interior space between the ends. The secondary seal spans across the interior space from one side to the other and is disposed between the two ends. In one embodiment, a single secondary seal is provided to divide the interior space into two chambers such that an equal portion of the known volume of spice is disposed in each chamber. Alternatively, a plurality of secondary seals 308 are provided that divide the interior space into a plurality of chambers 310 each containing an equal portion or fraction of the spice contained in the interior space. As illustrated, the segmented packet includes two secondary seals 308 that divide the interior space into three chambers. In this embodiment, for example, the known volume is one tablespoon, and each chamber includes one teaspoon of spice. Volume markings 312 are provided to show the overall volume and chamber volume.

In one embodiment, each secondary seal is capable of being selectively ruptured to reunite the two chambers adjacent that secondary seal without rupturing either primary seal, which would expose the spices contained within the interior space. Rupture of the secondary seals can be accomplished, for example, by applying pressure, i.e. squeezing, one or both of the chambers adjacent the secondary seal. Alternatively stretching force can be applied to the packet in the area of the secondary seal either parallel or perpendicular to the length of the seal. Rupturing of one of the secondary seals results in a reunited chamber 402 (FIG. 4), and, therefore, a combining of the volume of spice contained in both chambers. The contents and spice volume of the reunited chamber are obtained by tearing the appropriate primary seal. Therefore, 2 teaspoons can be obtained or fractions, e.g., ⅓, of a teaspoon can be obtained from a single tablespoon or teaspoon without exposing the balance of the tablespoon or teaspoon to light or air that would degrade the spice. The balance of the spice is thus preserved for future use. The secondary seals can be the same type of seal as the primary seal but in a weaker, i.e., thinner configuration. Alternatively, the secondary seals can be different types of seals than the primary seals that are selected based upon relative rupture strength.

In one embodiment, the spice packaging system includes a grinder capable of grinding the spice contained in the packet. The grinder holds an amount of spice to be ground substantially equivalent to the known volume of spice. In one embodiment, the grinder has a one teaspoon capacity. This grinder can be metal, for example stainless steel, plastic, ceramic or combinations thereof. The grinder is useful when whole spices are contained in the packet or when a finer grind is required than the grind size of the spice contained in the packet.

The present invention is also directed to a method for packaging spices. Referring to FIG. 7, a sheet of flexible packaging material is formed into a tube 702, and a first end 706 of the tube is sealed 704. Suitable methods for forming the tube and sealing an end are available and known in the art. A desired quantity of a single certified organic spice 708 is measured volumetrically. In one embodiment a ring or dish 710 having the desired volume is used and filled with the spice. In one embodiment, this volume is one teaspoon. Since a teaspoon can vary slightly in volume, preferably the teaspoon is about 5 ml. The desired volume of spice is changed by changing the dish. In addition, segmented dishes can be used, for example to fill segmented packets. The desired volume of spice is passed through a funnel and introduced into the interior space 710 of the tube 702. A passage between the dish and funnel is selectively opened and closed. For example, the top of the funnel can include a plurality of holes, and the bottom of the dish can include a single hole. The dish rotates relative to the funnel, and the single hole in the bottom of the dish moves sequentially in and out of alignment with the holes in the funnel to provide for introduction of the spices into the packet. The dish is filled when the holes are not aligned, providing a continuous filling mechanism.

The present invention utilizes smaller volumes of spice, e.g., 1 teaspoon, and leafy or tacky spices prevent flow problems for the introduction of the spices into the tube. In addition, the certified organic nature of the spices does not permit the introduction of flow aids. Therefore, a short burst of inert gas 712 is directed into the tube following the introduced volume of spice. Preferably, this gas is nitrogen. The short burst of inert gas has a pressure, flow and duration sufficient to ensure that the entire introduced volume of spice passes into the tube. In addition, the volume of inert gas can be sufficient to substantially fill and inflate the interior space of the packet, providing a cushion-type protection for the spices contained in the packet. The second end 714 of the tube opposite the first end is then sealed (not shown) using any suitable sealing process. The first and second ends seals and the flexible material are impervious to light, gas and moisture, as described above.

The measured volume of spices can be whole spices or ground spices. In one embodiment, the spices are ground to a grind size of about 1 to about 1.5 mm. In addition to filling a single volume of spice within the tube, multiple portions of the desired volume of spice can be filled into the tube. This yields the segment packet or tube embodiment as described above. In one embodiment, introduction of the measured volume of spice of spice blend into the tube includes introducing separately each one of a plurality of discrete portions of the desired measured volume, for example using the segmented dish. Suitable methods for introducing a portion of a measured volume are known and available in the art. A short burst of inert gas is directed into the tube following the introduction of each one of the discrete portions of the desired measured volume. After each short burst and before the introduction of the next portion of the spice, a secondary seal is introduced in the tube between any two portions of the spice in the tube. Each secondary seal is capable of being selectively ruptured to combine two adjacent portions without rupturing the seals located at the end of the tube. Alternatively, the seals between the portions of the measured volume can be the same as the seals on the ends of the tubes. In one embodiment, the desired measured volume is about 1 tablespoon, and the plurality of discrete portions is three discreet portions each comprising about 1 teaspoon.

In addition to using the inert gas burst, other steps can be used to facilitate the introduction of the entire measured volume of spice into the tube. In one embodiment, the tube and filling equipment, e.g., dish and funnel, are vibrated. In addition, the electrostatic properties of the tube, the desired measured volume of spice and the filling equipment are adjusted to facilitate introduction of the desired measured volume into the tube.

While it is apparent that the illustrative embodiments of the invention disclosed herein fulfill the objectives of the present invention, it is appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. Additionally, feature(s) and/or element(s) from any embodiment may be used singly or in combination with other embodiment(s) and steps or elements from methods in accordance with the present invention can be executed or performed in any suitable order. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments, which would come within the spirit and scope of the present invention.

Claims

1. A spice packaging system comprising:

a plurality of packets, each packet comprising: a flexible packaging material impervious to light, gas and moisture; an exterior; and an enclosed and sealed interior space;

a known volume of a single certified organic spice contained with the interior space of each packet; and

an inert gas surrounding each known volume of the single certified organic spice with the interior space.

2. The spice packaging system of claim 1, wherein the interior space comprises:

two opposing sides;

two opposing ends; and

a seal on one of the ends capable of being opened to access the interior space and subsequently closed to seal the interior space from light, gas and moisture intrusion.

3. The spice packaging system of claim 1, wherein the interior space comprises:

two opposing sides;

two opposing ends;

a primary seal on one of the ends capable of being opened to access the interior space and sealing the interior space from light, gas and moisture intrusion; and

a secondary seal spanning across the interior space from one side to the other and disposed between the two ends, the secondary seal dividing the interior space into two chambers such that an equal portion of the known volume of spice is disposed in each chamber, the secondary seal capable of being selectively ruptured to reunite the two chambers without rupturing the primary seal.

4. The spice packaging system of claim 3, wherein:

the known volume comprises about 1 tablespoon; and

the interior space further comprises two secondary seals dividing the interior space into three chambers, each chamber comprising about 1 teaspoon of the spice.

5. The spice packaging system of claim 1, wherein the known volume of spice comprises about 1 teaspoon.

6. The spice packaging system of claim 1, wherein the flexible packaging comprises polyethylene terephthalate.

7. The spice packaging system of claim 1, wherein the inert gas comprises nitrogen.

8. The spice packaging system of claim 1, wherein the known volume of a single organic certified spice comprises a known volume of the whole spice.

9. The spice packaging system of claim 1, wherein the known volume of a single organic certified spice comprises a known volume of ground spice having a grind size from about 1 mm to about 1.5 mm.

10. The spice packaging system of claim 1, further comprising a grinder capable of grinding the spice and of holding an amount of spice to be ground substantially equivalent to the known volume of spice.

11. The spice packaging system of claim 1, wherein the flexible packaging comprises biodegradable packaging.

12. A method for packaging spices, the method comprising:

forming a sheet of flexible packaging material into a tube;

sealing a first end of the tube;

measuring a desired quantity of a single certified organic spice volumetrically;

introducing the desired measured volume of spice into the tube;

directing a short burst of inert gas into the tube following the introduced volume of spice, the short burst of inert gas comprising a pressure, flow and duration sufficient to ensure that the entire introduced volume of spice passes into the tube; and

sealing a second end of the tube opposite the first end, the end seals and flexible material impervious to light, gas and moisture.

13. The method of claim 12, wherein the desired measured volume comprises about 1 teaspoon.

14. The method of claim 12, wherein the measured volume of spice or herb comprises whole spice.

15. The method of claim 12, further comprising grinding the spice to a grind size of about 1 to about 1.5 mm.

16. The method of claim 12, wherein the inert gas comprises nitrogen.

17. The method of claim 12, wherein the step of introducing the desired measured volume further comprises introducing separately each one of a plurality of discrete portions of the desired measured volume, the step of directing a short burst of inert gas into the tube further comprises directing the short burst of inert gas into the tube following the introduction of each one of the discrete portions of the desired measured volume, and the method further comprises establishing secondary seals in the tube between any two portions of the spice in the tube.

18. The method of claim 17, wherein the desired measured volume comprises about 1 tablespoon and the plurality of discrete portions comprises three discreet portions each comprising about 1 teaspoon.

19. The method of claim 17, wherein each secondary seal is capable of being selectively ruptured to combine two adjacent portions without rupturing the seals located at the end of the tube.

20. The method of claim 12, further comprising at least one of vibrating the tube and adjusting the electrostatic properties of the tube or the desired measured volume of spice to facilitate introduction of the desired measured volume into the tube.