Retail produce box and method for selling a variety of produce therein
There is provided an improved retail produce box, preferably for fresh potatoes. Each box comprises a bottom wall, four side walls with beveled corners where adjacent side walls meet, said bottom wall and side walls defining a substantially rectangular box interior. That interior is covered by a lid made from folded over extensions of two opposed side walls with one of said lid extensions at least partially overlapping the other lid extension to minimize light penetration into the box interior and allow for some settlement of contents after filling. The bottom wall may have a plurality of apertures for visual inspection of the contents and facilitating air circulation within. Preferably, the overlapping lid extension includes a hinged and tabbed section that can be flipped open for visually inspecting the box contents and lowered back down after. A plurality of such boxes, in various produce quantities, may be boxed together for shipping in a master container. A method for selling varying produce in the same box entails inserting a divider into that box to form chambers into which different varieties of potatoes, or potatoes along with other produce like onions, may be packaged.
This application claims priority to U.S. Provisional Application Ser. No. 61/195,327, filed on Oct. 6, 2008, the disclosure of which is fully incorporated by reference herein.
BACKGROUND OF THE INVENTIONThe packaging, transportation, retail display and storage of fresh vegetables and fruits require special environmental conditions, such as temperature, humidity, light, etc., for maintaining the freshness of such products in terms of food value and appearance until purchased and consumed. Proper packaging of such foods plays an important role in achieving desirable results.
Many types of produce packages are known. One common variety is a corrugated paperboard (fiberboard) container which is lightweight and readily available at relatively low cost. Corrugated paperboard/cardboard is also biodegradable and environmentally acceptable. Although such containers are commonly used for the packaging and distribution of wholesale quantities of produce, they are less often used for packaging smaller quantities of many kinds of produce including potatoes, onions, citrus and other fruits. Smaller quantities are usually presented loose, in paper and/or plastic net bags for retail purchase.
In instances when corrugated cartons are used, it is common practice to utilize one of the many standardized containers already available from manufacturers. Various container designs have been adapted from the bulk transportation of goods in their varying types, sizes and weights. Standard container designs and related specifications are primarily directed to parameters defining a container's carrying capacity and strength e.g. in terms of resistance to bursting or crushing under the various applied forces to which containers are subjected during transportation and storage. Much less attention has been paid to providing containers for the special environmental requirements of certain produce especially in the lesser quantities suitable for retail carry out.
When produce is sold in loose, bulk form, the consumer has the chore of picking through a display, selecting for acceptable quality, and bagging the selections for purchase. However, the handling of easily bruised fruits and vegetables in bulk, and their general deterioration due to exposure to the elements, result in considerable loss (or “shrink”) to the retailer. When fresh produce is packaged in other container forms like paper or plastic bags, the quality range in terms of product size, form and appearance is determined by the packager and may not suit the needs or desires of smaller volume retailers and/or their consuming public. In either case, the attention and care needed to maintain special quality characteristics is often lacking or minimal. Potatoes, for example, are subject to greening on excessive exposure to natural or artificial light. Accordingly, the bulk presentation/display of potatoes, especially white or yellow potatoes, in light-admitting containers can result in rapid, quality deterioration.
During storage, apples and other fruits give off ethylene gases which must be removed to maintain their “shelf” quality. Humidity control, where required, is difficult or impossible to achieve when produce is handled in bulk quantity lots, substantially open or fully closed containers. The size and shape of some produce, such as potatoes, is also critical for appearance and impacts the manner of cooking to be employed. In a microwave oven, for example, cooking time is a function of food item size. If the produce to be microwaved differs greatly in size, some may be overdone and others underdone.
Containers and boxes for potatoes and other produce items are known in the art. However, prior art containers suffer from one or more mechanical or economic disadvantages making them less than entirely suitable for their intended purpose.
One prior art potato carton/box is shown in Corso U.S. Pat. No. 5,018,663. While that carton was satisfactory for shipping and displaying extra grade potatoes, it did not achieve widespread use due to economic considerations.
Several years later, there was disclosed a reusable plastic container for shipping multiple cobs of corn in Hatton U.S. Pat. No. 5,642,854. That container had a locking lid and water access ports or holes.
A folding box for containing specimen samples was shown in Baumgärtner et al. U.S. Pat. No. 5,934,549. It had an inner and outer lid all of which could be made from a precut blank of cardboard.
The fiberboard blank for the container of Grabowski et al. U.S. Pat. No. 6,237,840 focused on an improved hand hole configuration. And a top, recessed handle was the subject of a family of patents all assigned to Weyerhaeuser. See, McKenna et al. U.S. Pat. Nos. 7,306,136, 7,306,137 and 7,314,158.
BRIEF DESCRIPTION OF THE INVENTIONOne objective of the present invention is to provide a produce box having a lid that allows for settlement of contents after filling and during shipment to its resale destination. A related objective of the invention is to provide a produce box that protects the box contents from most light until a prospective customer views the contents. Yet another objective provides a produce box with bottom viewing and venting holes or apertures while not interfering with structural rigidity especially when stacked high for transport and/or sales display.
Another objective of this invention is to provide a produce box, especially for holding fresh potatoes, that is efficient and economical to use. That box should be adaptable to filler machinery that dumps fresh potatoes directly into same. A further objective is to provide such a box in a variety of sizes, including 5 lb., 4 lb. 3 lb., 2.5 lb., 2 lb. and 1 lb. equivalents (all acceptable to Food and Drug Administration standards for produce shipping and storage). It is another objective to provide such boxes for common packing in a master container having dimensions and configuration suitable for standardization in the produce industry. An additional objective is to provide a master container holding 2 or more rows or layers of produce/potato boxes, with a lower row/layer including larger boxes than an upper layer situated above that lower layer. Yet another objective is to provide a master container holding 10 or more of the individual potato boxes, the master container being suitable for stacking on pallets for transport by truck and/or railcar.
Therefore, it is a primary objective of this invention to provide an improved, “hand-carryable” corrugated cardboard container for packaging, transporting and storing fresh produce, particularly items of a pre-selected size, and for aiding in the freshness maintenance of that produce by limiting light access to the container interior while providing a limited degree of air circulation. Such containers will promote the maintenance of desirable temperature and humidity conditions within the container while providing visual consumer access to the interior and its contents. With the use on internal container dividers, it is expected that the boxes of this invention may be filled with a variety of produce, either in the same field (as in both white and red potatoes) or in smaller serving convenience packs with other produce (like combinations of potatoes with onions, carrots, celery and/or garlic, for instance).
Further features, objectives and advantages of the present invention will become clearer when referring to the following detailed description of preferred embodiments made with reference to the accompanying drawings in which:
For every numerical range set forth herein, it should be noted that all numbers within the range, including every fraction or decimal between its stated minimum and maximum, are considered to be designated and disclosed by this description. As such, herein disclosing a preferred box weight limit between about 1 and 5 pounds of produce expressly includes box content levels of about 1.2, 1.5, 1.75 and 2 lbs. . . . and so on, up to about 4.5, 4.75 and 4.99 lbs. of deliverable produce.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of this invention, the preferred methods and materials are described herein.
Referring now to
In
Once each master container 10 of filled boxes is readied, it may be stacked, five master containers per tier and about 4 tiers high on a typical shipping pallet 20 as shown in
The design of produce containers according to this invention takes into account: (1) internal container dimensions which provide an interior volume accommodating produce of pre-selected size and specified number and weight; and (2) specification of corrugated sheet material which, while suitable for construction of containers having the required internal volume, can also be used for constructing containers which: (a) have outside dimensions such that a specified, integral number of containers will provide a full layer on a standard pallet bed; (b) accommodate a weight of contents such that a specified number of layers of containers on a pallet will provide a full pallet loading, and (c) have a compression strength sufficient to resist crushing and bursting when the containers are vertically stacked on the pallet in a sufficient number of layers to provide a roughly 2000 pound pallet loading.
With the foregoing combination of master containers/pallets, retailers can be provided with a more diverse array of produce packaging, i.e., in varying quantities of pounds per delivery. This is especially practical for smaller stores that are not supermarket chains or otherwise linked to larger distribution centers. It also allows organic grocery operations to provide their customers with greater selection in amount of materials purchased. All the while, these boxes provide consumer inspection capabilities and enhanced protection from the light thereby increasing produce shelf life and reducing losses due to spoilage from light.
The produce boxes of this invention are all preferably made from double-faced corrugated paperboard or cardboard sheet material, 100% recycled material. Most preferably, these boxes are made from cardboard stock having 125-150 psi burst strength with a B flute. The wall thicknesses for each box may be as thin as about ⅛ inch. The box embodiments in the accompanying
The boxes of this invention define hand holes for ease in carrying. In instances where the hand holes pass completely through all side wall layers and into the box interior proper, they further provide some air flow ventilation which allows for some produce degassing. Either embodiment of box lid, with or without flip top view ports, provides a beneficial a settlement feature that allows for overstuffing to some extent and accommodating some settling of contents during shipping without adversely affecting appearance.
The box, generally 30, comprises a bottom wall 32, a first pair of opposed side walls 34L and R; and a second pair of opposed side walls 36F and B. Together, the bottom wall 32 and four side walls 34L and R, 36F and B define a substantially rectangular box interior, indicated by arrow 38 in
The foregoing box 30 has a lid made from folded over extensions from two opposed side walls, elements 36F and B in the accompanying Figures. The first lid extension 42F from side wall 36F will be at least partially overlapped by the second lid extension 42B from side wall 36B. For this embodiment, the overlapping configuration of lid extensions 42F and B still permit some viewing of the produce contents. In fact, up to 80% of the potatoes in box 30 may be viewed when the lid 42F and B is fully opened. Better viewing of the contents leads to improved customer satisfaction. Paper and plastic bags generally permit viewing of less than 50% of their contents. More importantly, the lid 42F and B of this embodiment still protects the produce deposited within box interior 38 by substantially shielding potatoes and the like from “greening”. The greening of potatoes, especially white, yellow and gold varieties, is accelerated with exposure to light, either natural or artificial. And such greening poses a food safety risk. Greened potatoes emit a toxin which may cause the person consuming same to experience an upset stomach or intestinal disruptions. Accordingly, many retailers scour their stock for the onset of greening in order to pull such potatoes from sale and discard same.
Within bottom wall 32 of box 30, there is shown two sets of diamond-shaped apertures 44L and R. (While shown as sets of diamonds for easier die-cutting, it is understood that still other aperture shapes may be accommodated by this invention.) In a fully assembled box, such aperture sets 44L and R in the box bottom wall provide consumers with further means for visually inspecting a container's contents. To avoid any loss of contents, the individual openings comprising each aperture set should have a maximum dimension less than the minimum dimension of the intended produce to be packaged therein the container. Such openings are arranged in patterns wherein sufficient sheet material remaining between so as to avoid reduction of the strength of the assembled box container. Most useful for such purpose are a set of apertures in a parallelogram or “diamond” shape arranged horizontally, i.e. with their longer pattern dimension generally parallel to the box's front and back opposed side walls 36F and B, resulting in a generally “X-shaped” lattice area pattern that still provides maximum strength of the remaining bottom wall area.
As illustrated in
In cases where some degree of control of humidity within the container is desirable, the corrugated paperboard sheet material of which the container is constructed may contain a moisture-resistant material. For example, a mixture of cornstarch and caustic soda may be provided in the flutes of double-faced corrugated paperboard sheet. The additive will help reduce the “sweat” effect that occurs when certain products are removed from produce coolers. Moisture-resistant materials provide a box container that assists with maintaining freshness quality of the contained produce. An additional advantage of such construction is improved crushing and bursting strength by said material reducing the amount of water absorbed by naturally hygroscopic paperboard.
There are several alternate embodiments of this invention included herein. In these alternatives, elements common to the box of
The second embodiment of box 130 similarly includes a first lid extension 142F from side wall 136F and a second lid extension 142B from side wall 136B. In this case, however, first lid extension 142F is provided with a viewing aperture 146 through which access to box interior 138 can be achieved. On the overlapping lid portion of this embodiment, second lid extension 142B is pre-scored into a substantially trapezoidal shaped box lid 150. That trapezoidal box lid 150 is scored along most of its back edge 152 in a line substantially parallel to the fold edge 154 between lid extension 142B and sidewall 136B. On either side of score line 152, there is a segment of lid extension 142B that remains connected to serve as the left and right hinge sections 156L and R for trapezoidal box lid 150.
Along the trapezoidal side legs 158L and R to trapezoidal box lid 150, there is situated means for engaging that box lid 150 with most of the remainder to lid extension 142B. In
Referring now to
Referring now to
Preferably, the top edges of any divider should not reach all the way to the box lid so as to form compartments completely closed from one another. Rather, the divider insert should be spaced below a closed lid for allowing some air circulation between compartments.
With the foregoing divided box container, it is possible to pack, ship and market combinations of produce in lesser quantities such as those required by one person rather than family quantities of same. When divided into two or more separate compartments, the interior volumes of such boxes may be packaged as “sampler packs” addressing more than one variety of potatoes, i.e. red and whites together, whites and yellows, etc. Alternately, one may pack and sell varieties in several pre-selected grades, i.e. small russets and larger baking sized Idaho potatoes. Finally, subdivided boxes allow for the combination of potatoes with still other produce, including but not limited to sets of onions, carrots, celery and/or garlic for possibly marketing adjacent meat displays as part of a stew making promotion.
In
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Claims
1. A corrugated cardboard box for transporting and displaying fresh produce, said box comprising: (a) a bottom wall; (b) four side walls which define a substantially rectangular box interior, said box interior having a beveled corner where adjacent side walls meet; and (c) a lid made from folded over extensions from two opposed side walls with one of said lid extensions at least partially overlapping the other lid extension when assembled for minimizing light penetration into the box interior, said combination of beveled corners and overlapping lids providing said box with sufficient rigidity for greater transportation loading and display stacking.
2. The box of claim 1 which further comprises at least one hand hole that extends at least partially through each of two opposed side walls.
3. The box of claim 2, wherein said hand holes extend completely through said opposed side walls.
4. The box of claim 1, wherein the bottom wall further comprises a plurality of spaced apertures for some produce degassing and content inspection when flipped over.
5. The box of claim 1 which further comprises at least one divider insert for separating the box interior into two or more compartments, each compartment adapted for housing a separate type of produce.
6. The box of claim 5, wherein the compartments are substantially equally sized.
7. The box of claim 5, wherein one compartment may hold a first variety of potato and a second compartment a second variety of potato.
8. The box of claim 5, wherein a first compartment may hold one or more varieties of potatoes, and a second compartment a variety of onions.
9. The box of claim 8, wherein a third compartment may hold a variety of other produce selected from the group consisting of carrots, celery and garlic.
10. The box of claim 1, wherein the overlapping lid extension further comprises a hinged and tabbed section which can be manually flipped open for visually inspecting produce in the box interior and lowered back down after inspection.
11. The box of claim 11, wherein the hinged and tabbed section is substantially trapezoidally shaped.
12. The box of claim 1 which, after being packed with fresh produce, may be combined with other similar boxes in a master container having two or more tiers of such packed boxes.
13. A box for transporting and displaying one or more varieties of potatoes, said box being made from a folded blank of corrugated cardboard and comprising: (a) a bottom wall; (b) four side walls which define a substantially rectangular box interior, said box interior having a beveled corner where adjacent side walls meet; and (c) a lid made from folded over extensions from two opposed side walls with one of said lid extensions having a hinged, pre-cut section for manually flipping open to visually inspect the box interior and lowering back down after inspecting, said beveled corners and overlapping lids providing said box with minimized light penetration into the box interior and sufficient rigidity for greater transportation loading and display stacking.
14. The potato box of claim 13, wherein the hinged, pre-cut section is substantially trapezoidal in shape and frictionally engages with at least some areas of the lid adjacent to same.
15. The potato box of claim 13, wherein the hinged, pre-cut section includes at least one tabbed edge.
16. The potato box of claim 13 which further comprises at least one divider insert for separating the box interior into two or more compartments, each compartment adapted for holding a separate variety of potato.
17. The potato box of claim 13 which further comprises at least one divider for separating the box interior into a plurality of compartments, at least one of said compartments holding a produce other than potatoes, said produce selected from the group consisting of: onions, carrots, celery and garlic.
18. The potato box of claim 13, wherein at some portion of the box interior has been treated with a moisture-resistant material.
19. The potato box of claim 13 which further comprises at least one hand hole extending at least partially through each of two opposed side walls.
20. The potato box of claim 13, wherein at least one of the bottom wall and a side wall further comprises a plurality of spaced apertures for additional inspecting and some degassing.
21. A method for selling a variety of produce in a common retail box comprises:
- (a) providing a box made from a folded blank of corrugated cardboard, said box comprising: (i) a bottom wall; (ii) four side walls which define a substantially rectangular box interior, said box interior having beveled corners where adjacent side walls meet; (iii) a lid made from folded over extensions of two opposed side walls with one of said lid extensions at least partially overlapping the other lid extension and having a tabbed section that can be manually flipped open for visually inspecting the box interior and lowered back down thereafter; and (iv) at least one divider insert for separating the box interior into two or more compartments, each compartment adapted for holding a separate variety of produce, said beveled corners and overlapping lids providing said box with minimized light penetration into the box interior and improved rigidity during transportation loading and display stacking; and
- (b) filling a first box interior compartment with a first variety of produce and filling a second compartment with a second variety of produce.
22. The method of claim 21, wherein the compartments are substantially equally sized.
23. The method of claim 21, wherein the compartments are filled with different varieties of potatoes.
24. The method of claim 21, wherein one of the compartments is filled with a variety of potatoes and the other compartment with produce selected from the group consisting of: onions, carrots, celery and garlic.
Type: Application
Filed: Oct 2, 2009
Publication Date: Apr 8, 2010
Inventor: Thomas I. Corso (Pittsburgh, PA)
Application Number: 12/587,135
International Classification: B65D 5/46 (20060101); B65D 5/00 (20060101); B65D 5/42 (20060101); B65D 25/04 (20060101); B65B 1/04 (20060101);