Packaging tray and method of use

Abstract

A packaging system for packaging food on a plurality of trays is provided. The packaging system has a main conveyor configured to move each of the plurality of trays about the packaging system and a tray unloader for unloading one tray from a tray stack onto the main conveyor. The packaging system has a food loader configured to place the food into each of the trays and a food accessory loader configured to place a food accessory into a storage compartment of each of the trays.

Description

This application claims the benefit of U.S. Provisional Application No. 61/363,017 filed Jul. 9, 2010 which is herein incorporated by reference in its entirety.

BACKGROUND

Embodiments of the inventive subject matter generally relate to field of storing and packaging food. More specifically, embodiments of the inventive subject matter generally relate a tray for storing meat. More specifically still, embodiments of the inventive subject matter relate to the tray having a border around the tray, the border may have a storage compartment. More specifically, embodiments relate to a machine for manipulating the tray.

Meats such as sausages may be packed in Styrofoam, or plastic containers. The containers are typically rectangular shaped and the meat is placed inside the container. A plastic film may then be placed over the meat in the container, and/or around the entire container. The inside of the container is a rectangular shape and does not conform to the shape of the meat. Therefore, the meat often slides to one side during the shipping and stocking of the meat.

Despite the development of techniques for packaging meats, there remains a need to provide advanced techniques for packaging meats in containers.

BRIEF DESCRIPTION OF THE DRAWINGS

The present embodiments may be better understood, and numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

FIG. 1 depicts a diagram illustrating a perspective view of a packaging tray having a storage space.

FIG. 2 depicts a diagram illustrating a top view of the packaging tray.

FIGS. 3A and 3B depict diagrams illustrating a top view of a portion of the packaging tray.

FIG. 4 depicts a diagram illustrating a side view of a plurality of packaging trays being nested together.

FIG. 5 depicts a diagram illustrating a perspective view of the packaging tray and a food item.

FIG. 6 depicts a diagram illustrating a schematic view of a packaging system for de-nesting the packaging tray.

FIG. 7 depicts a schematic view of the tray dispenser system according to one embodiment.

FIG. 8A depicts a top view of the packaging tray engaged with the tray dispenser.

FIG. 8B depicts a cross-sectional side view of the packaging tray with the tray dispenser.

FIG. 8C depicts a cross-sectional side view of the packaging tray with an alternate tray dispenser.

FIG. 9A depicts a top view of the packaging tray engaged with an alternate tray dispenser.

FIG. 9B depicts a cross-sectional side view of the packaging tray with the alternate tray dispenser.

FIG. 10 depicts a flow chart depicting a method for using the packaging tray.

DESCRIPTION OF EMBODIMENT(S)

The present embodiments may be better understood, and numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings. These drawings are used to illustrate only typical embodiments of this invention, and are not to be considered limiting of its scope, as the invention may admit to other equally effective embodiments. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.

FIG. 1 depicts a packaging tray 100 for storing food. The packaging tray 100 may have a food storage area 102 and a storage compartment 104 for storing one or more food accessories 106. The food storage area 102 as shown is configured to store food, for example a plurality of sausages. Further, the food may be any suitable food for storing in the packaging tray 100 including, but not limited to, chicken beef, pork, fish, vegetables, fruits, and the like. The food storage area 102 may be shaped to match the typical contour of the food. Having the food storage area 102 shaped may minimize the material needed in the packaging thereby reducing storage space and transportation costs associated with packaging and shipping foods. In one embodiment, the food storage area 102 may be curved at each end 108 in order to match the contour of the sausage, or the food, and thereby minimize space required for storage. Although the food storage area 102 is shown as having a curved shape at the ends 108, it may have any shape suitable for matching the contour of the food stored such as square, rectangular, circular and the like.

The food storage area 102 of the packaging tray 100 may have a plurality of walls 110 which surround the food storage area 102. The walls 110 as shown have two side walls 112 and two end walls 114. The two side walls 112, as shown, are substantially parallel to one another and have a length that is longer than the end walls 114.

The end walls 114a and 114b, as shown, may be curved. The curve of end walls 114a and 114b may curve in the same direction relative to the packaging tray 100. For example, as shown in FIG. 1, one of the end walls 114b curves, or extends, away from the food storage area 102 while the other end wall 114a curves, or extends, into the food storage area 102. The curved walls, as shown, may have any suitable curvature. In one embodiment, the curvature of the end walls 114a and 114b are configured to match the curvature of sausages, for example Italian sausages, bratwurst, and the like. Although the end walls 114a and 114b are shown as being curved in the same direction, each of the end walls may be curved in opposite directions. Further, the end walls 114a and/or 114b may be angled rather than curved.

The walls 110 may have any suitable depth for containing the food within the food storage area 102. The depth may be a distance normal to the plane of a tray bottom 116, between bottom of the wall 110 located near the tray bottom 116 of the packaging tray 110 to a top of the wall 110. As shown in FIG. 1 each of the walls 110 have substantially the same depth. Although, the walls 110 are shown as having the same depth, the walls 110 may have varying depths depending on the type of food to be stored in the packaging tray 100. In one embodiment, the walls 110 may have a depth configured to be slightly larger than a depth of the food to be placed in the packaging tray 100. In this embodiment, the food would be surrounded on three sides with the packaging tray 100, while the fourth side or top may be covered with any suitable covering to cover the food including, but not limited to a plastic covering, a cardboard covering, and the like.

The walls 110 may be angled relative to the tray bottom 116. For example, the walls 110 may have a slightly offset angle from a plane perpendicular to the tray bottom 116, as shown in FIG. 1. The angled walls 110 may allow multiple packaging trays 100 to be stacked on top of one another in a space saving manner. Due to the angle of the walls 110 tray bottoms 116 may be proximate one another when empty packaging trays 100 are stacked on top of one another. Although the walls 110 are shown as being angled, it should be appreciated that the walls 110 may be perpendicular to the tray bottom 116.

The tray bottom 116 may be a substantially planar member coupled to the bottom of each of the walls 110. The tray bottom 116 may have a similar perimeter shape to the shape of the interior of the walls 110. As shown, the tray bottom 116 has two parallel straight ends coupled to the side walls 112 and two curved ends coupled to the end walls 114. The tray bottom 116 may be integrally formed with each of the walls 110, or selectively to one or more of the walls 110. Further, the tray bottom 116 may be a formed separately from the walls 110 and coupled thereto by any suitable method including, but not limited to, gluing, stitching, melting, and the like.

A border 118 may surround the walls 110 of the food storage area 102. The border 118 may extend from the top of the walls 110 away from the food storage area 102. The border 118 may therefore form a lip that extends from the walls 110 around the packaging tray 100. As shown in FIG. 1, the border 118 may be substantially parallel to the tray bottom 116. Although the border 118 is shown as being substantially parallel to the tray bottom 116, it should be appreciated that the border 118 may be angled relative to the tray bottom 116. The border 118, as shown, extends out a thickness t along the sides walls 112. The border 118 may extend a similar thickness t along the curved wall 114b that curves away from the food storage area 102. The border 118 along the other curved wall 114a that extends into the food storage area 102 may not match the shape of the curved wall and thereby form a storage border 120.

The storage border 120 may have a varying thickness t along the length of the storage border 120. The varying thickness may allow a terminal end 122 of the storage border 120 to be substantially linear. The terminal end 122 of the storage border 120 may be perpendicular to the side walls 110 as shown. The perpendicular terminal end 122 of the storage border 120 may assist one or more packaging machines in handling the packaging tray 100 as will be discussed in more detail below.

Due to the curved bottom end of the packaging tray 100, the storage border 120 located in the border 118 has an extra width W that may be used to provide the storage compartment 104. This allows the packaging tray 100 to have the storage compartment 104 without substantially increasing the overall perimeter of the border 118 and thereby the packaging tray 100. Although the storage compartment 104 is shown as being located on top of the border 118 it may be at any suitable location such as the bottom of the border 118, the tray bottom 116, the bottom of the packaging tray 100, the walls 110 of the food storage area 102, and the like.

FIG. 2 is a top view of the packaging tray 100 having the storage border 120 with the storage compartment 104. The storage compartment 104 may be configured and/or shaped to store any number of the food accessories 106. As shown in FIG. 2, the storage compartment 104 has the shape of a thermometer 200, or “done stick.” The storage compartment 104 may have a depth configured to store one and/or multiple thermometers 200.

FIG. 3A is a top view of a portion of the packaging tray 100 showing the storage compartment 104 having the thermometer 200 as the food accessory 106. The one or more thermometers 200 may be a disposable thermometer used to test the temperature of the food while cooking. As shown, the thermometer 200 may have a tip 300, a handle 302, and an indicator 304. The tip 300 may be configured to be placed in, and/or onto the food while cooking the food. As shown, the tip 300 has a pointed, or angled portion 306 configured to pierce the food. The handle 302 as shown is a wider flat portion that is configured to be gripped by a person when inserting and/or removing the thermometer 200 from the food. Although the tip 300 is shown as an angled portion 306, the tip 300 may be any suitable shape and/or surface for measuring the temperature of the food. Further, the handle 302 may be any suitable shape for gripping the thermometer 200. Although the thermometer 200 is shown as a flat thermometer having a tip for piercing the food, the thermometer 200 may be any suitable thermometer for placing in the storage compartment including, but not limited to, a flat thermometer for placing flat on the food, a standard mercury thermometer, a digital thermometer, and the like.

The indicator 304 as shown has a visual indicator 308 and a temperature indication 310. The visual indicator 308 may simply change colors when the tip 300 reaches a desired temperature, or give another visual alert. The visual indicator 308 as shown displays the temperature at which the food in the packaging tray 100 is cooked, or done. It should be appreciated that the indicator 304 may take any suitable form so long as the thermometer 200 indicates the temperature of the food, and/or when the food will reach a certain temperature. The thermometer 200 may be specifically designed for the food being prepared. For example, the cook temperatures for poultry may be higher than in red meat. Thus, for a poultry food item the thermometer 200 may have an indicator that alerts the cook that the poultry has reached the poultry cook temperature, or done temperature.

Although the storage compartment 104 and the food accessory 106 are described for storing the thermometer 200, it should be appreciated that they may be used for storing any food accessory such as, a condiment (for example ketchup, mustard, BBQ sauce, salt, pepper, spices, soy sauce, wasabi, and the like), a plastic storage bag, one or more chop sticks, a fork, and/or a tong, and the like.

FIG. 3B is a top view of a portion of the packaging tray 100 showing two of the storage compartments 104 having two separate food accessories 106. This may allow multiple food accessories 106 to be packaged as a set with the food and the packaging tray 100. Any of the food accessories may be used in combination to enhance the set of the packaging tray 100, for example, the food accessories 106 may include, but are not limited to, the thermometer 200 and a condiment, a fork and a knife, soy sauce and wasabi, and the like. Although there are only two storage compartments 104 shown with two food accessories 106, it should be appreciated that there may be any suitable number of storage compartments 104 having any suitable number of food accessories 106.

FIG. 4 depicts a side view of two of the packaging trays 100 ready to be stacked on top of one another. As shown, the walls 110 are sloped toward the center of the packaging tray 100. The slope of the walls 110 may allow empty packaging trays 100 to be stacked on top of one another thereby allowing the tray bottom 116 and the borders 118 of each of the packaging trays 100 to be proximate one another, or nested together. This nested arrangement allows a larger number of packaging trays 100 to be stacked on top of one another for shipping and storage.

FIG. 5 depicts a perspective view of the packaging tray 100 with the food accessory 106 (as shown in FIGS. 1-3B) removed from the storage compartment 104. In FIG. 5, the food 500 is a sausage and the food accessory 106 is the thermometer 200. The thermometer 200 may be placed in the food 500 during cooking of the food, as described above. The empty storage compartment 104, as shown, is contoured to the shape of the thermometer 200. By making the storage compartment 104 a similar shape as the thermometer 200 and/or the food accessory 106, the food accessory 106 may be prevented from moving and/or shifting during transport of the packaging tray 100. Although, the storage compartment 104 is shown to be shaped the same as the thermometer 100, it should be appreciated that the storage compartment 104 may be shaped to fit the contour of any suitable food accessory including, but not limited to, any of the food accessories 106 described herein. Further, the storage compartment 104 may have any suitable shape for holding one or more food accessories.

The packaging tray 100 as shown in FIGS. 1-5 may be made of any suitable material including, but not limited to, Styrofoam, plastic, cardboard, foam, aluminum, and the like.

The packaging tray 100 may further have one or more partitions (not shown) located in the food storage area 102. The partitions may be configured to keep portions of the food 500 separated. For example, if the food 500 is sausage, there may be a partition between each of the sausages in the packaging tray.

FIG. 6 depicts a portion of a packaging system 600 for packing each of the packaging trays 100 with the food 500 and/or the food accessories 106. The packaging system 600 may be located at a packing facility, for example a meat packing facility. The packaging trays 100 may be shipped to the packing facility empty and in one or more tray stacks 602. The tray stacks 602 may reduce the shipping size required to ship the packaging trays 100. Further, the concave and convex shape of the end walls 114 of the packaging tray 100 may reduce wasted space in the packaging trays 100 by having the packaging trays conform to the shape of the food 500. The reduction in wasted space and shipping size may increase the number of packaging trays 100 that may be shipped in a truck, railcar, and/or container thereby reducing transportation costs.

The packaging system 600 may have a tray unloader 604, a main conveyer 606, a food loader 608 and a food accessory loader 610. The packaging system 600 may be configured to separate the tray stacks 602 into individual trays, then load the food storage area 102 with the food 500, and seal the packaging tray 100 for shipping to a retailer (not shown). Optionally, the packaging system 600 may load the food accessory 106 onto the packaging tray 100.

The tray stacks 602, or portions thereof, may be placed on the tray unloader 604 portion of the packaging system. The tray unloader 604 may have a stack conveyer 612, a tray feed area 614, and a tray dispenser system 616. The tray dispenser system 616 may be configured to place one or the packaging trays 100 on the main conveyer 606 individually. The tray unloader 604 as shown is located above the main conveyer 606 thereby allowing the individual packaging trays 100 to be dropped onto the main conveyer 606. The tray unloader 604 may be a stand-alone unit that may be moved to a location proximate the main conveyor 606, or may be connected to and fixed to the main conveyor 606. Although the tray unloader 604 is shown as being located above the main conveyor 606, it should be appreciated that the tray conveyor 606 may be located at any suitable location for delivering the individual packaging trays 100 onto the main conveyor 606 including, but not limited to, next to the main conveyor 606.

The stack conveyor 612 may move the tray stacks 602 toward the tray feed area 614 to be delivered onto the main conveyor 606. As shown, the stack conveyor 612 is has a conveyor belt 618 that the tray stacks 602 rest on. The conveyor belt 618 may be powered by any suitable drive system (not shown) including, but not limited to, an electric motor, a pneumatic system, a hydraulic system, a combustion engine and the like. The conveyor belt 618 may move the tray stacks 602, at a constant rate in accordance with the rate each of the tray stacks 602 are fed onto the main conveyor 606. Further, the conveyor belt 618 may move, only when the tray feed area 614 is ready to accept a new tray stack 602. Any number of sensors and/or operator input may be used to signal to the drive system when to activate the stack conveyor 612. Although the stack conveyor 612 is shown as a conveyor belt 618, it should be appreciated that any suitable conveyor system may be used to move the tray stacks 602 into the feed area including, but not limited to, a pneumatic conveyor system, a hydraulic conveyor system, a gravity roller conveyor, gravity skate wheel conveyors, wire mesh conveyors, plastic belt conveyors, and the like.

The feed area 614 as shown is an open area 620 surrounded by one or more guide walls 622. The guide walls 622 guide the packaging trays 100 to the tray dispenser system 616. The guide walls 622 may be any suitable wall and/or surface for restricting the travel of the packaging trays 100 toward the tray dispenser system 616. As shown, there are two guide walls 622 although there may be any suitable number of guide walls 622 including, but not limited to, three guide walls 622 and four guide walls 622, so long as the guide walls 622 guide the packaging trays 100 to the tray dispenser system 616.

The tray dispenser system 616 may be configured to remove one of the packaging trays 100 from the tray stack 602 and deliver the packaging tray 100 onto the main conveyer 606. The tray dispenser system 616 may remove one of the packaging trays 100 from the tray stack 602 while preventing the remaining packaging trays 100 from moving onto the main conveyor 606, as will be discussed in more detail below.

The main conveyor 606 may move the individual packaging trays 100 through the packaging system 600. The main conveyor 606 as shown is a conveyor belt 618 for moving the packaging trays 100. The conveyor belt 618 may have any suitable drive system including, but not limited to, those described herein. Although the main conveyor 606 is shown as a conveyor belt 618, the main conveyor 606 may be any suitable conveyor system including, but not limited to, those described herein. The main conveyor 606 may have one or more dividers 624 for separating the packaging trays 100.

The main conveyor 606 may move the each of the empty individual packaging trays 100 to the food loader 608 (shown schematically). The food loader 608 may place the food 500 in each of the packaging trays 100. In the event the food 500 is one or more sausages, the food loader 608 may place the sausages in the packaging tray 100 in a manner that the natural curve of the sausages matches the curve of the end walls 114 of the packaging trays 100. The food loader 608 may be any suitable system and/or device for loading the food 500 on the packaging trays 100 including, but not limited to, one or more robotic arms, a worker, a feed system, and the like.

The food accessory loader 610 (shown schematically) may place the food accessory 106 into the storage compartment 104 of the packaging tray 100. The food accessory loader 610, as shown, is located downstream of the food loader 608 thereby placing the food accessory 106 in the packaging tray 100 after the food 500 is in the packaging tray 100. It should be appreciated that the food accessory loader 610 may be located upstream of the food loader 608. The food accessory loader 610 may be any suitable system and/or device for loading the food accessory 106 into the storage compartment 104 including, but not limited to, one or more robotic arms, a worker, a feed system, and the like.

FIG. 7 depicts a schematic view of the tray dispenser system 616, according to one embodiment. The tray dispenser system 616 may have one or more tray engagers 700 and a tray dispenser drive system 702 (shown schematically). The tray engagers 700 may be configured to engage one of the packaging trays 100 and move the packaging tray 100, and/or drop the packaging tray 100, onto the main conveyor 606. The tray dispenser drive system 702 may be configured to move the one or more tray engagers 700. The tray dispenser system 616 needs to engage and separate the packaging trays 100 without damaging the packaging trays 100.

The tray engagers 700, as shown, in FIG. 7 are arms 704 configured to engage the end walls 114, and/or the border 118 proximate the end walls 114, of the packaging tray 100. Because the end walls 114 of the packaging tray 100 are curved, the arms 704 may have a matching curved portion. As shown, the arm 704 engaging the packaging tray 100 near the end wall 114A curved into the food storage area 102 may have a convex engagement surface 706. The convex engagement surface 706 may be curved to mirror the curvature of the end wall 114A. The arm 704 engaging the packaging tray 100 near the end wall 114B curved away for the food storage area 102 may have a concave engagement surface 708. The concave engagement surface 708 may be curved to mirror the curvature of the end wall 114B.

Due to the curvature of the end walls 114A and 114B, a straight surface on the tray engagers 700 may decrease the amount of surface contact between the tray engager 700 and the packaging tray 100. The decreased surface contact may cause the packaging tray 100, and/or multiple packaging trays 100, to fall, or dislodge prematurely from the tray dispenser 616. The falling packaging trays 100 may cause a stoppage, or slow down, in the packaging operation. The stoppage may cause the meat packing facility to lose money due to lost production. The convex engagement surface 706 and the concave engagement surface 708 may greatly increase the surface contact between the tray dispenser 616 and the packaging tray 100. The increased surface contact may further reduce stress at the contact point between the tray dispenser system 616 and the packaging tray 100.

FIGS. 8A and 8B depict a top view and a cross-sectional side view of the packaging tray 100 engaged with the tray dispenser 616. The convex engagement surface 706 and the concave engagement surface 708 of the tray engagers 700, as shown, may have a shelf 800 configured to engage a bottom surface of the border 118 proximate each of the end walls 114A and 114B respectively. The shelf 800 may have a flat top 802 for supporting the border 118 and a concave and/or convex curved end 804A and 804B for mirroring the curvature of the end walls 114A and 114B respectively. The flat top 802 may support the packaging tray 100 from the bottom of the border 118. The concave and/or convex curved ends 804A and 804B may be configured to engage the outer surface of the end walls 114A and 114B, or leave a small gap therebetween.

The tray engagers 700 may further have a shoulder 806A and 806B. The shoulders 806A and 806B may engage an edge of the border 118 when the packaging tray 100 is supported by the tray engagers 700. The shoulders 806A and 806B may be curved to match the curvature of the border 118. For example, the shoulder 806A may be convex, or extend outwardly, to mirror the inwardly curved the wall 114A and the shoulder 806B may be concave, or curve inwardly, to mirror the outwardly curved the wall 114B. The shoulders 806A and 806B are shown as being perpendicular to the edge of the border 118 although it should be appreciated that the shoulders 806A and 806B may have any suitable angle relative to the edge of the border 118.

Although the tray engagers 700 are shown as having the convex and concave shoulders 806A and 806B, curved ends 804A and 804B it should be appreciated that one of the shoulders 806 may be straight to match the edge of the packaging tray 100 as shown in FIG. 1.

When the tray stack 602 enters the tray feed area 614 (as shown in FIG. 6) the lowermost packaging tray 100 may engage the tray engagers 700 of the tray dispenser 616. In FIGS. 7 and 8A and 8B, the tray engagers 700 are shown in a support position wherein the packaging tray 100 is supported by the tray engagers 700. In the support position, the flat top 802 on each of the tray engagers 700 may support the packaging tray 100 by engaging the bottom of the border 118, and/or any suitable location on the packaging tray 100. The tray engagers 700 may remain in the support position until the packaging tray 100 is to be placed on the main conveyor 606.

To move the packaging tray 100 onto the main conveyor 606, a support may prevent support the packaging trays 100 in the tray stack 602, with the exception of the lowermost packaging tray 100. The tray engagers 700 may then be rotated toward a release position by the drive system 702 as shown in FIG. 7. The rotation toward the release position is indicated by arrows 710 on FIGS. 7 and 8B. As the tray engagers 700 rotate toward the release position, the lower most packaging tray 100 slides off of the tray dispenser 616 and is placed on the main conveyor 606. The drive system 702 may then move the tray engagers 700 back to the support position to receive the next packaging tray 100.

In an embodiment, a secondary tray engager 750 (as shown in FIG. 7) may be used to catch the packaging tray 100 when it is released from the tray engager 700. As shown, the secondary tray engager 750 is a substantially cylindrical member 752 having the shelf 800 and a shoulder 752. As the tray engager 750 releases the lowermost packaging tray 100, the shoulder 806 of the secondary tray engager 750 may catch the lowermost tray 100. The tray engager 700 may then reengage the second to last packaging tray in the tray stack 602. A motor 712 may then rotate secondary tray engager 750 in order to mover the shelf 802 clear of the packaging tray 100 and allowing the shoulder 752 to optionally push the packaging tray 100 onto the conveyor 618. Any of the tray dispensers 616 may include the secondary tray engager 750.

The drive system 702 (as shown in FIG. 7) may be any suitable drive system for moving and/or rotating the tray dispenser 616 and/or the secondary tray engager 750. In one embodiment, the drive system 702 may have a motor 712, or motive device, configured to rotate a drive shaft 714. The drive shaft 714 may couple to and/or be integral with the tray engagers 700 of the tray dispenser 616. The motor 712 may be any suitable motor for motivating the tray dispenser 616 including, but not limited to, an electric motor, a pneumatic motor, a hydraulic motor, a combustion engine, and the like. The drive system 702 may have any suitable devices and/or systems to assist in the motivation and control of the tray dispensers 616 including, but not limited to, controllers, servos, pulleys, chain drives, drive shafts and the like.

FIG. 8C depicts a cross-sectional view of another embodiment of the tray engagers 700. As shown, the tray engager 700 may pivot about a location located above the lowermost packaging tray 100 of the tray stack. The tray engagers 700 may form an L-shaped member having the shelf 800 and the shoulder 806. The shelf 800 and/or the shoulder 806 may be convex, concave and/or straight in a similar manner as any of the tray engagers 700 described herein.

The tray dispensers 616 may be specifically designed to be removable and replaceable in order to customize the packing system 600 to the type of packaging tray being used. The tray dispensers 616 may be uncoupled from the drive system 702 and replaced with an alternate tray dispenser when the type of packaging tray is changed in the packing system 600. For example, the packaging tray 100B (as shown in FIGS. 8A and 8B) having two curved end walls 114 may be replaced by the packaging tray 100A having a straight border 118 on the curved end wall 114A. The tray engager 700A may then be replaced by a tray engager 700A having the convex curved ends 804A on the shelf 800 and a straight shoulder 806A thereby mirroring the configuration of the packaging tray 100A. The packaging system 600 may then use square trays (not shown). The tray engages 700A and 700B may then be replaced again by replacing the tray engagers 700A and 700B having straight ends (not shown) on the shelf 800 and straight shoulders (not shown). Although the tray dispenser 616 is described as being replaceable, it should be appreciated that the tray dispenser 616 may be replaced along with a portion of the drive system 702. For example, the drive shaft 714 and the tray dispensers 616 may form a unit that can be quickly removed and replaced.

FIGS. 9A and 9B show an alternative embodiment of the tray dispensers 616. As shown, the tray dispenser 616 is two shaft tray engagers 900A and 900B. The shaft tray engagers 900A and 900B may be drive shafts that have a curvature that mirrors the curvature of the border 118 of the packaging tray 100B. Each of the shaft tray engagers 900A and 900B may have the shelf 800 and the shoulder 806A and 806B as described above. As shown in FIGS. 9A and 9B, the tray dispenser 616 is in the support position. The drive system 702 may rotate the shaft tray engagers 900A and 900B toward the release position as indicated by arrows 710 in a similar manner as described above. As the shaft tray engagers 900A and 900B rotate to the release position, the packaging tray 100B may be released. Further, the outer perimeter 902 of the shaft tray engagers 900A and 900B (as shown in FIG. 9B) may engage and support the next packaging tray 100B in the tray stack 602 (as shown in FIG. 6). The shaft tray engagers 900A and 900B may be removed and replaced in any suitable manner including those described herein.

FIG. 10 depicts flow chart of a method of providing a food package to a consumer. The flow begins at block 1000 wherein a packaging tray is provided. The packaging tray may be any suitable packaging tray including, but not limitd to those described herein. The flow continues at block 1002, wherein a food is placed in a food storage area of the packaging tray 1002. The food may be any suitable food including those described herein. The flow continues at block 1004, wherein a food accessory is placed in a storage compartment on a border of the packaging tray. The flow continues at block 1006, wherein the packaging tray is wrapped in a manner that displays the food and the food accessory to a customer. The wrapping may be any suitable wrapping such as plastic, polymer, cardboard, paper, a combination thereof and the like.

Claims

1. A packaging system for packaging food on a plurality of trays, the packaging system comprising:

a main conveyor configured to move each of the plurality of trays about the packaging system;

a tray unloader for unloading one tray from a tray stack onto the main conveyor;

a food loader configured to place the food into each of the trays; and

a food accessory loader configured to place a food accessory into a storage compartment of each of the trays.

2. The packaging system of claim 1, wherein the tray unloader further comprises at least one tray engager configured to engage the tray at an end of the tray.

3. The packaging system of claim 2, further comprising a drive system configured to move the tray engager and thereby drop the lowermost tray from the tray stack.

4. The packaging system of claim 3, wherein the at least one tray engager has a curved shoulder and end configured to mirror the contours of the ends of the tray.

5. The packaging system of claim 4, wherein the at least one tray engager further comprises two tray engagers one having a convex shoulder and convex end and the other having a concave shoulder and concave end.

6. The packaging system of claim 4, wherein the at least one tray engager further comprises two tray engagers one having a convex shoulder and convex end and the other having a concave end with a straight shoulder.

7. The packaging system of claim 2, wherein the tray engagers are interchangeable in order to mirror the contours of the types of packaging trays used in the packaging system.

8. The packaging system of claim 1, wherein the food accessory is a thermometer.

9. A system for unloading a tray onto a main conveyor in a food packaging facility, the system comprising:

a stack conveyor configured to convey a tray stack toward a tray feed area;

a tray unloader located proximate the tray feed area and configured to remove a lowermost tray of the tray stack and place the tray onto the main conveyor wherein the tray unloader comprises: a tray engager for engaging an removing the lowermost tray; a drive system configured to move the tray engager; and

wherein each of the trays has a tray bottom wherein the tray bottom is substantially flat and has two substantially straight sides on opposite sides of a perimeter of the tray bottom and two curved ends wherein a first end is curved away from the tray bottom and a second end is curved into the tray bottom and two side walls each extending above the straight sides of the tray bottom and located on opposite sides of the tray bottom and two curved end walls each extending above the curved ends of the tray bottom and wherein each end of each of the end walls is coupled to an end of the side wall thereby forming walls extending from the perimeter of the tray bottom;

10. The system of claim 9, wherein the each of the trays further comprise a storage area for a food accessory and a food storage area for storing a food.

11. The system of claim 9, wherein the at least one tray engager has a curved shoulder and curved end configured to mirror the contours of the curved ends of the tray.

12. The system of claim 9, wherein the at least one tray engager further comprises two tray engagers one having a convex shoulder and convex end and the other having a concave shoulder and concave end.

13. The system of claim 9, wherein the at least one tray engager further comprises two tray engagers one having a convex shoulder and convex end and the other having a concave end with a straight shoulder.

14. The system of claim 9, wherein the tray engagers are interchangeable in order to mirror the contours of the types of trays used in the packaging system.

15. A method of packaging food comprising:

placing a tray stack onto a stack conveyor;

moving the tray stack toward a tray feed area;

dropping the tray stack into the tray feed area;

engaging a lowermost tray with a tray dispenser system;

using the tray dispenser system to lower the lowermost tray onto a main conveyor;

moving the tray toward a food loader and loading a food into the tray; and

moving the tray toward a food accessory loader and loading the food accessory into a storage area on a border of the tray.

16. The method of claim 15, wherein using the tray dispenser further comprises:

engaging the lowermost tray with a plurality of tray engagers;

rotating the tray engagers with a drive system and thereby releasing the lowermost tray;

17. The method of claim 15, further comprising engaging a convex end wall of the tray with a concave shoulder and concave end of the of the tray engager.

18. The method of claim 17, further comprising engaging a concave end wall of the tray with a convex shoulder and convex end of the of the tray engager.

19. The method of claim 15, wherein moving the tray toward the tray feed area further comprises moving the tray stack on a conveyor.