MX2008006291A - Method and packaging for baked, thaw and serve, or microwavable goods - Google Patents

Abstract

Packaging for heatable food portions comprises an ovenable tray including a plurality of serving containers connected by a detachable support matrix. In one embodiment, the support matrix is attached to the serving containers by hot melt glue which melts during baking or heating to automatically release the support matrix from the serving containers. Pre-fÃlled trays are shipped with display covers fitted to the serving containers, such that the covers may be placed on the individual serving containers after the food portions are baked and the serving containers are separated from the support matrix to provide individually packaged, freshly baked food portions for display.

Description

METHOD AND PACKAGING FOR BAKED, DEFROST AND SERVING OR MICROWAVE PRODUCTS Cross Reference with Related Requests This application claims the benefit of the Request U.S. Patent Provisional No. 60/7371 38 filed on November 16, 2005 and the Provisional Patent Application of E. U. No. 60/798422 filed May 5, 2006, the complete descriptions of which are incorporated herein by reference. Field of the Invention The present invention pertains generally to the packaging of frozen food items and specifically to frozen dough packing or paste based products, suitable for shipping to a bakery or restaurant where the product is prepared, displayed and sold to the user. final in the same packaging. BACKGROUND OF THE INVENTION It is known to make frozen dough or pasta-based products such as chocolate biscuits with nuts, cakes, custards, quiches, muffins, sweet rolls, pastries or the like and then freeze and pack in bulk the products for board a breadmaker, a restaurant or a convenience store. The product is typically unpacked and each unit of product is individually placed in a baking pan with a suitable mold liner. Afterwards, the product is placed in a retarder or defrosted in the installation. The product can also be tested before baking. After baking, let the product cool and then freeze or cover with sugar. Finally, the product is removed from the mold and placed in the packaging for display and sale to the customer. The patent of E. U. No. 4,986,432 assigned to Novacart S. P. A., of Italy discloses a baking tray comprising a support element 2 made of a laminar paper material having a plurality of holes 3 for receiving a plurality of cups 4 of pleated paper. The support element includes perforations 5 for separating the individual cups or groups of cups. The pleated paper cups can be attached to the support element by gluing the ring on its upper side of the cup with the supporting element or by bending the upper ring of the cup so as to capture the support element. The described baking tray is useful to some extent, but it is not suitable for pre-filling with dough or paste by an automated filler and transporting it to a stacked arrangement in a shipping container because the paper cups and the supporting element do not they are strong enough to withstand a high-speed line and spiral freezer in accordance with current practice. Another disadvantage is that the final product after baking is not adapted to be easily covered as a unitary portion for display and sale to a customer. What is needed is improved packaging and methodology that further reduce the work required by the breadmaker, the restaurant or the store. Brief Description of the Invention The present invention is generally incorporated by means of a tray that can be used in ovens, comprising a plurality of serving containers and a support matrix attached to the plurality of serving containers, wherein the support matrix is removable from the plurality of containers for service. In various embodiments of the tray, each of the plurality of service containers includes an open top and an eyebrow adjacent to the open top. In such an embodiment, the support matrix is bonded by hot melt adhesive to the underside of each eyebrow of the service container, so that the support matrix falls away from the eyebrows during baking. In another embodiment, the support matrix is bonded by non-hot melt adhesive to the underside of each eyebrow of the service container, and the support matrix is perforated to allow manual detachment of the support matrix after baking. In yet another modality, the support matrix includes a plurality of slots around each container to receive a portion of the eyebrow. The invention is further incorporated by means of a food package comprising a baking tray that includes a plurality of service containers and a support matrix attached to the plurality of service containers, wherein the support matrix is detachable from the plurality of service containers. service containers, and a plurality of food portions each received in a respective one of the plurality of service containers, whereby the tray and the plurality of food portions can be loaded as a unit in a cooking appliance and the support matrix detaching from the plurality of service containers after such loading to provide a plurality of separate service containers, each containing a prepared food. The invention is also incorporated by means of a food package comprising at least one pre-filled baking tray including a plurality of service containers, a support matrix removably attached to the plurality of service containers, and a plurality of portions of food received each in a respective one of the plurality of service containers; a plurality of covers adapted to be accommodated in the service containers; and a shipping container enclosing the tray or pre-filled trays and covers. Finally, the invention is incorporated by a method for preparing individually packaged food items for display to buyers, comprising the steps of: opening a shipping container enclosing a plurality of covers and a baking tray including a plurality of containers of service pre-filled with respective food portions and a support matrix removably attached to the plurality of service containers, wherein the plurality of covers are adapted to be accommodated on the plurality of service containers; remove the plurality of covers and the tray; heat the tray in a cooking appliance; separating the support matrix from the plurality of containers; and placing the plurality of covers over the plurality of service containers. In a particular embodiment, the step of separating the support matrix from the plurality of containers occurs automatically during the heating step of the tray in a cooking appliance because the support matrix is attached to the service containers by the adhesive Hot melt. BRIEF DESCRIPTION OF THE DRAWINGS The nature and mode of operation of the present invention will now be described more fully in the following detailed description of the invention taken with the Figures of the accompanying drawings, in which: Figure 1 is an isometric view of a baking tray formed according to one embodiment of the present invention, wherein the baking tray is shown before being filled. Figure 2 is a cross-sectional view of a portion of the baking tray shown in Figure 1. Figure 3 is a view similar to that of Figure 1, however the baking tray is shown after a support matrix thereof has fallen during baking. Figure 4 is a side elevational view of a baking tray serving container shown with a bonded cover. Figure 5 is a top plan view of a baking sheet formed in accordance with another embodiment of the present invention. Figure 6 is a top plan view of a baking tray formed according to yet another embodiment of the present invention. Figure 7 is a top plan view of a baking tray support matrix formed in accordance with a further embodiment of the present invention. Figure 8 is an isometric view showing a packable food package formed in accordance with an embodiment of the present invention; and Figure 9 is a flow diagram illustrating a method according to an embodiment of the present invention. Detailed Description of the Invention The present invention provides a shipping solution that can be shipped to food products in portions - for example portions of frozen dough or frozen baking dough and pre-baked dough or dough portions for heating - which reduces substantially the work involved in the preparation of portions for display and sale at a retail location such as a restaurant, breadmaker, convenience store, or other point of sale. The invention is incorporated by a packaging apparatus and work reduction methods based on the packaging apparatus for preparing food portions for display and sale. With reference to Figures 1 to 3, wherein a tray 10 is shown, formed according to an embodiment of the invention, comprising a plurality of service containers 12 and a support matrix 14 attached to the service containers 12 . Tray 1 0 is designed to support baking in an oven (conventional or microwave), and thus the service containers 12 and the support matrix 14 are manufactured from a suitable material that can be baked. A preferred baking material is paperboard that can be baked, however, those skilled in the art will understand that other materials that can be baked can be used, including, without limitation, plastics, corrugated and crystallized. These materials are also suitable as materials for packaging frozen foods, so that the trays 10 can be handled by food processing equipment, high-speed conveyor lines and spiral freezers without being damaged. In accordance with the present invention, the support matrix 14 is detachable from the plurality of service containers 12 or is perforated to allow the service containers to be separated from each other. In a embodiment shown in Figures 1 to 3, the support matrix 14 is attached to the service containers 12 by hot melt adhesive 16 selected to melt at a temperature preferably within a range of 121 ° C to 135 °. C. Some adhesives that are suitable are LOCTITE trademarks HYSOL 3x item # 83368, HYSOL SU PERPAC item # 83404 and HYSOL QUIKPAC item # 83399, available from Henkel Corp. in Rock Hill, Connecticut. As will be appreciated, the hot melt adhesive 16 melts during baking or heating when it reaches a predetermined temperature, which causes the support matrix 14 to detach from the service containers 12. In an advantageous arrangement, the service containers 1 2 each include an open top portion surrounded by an eyebrow 1 8 extending outwardly adjacent to the open top portion, and the support matrix 14 is joined by adhesive 16 of hot melt to the side 20 below each eyebrow 18. This arrangement is advantageous because the support matrix 14 drops from the eyebrows 18 by gravity when the hot melt adhesive 16 melts during baking or heating, as illustrated in Figure 3. In this way, the service containers 1 2 are automatically separated from one another during baking or heating. As best seen in Figure 3, the support matrix 14 includes a plurality of container receiving openings 15 in which the containers 12 are received.

Attention is now directed to Figure 4. Each of the individual service containers 12 can be covered by a transparent plastic cover 24 to provide freshly baked or heated, individually packaged food portions ready for display in an exhibit box or the similar ones. The covers 24 are preferably sized to press fit onto the service containers 12 in a manner known to those skilled in the art. Suitable materials for the cover include polyethylene (PET) and styrene, however, other materials can be used without departing from the invention. The shape of the service containers 1 2 and the covers 24 is not critical and may depend on the type of food being packaged, provided that the covers fit into the service containers. In accordance with the present invention, the service containers 1 2 of the tray 10 can be pre-filled with respective food portions 22 before being delivered to a restaurant, breadmaker, convenience store or other outlets. The food portions 22 may be frozen dough, frozen pasta, baked dough, baked pasta or other types of food items. In one embodiment of the invention, shown in Figure 8, a plurality of pre-filled trays 10 are stacked and enclosed in a shipping container 32 together with a stack of covers 24. The shipping container 32 is depicted as a box cardboard, however it can be a plastic bag or other container suitable for transportation. Each tray 10 is preferably sealed by a plastic sheet for shrink wrapping to protect the food portions 22 from foreign matter. Figure 5 illustrates a tray 1 10 formed according to an alternative embodiment of the present invention. The tray 1 1 0 is similar to the tray 1 0 of Figures 1 to 3, except that the tray 1 1 0 has a support matrix 1 14 which is attached to the service containers 12 by a non hot melt adhesive which is selected so that it does not melt during normal baking or heating, and the support matrix 1 14 includes perforations 126 below each eyebrow 18 that form a perforation contour around the service container, and perforations 1 28 near the perforations 126 forming perforated holes, whereby a user can perforate a hole through the support matrix 1 14 to allow better access of the finger to separate the service containers 1 2 from the support matrix 1 14 using the perforations 126 In this way, the support matrix 1 14 can be detached manually from the service containers 12. As will be understood, a small peripheral ring of the support matrix 1 14 will be left glued to the side below each eyebrow 1 8, thereby reinforcing each eyebrow 1 8 in an advantageous manner. Figure 6 shows a tray 210 according to another embodiment. The tray 21 0 is similar to the tray 1 1 0 of Figure 5, except that it includes service containers 212 having a circular shape instead of a rectangular shape, and the containers 21 2 are delineated by respective circular perforations 226 in the support matrix 214. The circular open upper portion of each container 212 is delimited by a circumferential eyebrow 218, and the associated perforation 226 is slightly offset from an outer edge of the eyebrow 218 just below the eyebrow. The punched hole perforations 228 are provided near the perforations 226 of contour similar to the embodiment of FIG. 5. As in the embodiment of FIG. 5, a small peripheral ring of the original support die 214 will be left gummed to the side of FIG. under each eyebrow 218 after the support matrix is peeled off, thereby reinforcing each eyebrow 218. Although the embodiments previously described herein use adhesive to attach a support matrix to a plurality of service containers, it is also possible to use other joining means. Figure 7 shows a support die 314 which includes a plurality of container receiving openings 315, each surrounded by a plurality of slots 330 arranged to receive portions of the eyebrow of a respective service container to join the matrix 31 of Support for service containers. Figure 9 is a flowchart, part of which shows preliminary manufacturing and shipping steps and part of which shows a method of the present invention whereby individually packaged food items, especially dough-based or pasta-based food products, are prepared. such as chocolate biscuits with nuts, cakes, custards, quiches, muffins, sweet rolls, pastries or the similes for display to buyers. The method is based on packaging solutions described above, which involves substantially less time, skill and effort than the prior art methods. Preliminary steps include filling the trays 1 0 with food portions 22 and freezing the pre-filled trays in the plant, as indicated in block 40, and packing a stack of trays 10 and a stack of covers 24 in a container 32. of shipping, as indicated in block 42. These preliminary steps can be performed by automated food processing equipment, for example by placing unfilled pans 10 on a high-speed conveyor that passes through a filling machine programmed to deposit portions 22 of food in service containers 12 and then deliver the pre-filled trays to a freezer, such as a coil freezer. The shipping container 32 encloses the pre-filled trays 10 and covers 24 and then delivers them to a specific destination, such as a fast service restaurant, breadmaker or convenience store according to block 44, where they can be stored in a freezer until they are needed. Blocks 46 to 62 of Figure 9 illustrate a method for preparing and displaying individually packaged fresh food items according to one embodiment of the present invention. First, in block 46, shipping container 32 is opened and unpacked, and covers 24 are set aside for use in a later step. Then, in block 48, the trays 10 are thawed on the site or placed in a retarder, if necessary. After thawing, trays 1 0 can be tested if testing is required for the particular food portions 22, as indicated by block 50. If testing is required, it is advisable to use a packing method that does not use adhesive of hot melt, otherwise the adhesive will melt prematurely during the test. Next, in block 52, trays 10 are placed in a cooking appliance, such as a conventional oven or a microwave oven for a predetermined time and in a predetermined oven position in order to bake or heat the portions. of food in a fresh way. Following baking or heating, the service containers 1 2 are removed from the cooking appliance and allowed to cool according to block 54. If hot melt adhesive was used for the bonding, then the support matrix has already been detached from the service containers 1 2 and the service containers 12 are individually removed (the detached support matrix 14 can be discarded or recycled); otherwise, the service containers 12 can be removed as part of the trays 10. If the food portions are of a type that is topped with frosting, or another auction, then the auctioning is applied in block 56. if necessary , trays 10 are separated into individual service containers in accordance with block 58 and a cover 24 is attached to each service container 12 in accordance with block 60. Finally, freshly prepared, individually packaged food portions are placed in a display for sale to customers according to block 62. As will be appreciated, the preparation steps can be performed by an employee without even touching the food portions 22, thus reducing the risk of contamination. In addition, the step of placing the food portions on a baking tray at home is completely eliminated, thereby saving time and eliminating the need to clean and store the baking trays. The present invention thus provides an advantageous "lifelong" approach to packing and preparing food that gives a real economic benefit to those who prepare freshly baked goods and other food items on the site for sale to the public.

Claims (24)

1. CLAIMS 1. A tray for baking comprising a plurality of service containers and a support matrix attached to the plurality of service containers, wherein the support matrix is detachable from the plurality of service containers.
2. 2. The tray according to claim 1, wherein the support matrix is attached to each of the plurality of service containers by means of an adhesive.
3. 3. The tray according to claim 2, wherein the adhesive is a hot melt adhesive. The tray according to claim 3, wherein each of the plurality of service containers includes an open top and an eyebrow adjacent to the open top, and the support matrix is bonded by hot melt adhesive to the bottom side of each service container eyebrow. The tray according to claim 2, wherein the adhesive is a hot melt adhesive and the support matrix is perforated to allow the support matrix to be detached from the plurality of service containers. The tray according to claim 5, wherein each of the plurality of service containers includes an open top and an eyebrow adjacent to the open top, the support matrix is joined by hot melt adhesive to the underside of each service container eyebrow, and the support matrix is perforated below each service container eyebrow to form a perforated contour around the corresponding service container. The tray according to claim 6, wherein the support matrix is perforated to provide a plurality of perforated openings that allow improved access of the fingers to the perforated contours around the plurality of service containers. The tray according to claim 1, wherein each of the plurality of service containers includes an open top and an eyebrow adjacent to the open top, and the support matrix includes a plurality of slots for each of the plurality of service containers, wherein the plurality of slots is arranged to receive portions of the eyebrow of a respective service container, whereby the support matrix is attached to the plurality of service containers. 9. A food package comprising: a baking tray that includes a plurality of service containers and a support matrix attached to the plurality of service containers, wherein the support matrix is detachable from the plurality of service containers; and a plurality of food portions each received in a respective one of the plurality of service containers; whereby the tray and the plurality of food portions can be loaded as a unit in a cooking appliance, and detach the supporting matrix from the plurality of service containers after such loading to provide a plurality of separate service containers each containing prepared food. The food package according to claim 9, wherein the support matrix is detached from the plurality of service containers while the tray is heated in a cooking appliance. eleven . The food package according to the claim 10, wherein the support matrix is attached to each of the plurality of service containers by hot melt adhesive. 12. The food package according to the claim 11, wherein each of the plurality of service containers includes an open top portion and an eyebrow adjacent to the open top portion, and the matrix is bonded by hot melt adhesive to the underside of each container eyebrow. of service so that the matrix falls from the service container eyebrows while the tray is heated in a cooking appliance. 13. A food package comprising: at least one pre-filled baking sheet that includes a plurality of service containers, a support matrix removably attached to the plurality of service containers, and a plurality of portions thereof. food each received in a respective one of the plurality of service containers; a plurality of covers adapted to be accommodated in a plurality of service containers; and a shipping container enclosing the at least one pre-filled tray and the plurality of covers. The food package according to claim 1, wherein each pre-filled tray is sealed by a shrink wrap plastic cover on top of the plurality of serving containers of the tray. The food package according to claim 1, wherein the plurality of covers is formed of transparent plastic. 16. The food package according to claim 1, wherein the plurality of covers are stacked. 7. The food package according to claim 13, wherein the shipping container is a cardboard box. 18. A method for preparing individually packaged food items for display to buyers, the method comprising the steps of: opening a shipping container enclosing a plurality of covers and a baking sheet including a plurality of pre-service containers filled with respective food portions and a support matrix detachably attached to the plurality of service containers, wherein the plurality of covers are adapted to be accommodated on the plurality of service containers; remove the plurality of covers and the tray from the shipping container; heat the tray in a cooking appliance; separating the support matrix from the plurality of containers; and placing the plurality of covers over the plurality of service containers. The method according to claim 1 8, wherein the step of separating the support matrix from the plurality of containers occurs automatically during the heating step of the tray in a cooking appliance. The method according to claim 18, wherein the step of separating the support matrix from the plurality of containers is carried out manually after the heating step of the tray in a cooking appliance. twenty-one . The method according to claim 18, wherein the food portions are frozen and the method further comprises the step of defrosting the food portions before the heating step of the tray in a cooking appliance. 22. The method according to claim 18, further comprising the step of placing the tray in a retarder before the heating step of the tray in a cooking appliance. The method according to claim 18, further comprising the step of testing the food portions before the heating step of the tray in a cooking appliance. 24. The method according to claim 18, further comprising the step of applying a finish to the food portions before the step of placing the plurality of covers over the plurality of service containers.