GB2507385A

GB2507385A - Moulded tray for fresh produce

Info

Publication number: GB2507385A
Application number: GB201314224A
Authority: GB
Inventors: Ronan Lynch
Original assignee: Individual
Current assignee: Individual
Priority date: 2013-01-21
Filing date: 2013-08-08
Publication date: 2014-04-30
Anticipated expiration: 2033-08-08
Also published as: GB2507385B; GB201300988D0; GB201314224D0

Abstract

A tray for fresh produce composed of a fibrous substrate and moisture-absorbing additive and comprising a plurality of cells for housing individual pieces of fruit. Also claimed are: a one-piece moulded tray; a packaged tray of fresh produce comprising the tray and individual pieces of fresh produce; and a process for making the tray.

Description

TRAY FOR FRESH PRODUCE

TECHNICAL FIELD

The present invention is directed to a tray for fresh produce, for example, a recyclable and/or biodegradable tray for fresh produce, a process for making the tray, and to a packaged tray of fresh produce comprising the tray and individual pieces of fresh produce.

BACKGROUND

Plastic and polystyrene are the dominant forms of packaging worldwide. They aie attiactive products owing to flexibility and/or low cost and ease of transport. In the fresh produce market, an important aspect is delivering to the consumer products that are fresh and safe. Plastics and polystyrene are commonly used for packaging fresh pioduce, such as fruit and vegetables. However, plastics are less attractive from an environmental perspective because they can be expensive to recycle, and consumers may in any case not bother to recycle and plastics tend to have poor or negligible biodegradability, whereas polystyrene cannot be recycled at all. Thus, there is growing demand for biodegiadable and iecyclable packaging.

More recently, there has been a growing demand for premium quality fresh produce, paiticulaily "piemium quality" fruit. Such products are marketed under biands such as "Perfectly Ripe" (TM) by Marks and Spencer (RTM), and "Ripe and Ready" (TM) by Sainsbury's (RTM). Fruit suitable for retail under such brands tend to be ripened longer before packaging. As such, they can be more susceptible to bruising and or degradation compared to less-ripe fruits. It is theiefore a challenge to get piemium quality products to the consumer without adversely effecting the quality of the fruit (e.g., bruising during transport and handling) and in a time frame in which the truit is not begun to degrade.

Therefore, there is an ongoing need for new packaging pioducts which aie environmentally friendlier than plastics or polystyrene, e.g., readily biodegradable and recyclable. Further, there is ongoing to need to develop such products which can facilitate development of the glowing premium quality flesh produce market, e.g., extend the shelf-life of fruits so that they can be packaged and transported and stored such that the fresh produce reaches the consumer in a state suitable for marketing as premium quality.

SUMMARY OF THE INVENTION

According to a first aspect, the present invention is directed to a tray for fresh produce, wherein the tray comprises a fibrous substrate and an additive for varying the moisture and/or water resistance of the tray, wherein the additive for varying the moisture and/or water resistance of the tray is present in an amount (i) sufficient to prevent the tray from absorbing moisture and/or water to the extent that the integrity of the tray is compromised in use, and (ii) such that the tray is able to absorb an amount of moisture and/or water to the extent that the flexibility of the tray is increased.

According to a second aspect, the present invention is directed to a tray for fresh produce, said tray comprising: a plurality of cells for housing individual pieces of fresh produce, wherein each cell is at least partly defined by a curved side-wall, wherein the curved side-wall is resiliently deformable such that locating a piece of fresh produce within the cell causes the side-wall to resiliently deform, thereby gripping the fresh produce. In certain embodiments, the tray of the second aspect has a composition according to the first aspect of the invention.

According to a third aspect, the present invention is directed to a one-piece moulded tray according to the first and second aspects of the present invention.

According to a fourth aspect, the present invention is directed to a biodegradable and/or recyclable tray according to the first, second and/or third aspects of the present invention.

According to a fifth aspect, the present invention is directed to a packaged tray of fresh produce comprising a tray according to any of the first, second, third and/or fourth aspects of the present invention and individual pieces of fresh produce located in the tray. In certain embodiments, the packaged tray of fresh produce comprises an outer wrapper which may comprise or consist of a transparent film.

According to a fourth aspect, the present invention is directed to a process for preparing the one-piece moulded tray according to the third aspect of the present invention! said process comprising: (i) preparing, providing or obtaining a pulp comprising suitable amounts of fibrous substrate, additive for varying the moisture and/or water resistance, and optional biocide; and (U) moulding a one-piece tray therefrom.

BRIEF DESCRIPTION OF THE FIGURES

Fig. 1A is a schematic depiction of an exemplary tray in plan view.

Fig. 1 B is a sectional view (perpendicular to the plan view) of the tray of Fig 1 A through A----A; and Figures 2 to 4 depict subject matter described in the priority application 0B1300988.1, with: Figure 2 showing a four compartment tray with the individual cups shaped to the shape of the fruit the tray is carrying; Figure 3 showing the height of the sides of the tray designed and manufactured to be at least 40% of the height of the contained fruit in order to prevent movement during transportation and storage; and Figure 4 showing the interior of the compartment, where the fruit makes contact with the tray, being of a softer composition in order to cushion the fruit.

DETAILED DESCRIPTION OF THE INVENTION

The tray is suitable for packaging individual pieces of fresh produce, particularly fresh produce for the premium quality market. Fresh produce includes fruit, vegetables and fungi, e.g., mushrooms.

The tray is suitable for packaging a wide range of fruits, such as, for example, apples and pears, grapes, citrus fruit, berries, melons, stone fruits, tomatoes, and exotic fruits.

Stone fruits include, apricots, avocados, cherries, dates, greengages, nectarines, peaches and plums, particular the soft skinned stoned fruits which are particularly sensitive to bruising and blemishing during packaging, transport and storage.

Citrus fruits include clementines, grapefruit, kumquats, lemons, limequat, minneolas, oranges, pomelo and satsunias.

Berries include strawberries, blueberries, blackberries, cranberries, gooseberries, raspberries, redcurrants, blackcurrants and white currants.

Melons include varieties such as cantelope, charantais, galia, honeydew, rock and water.

Exotic fruits include custard apple, figs, grenadillo, guava, kiwano (horned melon), kiwi, longuns, lychees, mangoes, mangosteen, passion fruit, paw paw, persimmon, physalis, pineapples (baby), pitahaya red, pitahaya yellow, pomegranates, prickly pear, quinces, rambutans, rhubarb, sharon fruit, star fruit, tamerillo and zespri golden.

Mushrooms include varieties such as button, cepes, chanterelles, chestnut brown, cup, enoki, flat, girolle, gold trumpet, mixed wild, morilles, mousseron, oyster, pied de bleu, pied de mouton, pink oyster, Portobello, shitaki, trumpe de Ia mor and yellow oyster.

The tray is suitable for packaging a wide range of vegetables, such as root vegetables, potatoes. onions and shallots, capsicums, broccolis, chillies, beans, mange tout and peas, exotic vegetables and a selection of other general vegetables.

Root vegetables include beetroot, carrots, celeriac, parsnips, swedes and turnips.

Onions and shallots include varieties such as button, cipolino, English, grelot. red, Spanish, strings, white skinned and banana.

Broccolis include sprouting broccoli, button sprouts, red, white and savoy cabbage, cauliflower, curly kale, purple broccoli and brussels sprouts.

Other general vegetables include aubergines, chicory, fennel, leeks, marrows, round courgettes and butternut squash.

In advantageous embodiments! the fresh produce is that which can be described as being generally spherical (e.g., nectarines, peaches, apples, oranges, plums, tomatoes, etc.) or comprise a generally spherical portion (e.g., avocado, pears, etc.).

In advantageous embodiments, the fresh produce is a stone fruit, particularly soft-skinned stone fruit.

The tray comprises a fibrous substrate and an additive for varying the moisture and/or water resistance of the tray.

The fibrous substrate may be derived from wood, grasses (e.g., sugarcane, bamboo) or rags (e.g., textile waste, cotton, hemp or flax), preferably from wood. In certain embodiments, the fibrous substrate is derived from recycled paper, for example, recycled paper board. In certain embodiments, the recycled paper board is pre-consumer waste. In an advantageous embodiment, the recycled paper board is corrugator trim (which is a pre-consumer waste product). As discussed below, the tray may be formed from a pulp comprising the fibrous substrate, for example, a pulp comprising recycled paper board, such as a pulp comprising corrugator trim. An advantage in using pre-consumer waste such as corrugator trim is that the waste does not require pre-processing to remove contaminants (e.g., ink, greases) normally associated with a post-consumer waste. However, in certain embodiments, the pulp may comprise post-consumer waste which will have been treated as necessary to remove any contaminants that would otherwise adversely affect the quality (e.g., food safety) of the fresh produce that is to be packaged in the tray.

Typically, the tray comprises at least about 80 wt. % fibrous substrate, based on the total weight of the tray, for example, at least about 85 wt. % fibrous substrate, or at least about 90 % fibrous substrate, or at least about 91 % fibrous substrate, or at least about 92 wt. % fibrous substrate, or at least about 93 wt. % fibrous substrate, or at least about 94 wt. % fibrous substrate, or at least about 95 wt. % fibrous substrate, or at least about 96 wt. % fibrous substrate, or at least about 97 wt. fibrous substrate, or at least about 98 wt. % fibrous substrate. The tray may comprise from about 90-99.5 wt. % fibrous substrate, for example, from about 90-99 wt. % fibrous substrate, or from about 90-98 wt. %, or 90-97 wt. %, or 90-96 wt. %, or 90-95 wt. %, or 90-94 wt. %, or 90-93 wt. % fibrous substrate.

The additive for varying the moisture and/or water resistance of the tray is present in an amount (i) sufficient to prevent the tray from absorbing moisture and/or water to the extent that the integrity of the tray is compromised in use, and (U) such that the tray is able to absorb an amount of moisture and/or water to the extent that the flexibility of the tray is increased. The additive is not formed as a coating on fibrous substrate, but instead is dispersed within and throughout the fibrous substrate. This may achieved during the manufacturing process in which the additive is mixed with pulp prior to moulding. Generally, the amount of additive for varying the moisture and/or water resistance of the tray may range from about 0.1 wt. % to about 20 wt. %, based on the total weight of the tray, for example, from about 0.1 to about 15 wt. %, or from about 0.1 to about 10 wt. %, or from about 0.5 to about 8.0 wt. %, or from about 0.5 to about 6.0 wt. %, for from about 0.5 to about 5.0 wt. %, or from about 1.0 to about 4.5 wt. %, or from about 1.0 to about 4.0 wt. %, or from about 1.0 wt. % to about 3.5 wt. %, or from about 1.0 to about 3.0 wt. %, or from about 1.0 to about 2.5 wt. %, or from about 1.0 to about 2.0 wt. %, or from about 1.5 wt. % to about 4.5 wt. %, or from about 2.0 wt.

% to about 4.0 wt. %, or from about 2.0 to about 3.5 wt. %, or from about 2.5 wt. % to about 3.5 wt. %, or from about 2.0 to about 3.0 wt. %.

Requirements (i) and (ii) mean that the tray includes an amount of the additive such that the tray is able to absorb a certain amount of moisture and/or vapour to increase the flexibility of the tray (or conversely decrease the rigidity of the tray), but prevented from absorbing too much moisture and/or water such that the tray fails in use (e.g., it becomes too bendy such that the fresh produce is no longer adequately protected by the tray, or even disintegration of the tray). Typically, between packaging of fresh produce in the tray and point of sale in a retail shop or supermarket, a period of up to about 5 (or even 6 or 7) days may elapse. Thus, a level of additive should be selected such that the tray comprising fresh produce does not fail following packaging, transportation, storage and display over a 5 day period.

In certain embodiments, the level of additive should be selected such that the tray comprising fresh produce does not fail following packaging, transportation, storage and display over a 5.5 day period, or a 6 day period, or a 6.5 day period, or 7 day period.

Generally, the longer the period between packaging and sale, the greater the amount of additive that will be required to prevent the tray from absorbing too moisture and/or water. A skilled person will be able to determine the appropriate amount of additive by packaging a tray with fresh produce and then storing the packaged tray with fresh produce at ambient conditions over a 5 day period (or a 5.5 day period, etc) and assessing the integrity of the tray and the end of the period.

If in a first experiment the tray is found to fail, the skilled person will be able to adjust the amount of additive and re-test. The level of water and/or moisture absorbed by the tray may be observed by weighing the tray over a period of time when it is stored in a controlled environment. e.g., under chilled conditions such as below 5 °C, or at ambient conditions, e.g., at a temperature of from 18-25 °C. Because the tray is not wholly water resistant (as one might expect with a water-proof coating, for example, or a plastic tray), the tray absorbs a certain amount of water and/or moisture. This has the effect of increasing the flexibility of the tray over a period of time, for example, gradually over a period of tray. This is advantageous because the fresh produce, e.g., fruit, housed within the tray will tend to soften the longer it is stored.

As the fresh produce softens it will become more susceptible to damage, e.g., bruising, which as discussed above is undesirable, particularly in the premium quality fresh produce market. However, because the tray gradually increases in flexibility as water and/or moisture is absorbed, the tray will be expected to cause less damage, if any, to the fruit compared to a tray which is totally water resistant (e.g., a polystyrene foam tray or any plastic tray). This is particularly so in the trays of the invention which are designed to resiliently deform and grip the fresh produce. In such embodiments, the gripping force caused by the resiliently deformable side-walls may gradually decrease over time as water and/or moisture is absorbed so that as the fresh produce softens it less susceptible to damage.

A further advantage in having the tray able to absorb an amount of water and/or moisture is that this reduces the amount of water that may otherwise pool oi collect in the tray during storage. Such water may come from the fresh produce itself or from the atmosphere in which the tray is stored. As one skilled in the art will appreciate, the quality of fresh produce may be compromised by storage in the presence of water and/moisture. For example, the fresh produce may be susceptible to rotting or fungal growth. Whilst conditions in a transportation vehicle, shop or supermarket, particularly during transportation and storage prior to display, may be controlled to (i) minimize the formation and pooling of water in the bottom of fruit trays and/or (U) enhance evaporation of any water that forms during storage, the trays of the invention offer an improvement because a certain amount of water is absorbed (in complete contrast to a plastic tray) meaning (a) there is relatively less water to cause rotting of the fresh produce, and (b) less water needs to be evaporated though manipulation of the environmental in the transportation, storage and/or display area.

In certain embodiments, the additive for varying the moisture and/or water resistance of the tray is wax, for example, natural wax or synthetic wax. In certain embodiments, the wax is a natural wax selected from group consisting of paraffin wax, beeswax, rice bran wax, carnuba wax, candelilla wax, ouricury wax, sugarcane wax, retamo wax, lanolin and jojoba oil, and mixtures thereof. Advantageously, the wax is a paraffin wax. A paraffin wax is understood to refer to mixtures of mainly straight-chain, saturated hydrocarbons produced from petroleum, lignite or shale tar oil. An exemplary paraffin wax is BIM SE 9244, available from BIM (RTM) Kemi Sweden AB.

Like all of the components of the trays of the invention, the additive for varying the moisture and/or water resistance of the tray should comply with any regulatory requirements dealing with food packaging. These may vary depending on the territory in which the tray is to be used and sold. For example, the additive for varying the moisture and/or water resistance of the tray preferably complies with FDA: 21 CFR 176.170 (2012); FDA: 21 CFR 176.180 (2012); and BfR X)(XVI (2012) "Paper and board for food contact".

In certain embodiments, the tray comprises at least about 80 wt. % fibrous substrate and from about 0.1 to about 10 wt. % of the additive for varying the moisture and/or water resistance of the tray, based on the total weight of the tray, for example, at least about 90 wt. % fibrous substrate and from about 0.5 to about 5 wt.% of the additive for varying the moisture and/or water resistance of the tray, or at least about 95 wt. % fibrous substrate and from 0.5 to about 5 wt. % of the additive for varying the moisture and/or water resistance of the tray.

In certain embodiments, the tray is coloured. By coloured is meant that the colour of the tray is different to that of the natural colour of the fibrous substrate from which the tray is formed. Thus, in certain embodiments, the tray comprises a colourant, for example, a dye or pigment, preferably a dye. The colourant, e.g., dye, may be added during preparation of the pulp from which the tray is to be moulded, as discussed below. The colourant may be selected so to impart and desired colour to the tray. In certain embodiments, the colourant is a black colourant, blue colourant or a mixture of black and blue colourant, for example, a black dye, a blue dye or a mixture of black and blue dye. An exemplary black dye is Cartasol Black M-G liquid, available from Clariant (RTM) Products, Switzerland. An exemplary blue dye is Cartasol Blue K5R liquid, available from Clariant (RTM) Products, Switzerland.

The colourant should comply with any regulatory requirements pertaining to the use of colourants in food packaging. These may vary depending on the territory in which the tray is to be used and sold. For example, the colourant preferably complies with Regulation (EC) No 1935/2004 of the European Parliament and of the Council of 27 October 2004 on materials and articles intended to come into contact with food. The tray may comprise up to about 5 % by weight colourant, based on the total weight of the tray, for example, from about 0.1 to about 4.5 wt. % colourant, or from about 0.5 to about 4.0 wt. % colourant, or up to about 3.5 wt. % colourant, or up to about 3.0 wt. % colourant, or up to about 2.5 wt. % colourant, or up to about 2.0 wt. % colourant, or up to about 2.0 wt. % colourant, or up to about 1.5 wt. % colourant, or up to about 1.0 wt.

% colourant.

In certain embodiments, the tray further comprises a biocide. This may be added to protect the fresh produce, for example, to prevent or inhibit microbial spoilage, e.g., rotting, of the fresh produce, and also to protect the manufacturing equipment for making the tray. The biocide may be a synthetic or natural biocide, preferably a synthetic biocide. An exemplary natural biocide is chitosan. The biocide may be an antimicrobial agent, for example, a germicide, antibacterial agent, antifungal agent, antiprotozoal agent, or a antiparasite agent. Antimicrobial agents also include weak acids, organic acids (.e.g, e.g. lactic acid, citric acid, acetic acid, and their salts), bacteriocins, enzymes, and fungicides, among others.

In certain embodiments, the biocide is based on a quaternary ammonium compound.

Typically, these compounds comprise one or more polar quaternary amine head groups and a hydrophilic tail (e.g., a long alkyl chain). Although there can be many variations in the minutiae of their structures, the length of the alkyl chain is generally between about 8 and 20 carbon atoms, for example, between about 8 and 16 carbon atoms. An exemplary biocide of this type is Solcide SL 106 (Revision Nr: 0 of 15-08- 2011), available from Solstar (RTM). It is based on a twin chain quaternary ammonium compound. This biocide may also comprise glutral.

In certain embodiments, the biocide may be based on a glutaraldehyde compound and/or a isothiozolone compound, for example, 5-chloro-2-methyl-2H-isothiazol-3-one and/or 2-methyl-2H-isothiazol-3-one. An exemplary biocide is Solcide P 103 (Revision Nr: 0 of 12-05-2010), available from Solstar (RTM). Another exemplary biocide is Solcide P 112 (Revision Nr: 0 of 22-03-2011), available from Solstar(RTM).

In certain embodiments, the biocide may be based on an amide compound, for example, a propionamide, such as, for example, 2,2-di-bromo-3-nitrilo-propionamide.

An exemplary biocide is Solcide P 107 (Revision Ni: 0 of 10-04-2010), available from Solstar (RTM).

The biocide should comply with any regulatory requirements pertaining to the use of biocides in food packaging. These may vary depending on the territory in which the tray is to be used and sold.

In certain embodiments, the tray comprises up to about 3 wt. % biocide, for example, up to about 2 wt. % biocide, or up to about 1 wt. % biocide, or up to about 0.9 wt. % biocide, or up to about 0.8 wt. % biocide, or up to about 0.7 wt. % biocide, or up to about 0.6 wt. % biocide, or up to about 0.5 wt. % biocide, or up to about 0.4 wt. % biocide, or up to about 0.3 wt. % biocide, or up to about 0.2 wt. % biocide. Typically, when present, the tray will comprise at least about 0.05 wt. % biocide, for example, at least about 0.1 wt. % biocide.

In certain embodiments, the biocide is Houghto-cide 497.

The biocide may be added during preparation of the pulp from which the tray is to be moulded, as discussed below.

In certain embodiments, the tray consists of fibrous substrate and additive for varying the moisture and/or water resistance of the tray. In such embodiments, the fibrous substrate may constitute at least about 90 wt.%, or at least about 95 wt. % of the tray, with the balance additive for varying the moisture and/or water resistance of the tray.

In certain embodiments, the tray consists of fibrous substrate, the additive for varying the moisture and/or water resistance of the tray and colourant. In such embodiments, the fibrous substrate may constitute at least about 90 wt.%, or at least about 95 wt. % of the tray, with the balance additive for varying the moisture and/or water resistance of the tray and colourant.

In certain embodiments, the tray consists of fibrous substrate, the additive for varying the moisture and/or water resistance of the tray, colourant and biocide. In such embodiments, the fibrous substrate may constitute at least about 90 wt.%, or at least about 95 wt. % of the tray, with the balance additive for varying the moisture and/or water resistance of the tray, colourant and biocide.

In certain embodiments, the tray comprises: (i) from about 90-98 wt. % fibrous substrate; (U) from 0.1 to about 5 wt. % additive; (iii) from about 0.1 to about 4 wt. % colourant; and (iv) up to about 2.0 wt. % biocide, for example, up to about 1.0 wt. % biocide.

In accordance with the second aspect of the tray and in advantageous embodiments of the first aspect of the tray, the tray comprises a plurality of cells for housing individual pieces of fresh produce, wherein each cell is at least partly defined by a curved side-wall, wherein the curved side-wall is resiliently deformable such that locating a piece of fresh produce within the cell causes the side-wall to resiliently deform, thereby gripping the fresh produce. As such, each cell is tailored to the individual piece of fresh produce, e.g., nectarine or peach, that is housed therein.

Advantageously, the tray is a one-piece moulded tray which, when having a composition according to the first aspect of the invention, may be biodegradable and recyclable.

In the following discussion, reference is made to the illustrated embodiments depicted in Fig. 1A and 1 B. References to the figures are made to illustrate the invention and are not intended to limit the embodiments described below to embodiments having precisely the features depicted in the figures. In the following discussion, the invention may tend to be discussed in terms of a tray for fruit, and in relation to aspects where a tray for fruit is manufactured. The invention should be construed as being limited to such embodiments, and it will be understood that reference to fruit includes references to fresh produce.

In accordance with preferred embodiments, the curved side-wall (5) extends between a base (4) and an outer rim (1) of the tray and the steepness of the curved-side wall (5) increases with the height (h) of the tray. The base (4) is the lowermost part of the tray and as shown in the figures may constitute a part of each cell (p, q, r, s) of the tray.

Individual pieces of fruit are located in a cell. Preferably, one piece of fresh fruit is located in each cell (p, q, r, s).

In certain embodiments, the tray is configured such that a force required to deform the curved side-wall is less than the force required to damage a piece of fresh fruit. A person of skill in the art will be able to configure the tray according, depending on the type of size of fruit which is to be housed in each cell. Generally, the force required to damage (e.g., bruise) a soft-skinned fruit will be less than the force required to damage a harder skinned fruit, such as an apple. A person of skill in the art will be able to test a tray to determine if the force exerted by the curved-wall is likely to cause damage to the fruit and, if necessary, adjust the configuration of the tray (e.g., by reducing the steepness of the curved side-wall).

The intention is for the tray to grip the fruit to some extent, thereby securing the fruit in place. However, to minimise the contact area where the fruit is gripped, in certain embodiments, each cell is advantageously elongate in plan view (see Figure 1A).

Thus, in certain embodiments, each cell (p, q, r, s) is longer in a first direction (Y), which may be considered the length of the cell, which is perpendicular to a second direction (X), which may considered the width of the cell. In certain embodiments, the curved side-wall (5) at its steepest point is orientated in a plane which is perpendicular to the second direction (X), and/or parallel to the first direction (Y). In certain embodiments, the first direction is at least about 5 % longer than the second direction, for example, at least about 10 % longer than the second direction, or at least about 15 % longer than the second direction.

To facilitate the gripping action of the resiliently deformable side walls, the width of a cell along the second direction (X) is typically less than the diameter of an individual piece of fruit having a generally spherical portion to be located in the cell. The diameter of a piece of fruit is normally determined using a calliper. The diameter is the longest dimension, in mm, between points on the surface of the fruit that can be measured using a calliper. For example, a nectarine typically will have a diameter of from about 50 to about 80 mm, as measured by a calliper. Thus, the action of housing the fruit within the cell causes the resiliently deformable curved side wall to deform outwards.

In certain embodiments, the outer rim (1) defines, approximately, a rounded quadrilateral. The quadrilateral may be a square or rectangle. In certain embodiments, the outer rim defines a squircle.

The cells of the tray may be arranged linearly, side-by-side, within the outer rim. This arrangement would typically require the outer rim to define a rounded rectangle.

Preferably, each cell is separated from an adjacent cell by an internal divider (3). The internal divider is preferably of a height less than the height (h) of the other rim (1).

This means that the side wall of the cell proximate the internal divider is relatively less steep than curved side wall (5), and so the cell wall proximate the internal divider is relatively rigid compared to than curved side-wall (5). This enhances the structural integrity of the tray as a whole.

In certain embodiments, the height (h) of the tray is at least about 20 % the diameter (as defined above) of an individual piece of fruit, for example! at least about 20 % to no more than about 80 % the diameter of an individual piece of fruit. In certain embodiments, the height of the tray is at least about 25 % of the diameter of an individual piece of fruit, for example, about 30 %, or at least about 35 %, or at least about 40 %, or at least about 45 % the diameter of an individual piece of fruit. Where the fruit in a tray varies in size, the height pertains to the largest piece of fruit. In certain embodiments, height of the tray is from about 30 % to about 45 % of the diameter of an individual piece of fruit, for example, from about 30 % to about 40 % of the diameter of an individual piece of fruit. In certain embodiments, the height of the tray is at least about 20 mm, for example from about 20 to about 120 mm, or from about 25 to about 100 mm, or from about 30 to about 80 mm, or from about 30 to about mm, or from about 30 to about 60 mm, or from about 20 to about 50 mm. or from about 20 to about 45 mm, or from about 25 to about 50 mm, or from about 30 to about mm, or from about 35 to about 50 mm, or from about 25 to about 40 mm, or from about 25 to about 35 mm, oi from about 30 to about 40 mm, or from about 35 to about mm.

The number of cells in a tray may vary. In certain embodiments, the tray comprises between 1 and 16 cells, for example, 2 or 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10, or 11, 0112! or 13. or 14, or 15, or 16 cells. In certain embodiments, the tray comprises 2.

or 3, 014, 015, or 6 cells arranged linearly, side-by-side. In certain embodiments, the tray comprises four cells (p, q, r, s) arranged about a central point (2), again with each cell separated from an adjacent cell by an internal divider (3). In certain embodiments, the tray may comprise six cells (or even eight cells) with any four adjacent cells arranged about a central point, i.e., the cells are arranged in two parallel rows of three (or tour) cells. In certain embodiments, such as the four cell embodiment above, the cells are arranged symmetrically about the central point, e.g., with a plane of symmetry running along the length direction Y, through the central point, and/or a plane of symmetry running along the width direction, X, through the central point.

As depicted in Fig la., each cell may be generally hemi-ovoid in shape, although deviations from a mathematically perfect semi-ovoid are permitted.

In certain embodiments, each cell may be generally circular in profile and/or generally hemi-spherical in shape.

In particularly preferred embodiments, the plurality of cells are arranged such that individual pieces of fresh produce do not touch each other when located within the cells. Thus, for example, in embodiments in which the tray comprises internal dividers, the dividers may be sized such that the fruit in adjacent cells do not touch. This is advantageous as it reduces the chances of damage to the outer surface of the fruit and may also serve as a physical barrier to the migration of lot or fungal growth from one piece of fruit to another.

In certain embodiments, the overhang portion of the outer rim is minimized in order to reduce the rigidity of the tray. The overhang portion is not shown in the Figures.

However, it comprises a lip extending away from and generally downward from the outer rim. Generally, the larger the lip, the more rigid the outer rim. This can have a detrimental effect on fruit during transportation and storage. The size of the lip may be reduced during the manufacturing process, as discussed below, by careful transfer of the rnoulded tray from the mould to the drying stage.

The walls of the tray will generally be of uniform thickness, for example, between about 0.5 and 1.5 mm in thickness, for example, between about 0.7 and 1.4 mm, in thickness, for example, between about 0.8 mm and 1.3 mm in thickness, for example, between about 0.9 and 1.2 mm in thickness.

The present invention is also directed to a packaged tray of fresh produce comprising a tray according to first and/or second aspects of the invention and individual pieces of fresh produce. In preferred embodiments, the packaged tray of fresh produce comprises an outer wrapper. The wrapper may comprise or is (i.e., consist of) a transparent film, which may be perforated. Perforations may enhance the breathability of the film. Labelling may be fixed to the wrapping, by physical means or by printing directly on to the wrapper.

In accordance with a third aspect of the invention, a process is provided for preparing the one-piece moulded tray of the invention. The process comprises: i) preparing, providing or obtaining a pulp comprising suitable amounts of fibrous substrate, additive for varying the moisture and/or water resistance, and optional biocide; and ii) moulding a one-piece tray therefrom.

The fibrous substrate may be pulped in any suitable pulper. Such apparatus is well known to the those skilled in the art.

Advantageously, the pulp is obtained by pulping recycled paper or paper board, e.g., corrugators trim, to obtain a recycled paper pulp and mixing in appropriate amounts of the additive for varying the moisture and/or water resistance of the tray, colourant and biocide.

The fibrous substrate, e.g., recycled paper or paper board, may be added to the pulper pre-shredded. Typically, the solid content of the pulp is up to about 10 wt. %, based on the total weight of the solid. An appropriate an amount of water relative to the amount of fibrous may be added in order to achieve the desired solids content. In certain embodiments, the solids content in the pulper is less than about 8 wt. %, or less than about 6 wt. %, or less than about 5 wt. % or less than about 4 wt. %, or less than about 3 wt. %, or less than about 2 wt. %. In certain embodiments, the solids content in the pulper is about 1-6 wt. %, for example, from about 2-5 wt. %, or from about 3-5 wt. %, or from about 3-4 wt. %, or from about 3.5-4.5 wt. %.

Typically, the additive for varying the moisture and/or water resistance of the tray, e.g., wax, and optional colourant and biocide are added during pulping in suitable amounts depending on the desired composition of the tray. In certain embodiments, the biocide, when present, may be added in the water feed to the pulper, for example, added in the white water tank fluidly connected to the pulper. Following pulping, the resultant pulp is forwarded to the moulding apparatus. The solids content of the pulp may be reduced (i.e., by making down with additional water) as it passed to the moulding apparatus. In certain embodiments, the solids content of the pulp is less than about 2 wt. % for moulding, for example, between about 1 and 2 wt. %, or from about 1.4 to about 1.8 wt.

%, or from about 1.5 to about 1.7 wt. %. The pulp is typically stored in a pulp tank.

In preferred embodiments, the tray is vacuum moulded from the pulp. In certain embodiments, a wire mesh mould tailored to the shape of the tray is submerged in a vat (or any other suitable means for storing the pulp) comprising the pulp. In these embodiments, the wire mesh mould would be regarded as a "male" tool with the cavities (corresponding to, for example, the cells of the tray) protruding upwards from a substantially flat base. A vacuum is then applied from within the mould tool. The vacuum pulls the paper on to the mesh surface of the tool and perforations in the body of the tool allow the water to pass through, leaving the pulp behind formed into the desired shape of tray. In an alternative embodiment, the pulp is applied to the wire mesh mould by spraying, before the vacuum being applied as described above. The moulded tray is then transferred to a drying stage.

Typically, the tray is removed from the mould by suction and then set down on a conveyor belt (with the back surface of the tray (which in use would be the base of the tray) facing upwards. In a preferred embodiments, the setting down during transfer includes the use of air, known as transfer air, to blow the tray from the transfer on the conveyor belt. In advantageous embodiments, the air flow is reduced or controlled to cause the tray to settle gently on the conveyor belt so to minimize the extent of the overhang portion of the outer trim. In this respect, the greater the force with which the tray meets the conveyor belt, the greater the overhang portion that forms because the outer rim of the tray tends to be pushed out upon contact with the surface of the conveyor belt.

Following transfer and set down the tray is dried and then sent for storage or packaging. Drying may be performed by any suitable drying means, for example, a drying oven. In a preferred embodiment! drying is performed using super-heated steam, e.g., using a Merrill Airdyne dryer. This advantageously reduces the drying time, for example, to 15 mins or less per tray, for example, 12 mins or less, or about 10 mins.

In certain advantageous embodiments, the tray whilst attached to the mould is subjected to a wet press, typically applied to the back surface of the tray using a "female" mould complimentary in form to the "male" moulding tool. This has the advantage of compacting the tray and also serves to reduce the water content, pre-drying, by upto about 10 wt. %. This means less energy is required in the drying stage because there is less water to dry out from the tray. Further, the wet press tends to smooth out the back surface of the tray, which can be aesthetically pleasing to the eye.

For the avoidance of doubt, the present application is also directed to the subject-matter described below, which corresponds to the subject-matter described in the UK priority application, GB1 300988.1.

Moulds may be created resultant from the tailored design requirements of the specific fruit.

To accommodate stability of the fruit during transportation, the individual cups may be tailored to the shape of the fruit (see figure 2).

The side walls of the tray may be measured to be at least 40% of the fruit in order to enhance stability (see figure 3).

The interior of the cups may be designed to be soft in order to prevent bruising of the fruits (see figure 4).

A mixture of recycled paper fibres, biocide (Houghto-cide 497) and wax may be blended together in a hydra pulper, slurrying the mix.

Wax may be added to the mixture in order to overcome moisture related degradation of the structural integrity of the finished product.

Houghto-cide 497 may be added to the mixture in order to overcome fruit rotting during cold transportation.

The slurry form mix is typically transferred via a series of pumps and valves to a moulding machine.

The design of the underside of ESPuIp trays may be deliberately course textured in order to enhance the eco-friendly image of the customer and to reinforce the biodegradable nature of the packaging.

The ESPuIp trays are then formed using a vacuum moulding process.

A drying process is then applied, optionally either through an oven or a heated press.

Additional subject-matter is described in the following numbered paragraphs: 1. A ripened fruit tray constructed of heat-dried vacuum moulded recyclable pulped paper consisting of recycled paper fibres! biocide (Houghto-cide 497) and wax, tailored to the shape of individual fruit.

2. A ripened fruit tray according to numbered paragraph 1 in which the internal compartments are constructed to cushion the contained fruit during transportation.

3. A ripened fruit tray according to numbered paragraph 1 in which the underside of the tray is deliberately course textured in order to specifically identify the product as eco-friendly.

4. A ripened fruit tray according to numbered paragraph 1 in which the pulped paper slurry is blended with wax in order to increase stability.

5. A ripened fruit tray according to numbered paragraph 1 in which the pulped paper slurry mixture is blended with Houghto-cide 497 to prevent rot of fruit and degradation of the structural integrity of the tray during cold transportation and storage.

Also disclosed is a form moulded pulped paper tray to contain and preserve ripened fruit in its picked state utilising tailored open structure material for moisture absorbency and rot prevention, and custom structural design to prevent damage to the fruit during tiansportation and display.

Claims

CLAIMS1. A tray for fresh produce, wherein the tray comprises a fibrous substrate and an additive for varying the moisture and/or water resistance of the tray, wherein the additive for varying the moisture and/or water resistance of the tray is present in an amount (i) sufficient to prevent the tray from absorbing moisture and/or water to the extent that the integrity of the tray is compromised in use, and (ii) such that the tray is able to absorb an amount of moisture and/or water to the extent that the flexibility of the tray is increased.
2. The tray according to claim 1, wherein the fibrous substrate is derived from wood, grasses (e.g., sugarcane, bamboo) or rags (e.g., textile waste, cotton, hemp or flax).
3. The tray according to claim 2, wherein the fibrous substrate is derived from recycled paper.
4. The tray according to any preceding claim, wherein the tray comprises at least about 80 wt. % fibrous substrate and from about 0.1 to about 10 wt. % of the additive for varying the moisture and/or water resistance of the tray, based on the total weight of the tray.
5. The tray according to claim 4, wherein the tray comprises at least about 90 wt.% fibrous substrate and from about 0.5 to about 5 wt. % of the additive for varying the moisture and/or water resistance of the tray.
6. The tray according to any preceding claim, wherein the additive for varying the moisture and/or water resistance of the tray is wax.
7. The tray according to claim 6, wherein the wax is a natural or synthetic wax.
8. The tray according to 7, wherein the wax is a natural wax selected from the group consisting of paraffin wax, beeswax, rice bran wax, carnuba wax, candelilla wax, ouricury wax, sugarcane wax, retamo wax, lanolin and jojoba oil, and mixtures thereof.
9. The tray according to claim 8, wherein the wax comprises or is paraffin wax.
10. The tray according to any preceding claim! further comprising a biocide, for example, an antimicrobial agent, optionally wherein the biocide is based on a quaternary ammoniurn compound.
11. A tray for fresh produce, said tray comprising: a plurality of cells for housing individual pieces of fresh produce, wherein each cell is at least partly defined by a curved side-wall, wherein the curved side-wall is resiliently deformable such that locating a piece of fresh produce within the cell causes the side-wall to resiliently deform, thereby gripping the fresh produce.
12. The tray according to claim 11, wherein the curved side-wall extends between a base and outer rim of the tray and the steepness of the curved-side wall increases with height.
13. The tray according to claim 11 or 12, wherein the force required to deform the curved side-wall is less than the force required to damage a piece of fresh produce.
14. The tray according to any one of claims 11-13, wherein each cell is generally elongate in plan view.
15. The tray according to claim 14, wherein each cell, in plan view, is longer in a first direction (length) which is perpendicular to a second direction (width).
16. The tray according to claim 15, wherein the curved side-wall at its steepest point is orientated in a plane which is (i) perpendicular to the second direction, and/or (ii) parallel to the first direction.
17. The tray according to claim 15 or 16, wherein the first direction is at least about % longer than the second direction, for example, at least about 10 % longer than the second direction, or at least about 15 % longer than the second direction.
18. The tray according to any one of claims 16-18, wherein a width of a cell along the second direction is less than the diameter of an individual piece of fresh produce having a generally spherical portion to be located in the cell.
19. The tray according to any one of claims 12-18. wherein the outer rim defines, approximately, a rounded quadrilateral.
20. The tray according to claim 19, wherein the quadrilateral is a square or rectangle.
21. The tray according to any one of claims 11-20. wherein cells arranged side-by-side within the outer rim, each cell separated from an adjacent cell by an internal divider, optionally wherein the internal divider is of a height less than the height of the other rim.
22. The tray according to claim any one of claims 11-21, wherein the tray comprises four cells arranged about a central point, each cell separated from an adjacent cell by an internal divider, optionally wherein the internal divider is of a height which is less than the height of the outer rim.
23. The tray according to claim 22, wherein the cells are arranged symmetrically about the central point.
24. The tray according to any one of claims 11-23, wherein each cell is generally hemi-ovoid in shape.
25. The tray according to any one of claims 11-24, wherein the plurality of cells are arranged such that individual pieces of fresh produce do not touch each other when located within the cells.
26. The tray according to any one of claims 11-25, wherein an overhang portion of the outer rim is minimized in order to reduce the rigidity of the tray.
27. The tray according to any preceding claim, wherein the tray is a one-piece moulded tray.
28. A one-piece moulded tray according to any one of claims 11-27 and having a composition as defined in any one of claims 1-10.
29. A biodegradable and/or recyclable tray according to any preceding claim.
30. A packaged tray of fresh produce comprising a tray according to any preceding claim and individual pieces of fresh produce, optionally wherein the packaged tray of fresh produce comprises an outer wrapper, optionally wherein the outer wrapper comprises or is a transparent film.
31. A process for preparing the one-piece moulded tray according to claim 28, said process comprising: i) preparing, providing or obtaining a pulp comprising suitable amounts of fibrous substrate, additive for varying the moisture and/or water resistance, and optional biocide; and H) moulding a one-piece tray therefrom.
32. The process of claim 31, wherein the is obtained by pulping recycled paper to obtain a recycled paper pulp and mixing the pulp with the additive for varying the moisture and/or water resistance and optional biocide.
33. The process according to claim 32, wherein moulding is by vacuum moulding.
34. The process according to any one of claims 31-33, further comprising drying the tray, optionally using superheated steam.
35. The process according to any one of claims 31-34, wherein following formation of the tray in the mould and prior to transfer to a drying stage, the tray is wet pressed while in the mould.Amendments to claims have been filed as followsCLAIMS1. A one-piece moulded tray for fresh produce, wherein the tray comprises a fibrous substrate and from 0.1 to 10 wt. % of a moisture-absorbing additive, based on the total weight of the tray, wherein the tray comprises a plurality of cells for housing individual pieces of fresh produce, wherein each cell is at least partly defined by a curved side-wall, wherein the curved side-wall is resiliently deformable such that locating a piece of fresh produce within the cell causes the side-wall to resiliently deform, thereby gripping the fresh produce; and wherein the moisture-absorbing additive is wax.2. The tray according to claim 1, wherein the fibrous substrate is derived from 3. The tray according to claim 2, wherein the fibrous substrate is derived from recycled paper.4. The tray according to any preceding claim, wherein the tray comprises at least 0 80 wt. % fibrous substrate based on the total weight of the tray.o 5. The tray according to claim 4, wherein the tray comprises at least 90 wt. % fibrous substrate and from 0.5 to 5 wt. % of the additive for varying the moisture and water resistance of the tray.6. The tray according to claim 1, wherein the wax is a natural or synthetic wax.7. The tray according to 6, wherein the wax is a natural wax selected from the group consisting of paraffin wax, beeswax, rice bran wax. carnuba wax, candelilla wax, ouricury wax, sugarcane wax, retamo wax, lanolin and jojoba oil, and mixtures thereof.8. The tray according to claim 7, wherein the wax comprises or is paraffin wax.9. The tray according to any preceding claim, further comprising a biocide.10. The tray according to claim 9, wherein the biocide is an antimicrobial agent.11. The tray according to claim 9, wherein the biocide is based on a quaternary ammonium compound.12. The tray according to claim 1, wherein the curved side-wall extends between a base and outer rim of the tray and the steepness of the curved-side wall increases with height.13. The tray according to claim 12, wherein each cell is generally elongate in plan view.14. The tray according to claim 13, wherein each cell, in plan view, is longer in a first direction (length) which is perpendicular to a second direction (width).15. The tray according to claim 14, wherein the curved side-wall at its steepest point is orientated in a plane which is (i) perpendicular to the second direction, and (ii) parallel to the first direction.16. The tray according to claim 14 or 15, wherein the first direction is at least 5 % longer than the second direction.17. The tray according to any one of claims 12-16, wherein the outer rim defines, approximately, a rounded quadrilateral.18. The tray according to claim 17, wherein the quadrilateral is a square or o 19. The tray according to any one of claims 12-18, wherein cells arranged side-by-side within the outer rim, each cell separated from an adjacent cell by an internal divider, optionally wherein the internal divider is of a height less than the height of the other rim.20. The tray according to claim any one of claims 1-19, wherein the tray comprises four cells arranged about a central point, each cell separated from an adjacent cell by an internal divider, optionally wherein the internal divider is of a height which is less than the height of the outer rim.21. The tray according to claim 20, wherein the cells are arranged symmetrically about the central point.22. The tray according to any one of claims 1-21, wherein each cell is generally hemi-ovoid in shape.23. A biodegradable tray according to any preceding claim.24. A recyclable tray according to any one of claims 1-22.25. A packaged tray of fresh produce comprising a tray according to any preceding claim and individual pieces of fresh produce, optionally wherein the packaged tray of fresh produce comprises an outer wrapper, optionally wherein the outer wrapper comprises or is a transparent film.26. A process for preparing the one-piece moulded tray according to any one of claims 1-22, said process comprising: i) preparing, providing or obtaining a pulp comprising suitable amounts of fibious substrate, wax, and optional biocide; and ü) moulding a one-piece tray therefrom.27. The process of claim 26, wherein the pulp is obtained by pulping recycled paper to obtain a recycled paper pulp and mixing the pulp with the wax and optional C) biocide.N-28. The process according to claim 27, wherein moulding is by vacuum moulding.29. The process according to any one of claims 26-28, further comprising drying the tray, optionally using superheated steam.30. The process according to any one of claims 26-29, wherein following formation of the tray in the mould and prior to transfer to a drying stage, the tray is wet pressed while in the mould.