Abstract:
According to the present disclosure, there is provided a container to food product ( 20 ) having a self-standing flexible pouch ( 22 ); a raw wet protein portion ( 14 ) disposed within the pouch ( 22 ); and a closure ( 34 ) sealing the pouch ( 22 ). There may also be provided a method of packaging a raw wet protein portion ( 14 ) for retail, the method comprising: opening an empty self-standing flexible pouch ( 22 ); filling the empty pouch ( 22 ) with a raw wet protein portion ( 14 ); and sealing the pouch ( 20 ).

Description:
FIELD 
       [0001]    The present invention describes a food product and a method of packaging a raw wet protein product for retail. In particular, a food product packaging comprising a self-standing flexible pouch and raw wet protein portions is described. 
       BACKGROUND 
       [0002]    The sale of raw wet protein products, in particular poultry, typically involves packaging made out of 3 components. A tray, such as a rigid plastic or polystyrene tray or container on which the meat is placed, a plastic film and a conventional wrap label are all required. The space beneath the plastic film can contain gases to prevent the food from deteriorating/to stop its appearance degrading with time. Such packages are sometimes called tray lidded CAP (controlled atmosphere packaging) packs. Such packages are typically sold in the chiller cabinets of supermarkets as a fresh product. Such packages are ubiquitous primarily because they are easily stackable and present the product to the consumer. 
         [0003]    A problem with tray lidded CAP packs are that they only allow for a limited number of display options, due to the pack layout. Additionally, the rigid materials used tend to occupy more space in consumer bins and landfill. 
         [0004]    Focusing on the disadvantages of conventional packaging (such as tray lidded CAP packs) of raw wet protein products for producers, during the filling process, the empty trays, film and conventional wrap label all need to be transported to the filling factory. For example, the storage requirements for 50,000 trays and the associated film and conventional wrap are approximately 7 pallets vs. 1 pallet for 50,000 flexible pouches. Based on 7½ million trays per annum, this equals approximately 709 pallets or 27 full load lorries. 
         [0005]    A problem with transporting traditional polystyrene trays is that they take up a lot of space for their weight. The delivery lorry still uses fuel, and wears itself out, driving with a very light load of plastic trays. The plastic trays take up a lot of space in the packaging factory whilst they are waiting to be used. 
         [0006]    A further problem for conventional packaging is that the trays require manual handling during filling to ensure that the product is orientated the correct way in the packaging. This is labour intensive. Once packed, the plastic trays are weighed and allowed to proceed along a conveyor belt to a sealing station, where the plastic film is sealed to the tray, covering the raw wet protein inside the tray. Manual handling can cause cross contamination including transfer of uncooked meat juices or products to the outside of the tray, lid, conventional wrap, staff and all ancillary equipment. Different tray sizes, used for different products, also require an associated downtime and changeover of tools, with the associated additional time and cost involved. 
         [0007]    One final important issue is that the machines used to apply the raw wet protein portions to the tray require gas flushing of the complete tool chamber in order to ensure that the atmosphere (also called premix air) sealed within the tray by the lid is of the required constituents. The trays are then driven by lorry to a supermarket and put into typically waist-high refrigerated cabinets for display to be purchased by customers. 
         [0008]    The meat packing industry is very conservative when it comes to safety. There are on-going concerns about bacterial contamination of raw wet protein. The manufacturing factories are very reluctant to change anything for fear of causing contamination problems. 
         [0009]    For retailers, conventional trays offer only a limited number of chiller cabinet display options. This is a particular issue for these products because the graphics are typically restricted to the front lid only or the conventional wrap label. Both the front lid and the conventional wrap label are generally aligned away from the consumer, making the product packaging less appealing. Again, based on 7½ million trays, approximately 44,000 kg of packaging is used, which retailers are required to declare. Additionally, as noted above, there is a risk of cross contamination due to transfer from the packer in the production and filling factory to the store and on to the consumers shopping trolley, which may contain other products including baby food, fresh fruit and salads. 
         [0010]    Additional considerations are the current disadvantages of the present tray lidded CAP packs for the consumer. In addition to the cross contamination issues during purchase of the tray, there is further risk of cross contamination within shopping bags and fridges. The lids of the CAP trays are typically weld sealed and require the use of a sharp implement to open the packs. Once opened, of raw wet protein generally has to be handled before being transferred into a cooking vessel, which is unpleasant for some people. Any unused or accidentally opened raw product has to be used at once or stored in a separate leakproof container. If the product is to be frozen, the trays due to their bulky and rigid nature occupy significantly greater space in the freezer than the raw wet protein product. Once used, the recyclable trays are rigid, bulky and occupy a lot of bin space. 
         [0011]    It is known to make plastic pouches for cereals that are self-standing. However, dry foodstuffs, such as cereals, are often packaged in a completely different factories than raw wet protein products (such as raw meat). Dry foodstuffs are quite a different industry. For example, such pouches may not have special atmospheres inside them involving Vac/gas flush cycle. It is also known to make non-self-standing sachets of cooked protein—for example catfood. However, such pouches do not self-stand, require refrigeration and are not “pure” unalloyed, meat—it is meat in a sauce, or meat in a jelly, and has often been cooked. It is not uncooked, natural, “raw”, meat for human consumption. Accordingly, the processes for such retort cooking products are by necessity different to the requirements for a chilled raw product. 
         [0012]    This invention provides an alternative packaging solution for raw wet protein products that at least partially addresses or alleviates the above disadvantages of conventional packaging. 
         [0013]    In summary, for at least the reasons outlined above, an improved raw wet protein product and method for packaging a raw wet protein product for retail is desired. 
       SUMMARY 
       [0014]    These and other aspects of the invention will be apparent from, and elucidated with reference to, the embodiments described hereinafter. 
         [0015]    According to a first aspect of the present invention, there is provided a food product comprising: a self-standing flexible pouch; a raw wet protein portion within the pouch; and a closure sealing the pouch. 
         [0016]    By providing a food product with raw wet protein portions in such pouches or packaging the waste of packaging is significantly reduced. This reduces the packaging for the producer, retailer and particularly the consumer therefore increasing the green, ecologically sound, nature of the packaging when compared to traditional raw meat packaging. 
         [0017]    By self-standing, it is intended that the product is able to stand upright on a substantially flat surface such as a refrigerated display shelf without support. Such self-standing pouches are sometimes called self-supporting pouches or upstanding pouches. Typically, such self-standing pouches are taller than they are wide—this creates a pleasing appearance on display shelving (the appearance that they are standing upright). 
         [0018]    For example, a packaging factory typically orders one pallet of plastic pouches or even a roll of plastic film if the pouches are made from the film on-site. The empty plastic pouches (if they are pre-formed/made elsewhere), or the roll of film, takes up far less space in the delivery lorry. The plastic pouches are typically lighter than a polystyrene tray. However a further advantage is that it is a more efficient use of the delivery logistics, and storage logistics, at the packaging factory to have plastic pouches. The pouches are normally formed from a single sheet of plastic folding, and sealed to itself. 
         [0019]    Once purchased, the consumer can take the packaging home and open it—for example by cutting open the top. In some embodiments the opening of the closure allows the raw wet protein portion to be dispensed by upturning and squeezing the pouch. The consumer may then pour or squeeze the wet protein foodstuff out of the packet/pouch. This can avoid the user touching the chicken—some consumers do not like to touch wet raw wet protein portions. 
         [0020]    In other examples, the closure is integral with the pouch and is optionally a tearable portion of the pouch. Alternatively, the closure is a zipper for sealing the pouch. In such embodiments, the zipper allows the pouch to be resealed after opening. 
         [0021]    In embodiments the pouch can have an antibacterial coating. This coating is typically on the external surface of the pouch. 
         [0022]    It can be appreciated that the raw wet protein portion may consist mainly of raw wet protein in addition to associated products such as water. Sauces and/or marinades may also be added to the pouch to form part of the intended raw wet protein portion for consumption. The raw wet protein portion may be a poultry meat portion. For example, diced chicken, strips of chicken, or small chicken fillets. Other wet small piece raw protein foodstuff/solid foodstuffs may also be used, for example pork, lamb, venison, rabbit, minced meat, fish, shellfish, etc. 
         [0023]    One advantage of using a pouch is that label information may be used that is printed directly onto the pouch. The label information on the pouches can be displayed vertically—as opposed to the traditional way of displaying flat trays of chicken—which is horizontally—and where customers have to look down at the label to see it—and so there is a limit in the height at which packaged chicken can be displayed in a supermarket. By having the label information/graphical information on the pouch on the pouch displayed vertically, the pouches can be displayed to users at higher heights, including above waist height, for example at chest height, eye level, etc. 
         [0024]    Due to the nature of the raw wet protein portions within the pouch, the packaging typically requires refrigeration. 
         [0025]    The pouch of the food product will in many embodiments be transparent, or at least partially transparent such as having a transparent window—so that the customer can see the raw wet protein portion, and can see that it looks fresh. This can be an important buying criterion. An attraction of raw wet protein in a transparent pouch is that you can see the meat, and decide that you like the look of it prior to purchase. 
         [0026]    The pouch may have an altered internal atmosphere. The composition of the altered internal atmosphere can be tailored to keep the wet protein portion in the best condition to prevent the wet protein from soiling in taste and/or appearance. 
         [0027]    When the raw wet protein portion is removed from the pouch, the packaging is typically able to be flattened. For example, when the end user opens the plastic pouch and dispenses the raw wet protein portion they are left with a flat, thin, flexible, plastic pouch that takes up very little space. They can put this into their domestic rubbish bin and it takes up far less space than a conventional polystyrene tray, which has a depth, due to side walls, and is quite rigid—some people break the polystyrene tray into two to reduce the space it takes up. The volume of landfill is therefore reduced by using the present invention. 
         [0028]    The pouches do not have to be substantially rectangular, they may be shaped to provide aesthetic benefits, such as to reflect the contents and/or origin of the raw wet protein contained therein. 
         [0029]    According to a second aspect of the present invention there is provided a method of packaging a raw wet protein portion for retail, the method comprising: opening an empty self-standing flexible pouch; filling the empty pouch with a raw wet protein portion; and closing and sealing the pouch. By empty, it is appreciated that this means generally empty of existing products. Indeed, typically, such self-standing flexible pouches are normally provided flat. Accordingly, the step of opening the pouch may require some inflation of the pouch. Alternatively, or additionally, the pouch may be pinched open or it may be opened in another conventional way. 
         [0030]    The machine for filling the packets/pouches can also weigh them after filling, and instead of having 10 people pick up strips of raw wet protein portions such as chicken and pieces of chicken and placing them in polystyrene trays on a moving conveyor belt, and a human weighing the filled tray, there will be no one at all filling the container—a filling machine will have raw wet protein portions fed into it, and the machine will have a weighing station for ensuring a consistent weight of raw wet protein portions, a filling station for filling the pouches, an atmosphere modification station for injecting an altered atmosphere into the pouches, and a sealing station for sealing closed the pouches. All of these stations might be located at the same place—all the stations might be the same station. Typically, it can be a rotary or carousel arrangement with different functions at different places. 
         [0031]    After filling the pouch the method can further comprising the steps of: evacuating air from within the unsealed filled pouch; and injecting a pre-mixed gas into the evacuated pouch. The pre-mixed gas may be a composition for preserving the raw wet protein portions as outlined in the first aspect. Air may be evacuated from the unsealed filled pouch by insertion of a snorkel into the pouch. The pre-mixed gas may also be injected into the evacuated pouch using the snorkel or an additional snorkel. This step may be performed prior to closing the pouch or prior to sealing the pouch after closing the pouch—in the latter case, the snorkel may be inserted into the closed pouch or the pouch may be closed around the snorkel, which is then removed. 
         [0032]    Then the package is sealed with the “altered” atmosphere inside it. The sealing is performed quick enough to ensure that the altered special atmosphere remains within the package. This is not the same thing as filling the packet in a general chamber of special atmosphere; advantageously the entire room does not need to be in the special atmosphere. 
         [0033]    Opening the pouch may further comprise the step of confirming that the pouch is fully open. A sensor can be used in the machine to detect if the pouches are open. If the sensor detects that the pouch is not open, a signal is sent to pause the production line and to not drop the wet protein portions until the next bag arrives. This ensures that the raw wet protein portions are correctly inserted into the pouches. 
         [0034]    Sealing the pouch can further comprise the step of applying heat and/or pressure to a portion of the pouch. This acts to seal the pouch, typically along a predefined portion of the pouch aligned with a tear notch or zipper. After sealing, the sealed pouch can be cooled to ensure the seal is fully cured. 
         [0035]    Once filled and sealed, the sealed pouch is discharged for further processing. This may include weighing or labelling or metal detector stations. 
         [0036]    The pouches may have an antibacterial coating. The coating may be applied to the outside surface of the pouch and optionally also to the inside surface of the pouch. Application to the outside of the pouch aids prevention of cross-contamination. The pouches may be either provided to the machine for filling the pouches with the antibacterial coating pre-applied (i.e. before filling of the pouches), or the coating may be applied to the filled pouches (for example by spraying or printing). 
         [0037]    According to another aspect of the present invention there is defined a raw wet protein portion packaged according to the second aspect. 
         [0038]    According to a third aspect, there is provided a self-standing flexible pouch for packaging wet protein portions, said pouch comprising: a closure for sealing the pouch; wherein the pouch has an antibacterial coating, optionally or preferably on the external surface of the pouch. It can be appreciated that features described as relevant to the first aspect (and second aspect) can be applied to the third aspect. 
         [0039]    According to another aspect, there is provided a refrigerated display unit having a shelf, wherein the packaging according to any embodiment of the first aspect is provided on the shelf such that the pouch is presented vertically. The pouch may be presented at approximately above waist height of an average consumer. 
         [0040]    According to another aspect of the present invention, there is provided a method of decanting raw wet protein portions from packaging, comprising the steps of: providing a food product packaging according to any embodiment of the first aspect; opening the closure to allow access to the raw wet protein portion; inverting the packaging; and/or squeezing the packaging. 
         [0041]    According to another aspect of the present invention there is provided a method of reducing packaging waste of packaged raw wet protein, the method comprising providing a packaged raw wet protein portion in a food product packaging according to any embodiment of the first aspect. 
         [0042]    According to another aspect of the present invention there is defined the use of a self-standing plastic pouch in the packaging and display of packaged raw wet protein portions to reduce the volume of domestic waste associated with the packaging once the raw wet protein has been used by a consumer. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0043]    Embodiments will be described, by way of example only, with reference to the drawings, in which 
           [0044]      FIG. 1  illustrates a known sealed food product packaging; 
           [0045]      FIG. 2  illustrates an empty opened pouch according to aspects of the present invention; 
           [0046]      FIG. 3  a food product according to aspects of the present invention, including the pouch of  FIG. 2 ; 
           [0047]      FIG. 4 a    is a side view of a known production line for producing food products as shown in  FIG. 1 ; 
           [0048]      FIG. 4 b    is a top view of the production line of  FIG. 4   a;    
           [0049]      FIG. 5 a    is a side view of a production line for producing food products as shown in  FIG. 3 ; 
           [0050]      FIG. 5 b    is a top view of the production line of  FIG. 5   a;    
           [0051]      FIG. 6  is an enlarged section of part of the production line shown in  FIG. 5   b;    
           [0052]      FIG. 7 a    is a side view of part of the production line shown in  FIG. 6 ; 
           [0053]      FIG. 7 b    is a top view of the part shown in  FIG. 7 a   ; and 
           [0054]      FIG. 8  is a schematic of a valve system shown in  FIGS. 7 a    and  7   b.    
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0055]      FIG. 1  shows a known food product  10  for the packaging and display of raw wet protein portions, such as portions of poultry or other raw wet protein products, including fish, shellfish, pork, beef, etc. Such food product packaging is sometimes called tray lidded CAP pack.  FIG. 1  shows a tray  12  into which portions  14  of raw wet meat protein are typically placed. The trade  12  may be transparent, translucent or any other colour chosen typically to enhance the appeal of the finished food product on the supermarket shelf. The tray is typically made from polystyrene or other such rigid plastic material The tray  12  defines a space into which the portions  14  are placed. The tray may be sealed by a, typically transparent, plastics film  16  and may be adorned with a label (not shown). 
         [0056]      FIG. 2  shows a food product  20  according to aspects of the present invention. The product  20  has a pouch  22  with an opening  24 . The opening  24  allows access to the interior of the pouch  22  into which portions of raw wet protein portions  14  may be placed. The product  20  also has a transparent window or portion  26  through which the portions  14  can be viewed by a consumer. It can be appreciated that the size, transparency and presence of the transparent portion may be tailored for different food products. The product  20  also features a tear strip  28  that allows for removal of a top portion  30  of the pouch  22  after the pouch has been sealed, allowing access to the contents of the pouch  22 . 
         [0057]    The pouch  22  of the food product  20  is provided with a base portion  32  that is at least as wide as the opening  24 . This allows the food product  20  to be self-supporting or upstanding so that it can be placed onto a shelf vertically, displaying the contents or labelling of the pouch  22  to a consumer. As shown, the pouch  22  is generally taller than its width and depth to create the illusion that the pouch  22  is standing whilst on display. The pouch  22  may be tapered, that is the opening  24  may be smaller than the base portion  32 , but generally the opening  24  and base portion  32  are the same size. 
         [0058]    The opening  24  is shown as running along the upper length of the pouch  22 , however it can be appreciated that the opening may be smaller in size and only allow access across a portion of the upper surface  30  of the pouch  22 . Additionally or alternatively, the opening  24  may be provided at least partially on the side wall of the pouch  22  to create a side or corner opening. 
         [0059]    The pouch  22  is typically made from a laminate structure comprising several layers such as polypropylene contacting the raw wet protein portions and polyester as an outer layer to provide strength to the pouch and a printable surface. Barrier layers such as aluminium foil and abrasion resistance layers such as nylon may also be provided. This construction allows the pouch  22  to be flexible whilst self-standing or self-supporting. It also allows the pouch  22  to be flattened when empty. 
         [0060]      FIG. 3  shows the food product  20  of  FIG. 2  after the mouth or opening  24  of the pouch  22  has been sealed. In the example shown, the top portion  30  of the pouch  22  above the tear strip  28  has been heat sealed to bond the opening  24  closed. Accordingly, the closure  34  is integral with the pouch  22 . It can be appreciated that other closures may be used including a zipper. Use of a zipper allows for resealing of the pouch  22  after opening. 
         [0061]    The pouch  22  is provided with an antibacterial coating (not shown) provided on the external surface of the pouch  22 . Label information and graphical information can be printed directly onto the external surface of the pouch providing a cleaner and neater finished look to the product  20 . Such information is provided vertically to allow consumers to view the information easily when the product is stacked vertically and self-standing on a shelf. 
         [0062]      FIGS. 4 a  and 4 b    show a production line  100  for providing the food products  10  shown in  FIG. 1 . The production line has workers  102 , in the example shown 14 workers  102 , at different stages of the production line. In the example shown, 12 workers are at a weigh and fill station  104  where trays  106  are filled with raw wet protein portions and weighed. The trays  106  are then placed onto a conveyor and into a tray lidding machine  108  where the transparent film  16  is added. Once sealed, the trays  106  are re-weighed at a weighing station  110  and a label applied at station  112 . Finally, the labelled, sealed trays are collected at station  114 . 
         [0063]      FIGS. 5 a  and 5 b    show a production line  200  according to the present disclosure. Only two workers  102  are required for this production line, increasing labour efficiency. 
         [0064]    In use, raw wet protein pieces  14  are provided to conveyor  210 . Conveyor  210  provides the portions to a hopper  220  that weighs and sorts the wet protein into portions  14 . 
         [0065]    A separate machine  230  provides empty pouches  22  to a carousel  240 . The empty pouches  22  may be provided with an antibacterial coating already applied to the external surface of the pouches  22 . Once loaded, the pouches  22  are opened using a gripper device (not shown). A sensor is used to confirm that the pouch has been opened. Conditional on the sensor indicating that the pouch is open, a signal is sent to the hopper  220  to provide the portions  14  into the pouch  22 . Once filled, the pouches  22  are treated and sealed (see  FIGS. 6 and 7 ) before being provided to another conveyor  270  where they are reweighed and pass through a metal detector  280  before being collected at station  290 . 
         [0066]      FIG. 6  shows an enlarged portion of the carousel  240  showing a vacuum gas station  250  and a heat seal station  260 .  FIGS. 7 a  and 7 b    show the detail of the vacuum gas station  250 . In use, a filled pouch  22  is provided to the station with the opening  24  open. Once the machine comes to a standstill, snorkels  252  drop into the pouch  22  through opening  24 . Gripper arms (not shown) move apart to stretch the pouch opening  24 . The opening is then closed to provide an air tight seal using rubber coated jaws. Via a valve system  254 , air is removed from the pouch  22  and protective gas is injected. Once this procedure is complete, the snorkels  252  withdraw from the pouch  22  and the pouch is provided to the sealing station  260 . As the pouch moves between stations, the top of the pouch  22  is held closed by biased guides, such as spring loaded guides. The pouch  22  is then heat sealed to achieve a hermitic seal and to form a closure  34 . An antibacterial coating may then be applied to the external surface of the pouch  22  (if not already present), for example by spraying. 
         [0067]    Details of the valve system  254  are shown in  FIG. 8 . Snorkels  252  are provided with gas from a reservoir  254   a  via a regulator  254   b . Gas valves  254   c  regulate the supply of the protective gas from the reservoir  254   a . In addition, vacuum may be provided by a vacuum pump  254   d  supplied by opening vacuum valves  254   e . A sediment  254   f  and filter  254   g  are provided to protect the pump  254   d . The system may be flushed and cleaned with water via water valve  254   h  regulating supply of water connection  254   i.    
         [0068]    It should be noted that the Figures are diagrammatic and not drawn to scale. Relative dimensions and proportions of parts of these Figures have been shown exaggerated or reduced in size, for the sake of clarity and convenience in the drawings. The same reference signs are generally used to refer to corresponding or similar feature in modified and different embodiments. 
         [0069]    From reading the present disclosure, other variations and modifications will be apparent to the skilled person. Such variations and modifications may involve equivalent and other features which are already known in the art of vacuum switching, and which may be used instead of, or in addition to, features already described herein. 
         [0070]    Although the appended claims are directed to particular combinations of features, it should be understood that the scope of the disclosure of the present invention also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalisation thereof, whether or not it relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as does the present invention. 
         [0071]    Features which are described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. The applicant hereby gives notice that new claims may be formulated to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom. 
         [0072]    For the sake of completeness it is also stated that the term “comprising” does not exclude other elements or steps, the term “a” or “an” does not exclude a plurality, and reference signs in the claims shall not be construed as limiting the scope of the claims.