Abstract:
Pickled products immersed in a pickling solution are packaged in a cardboard box for shipment to customers. The box is lined with a plastic bag to protect the pickled products and pickling solution from contaminants, and to prevent the pickling solution from leaking. The cardboard boxes may be arranged in multiple layers on a pallet for shipment. The pickled products may be put in the box in a pickled state or in a raw state, whereupon they cure to the pickled state during shipment.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to methods of packing and shipping pickles, and, more particularly, to methods in which pickles may be packaged in bulk containers and shipped over large distances. Still more particularly, the present invention is directed to packing and shipping methods in which cucumbers may be pickled or cured in their shipping containers. 
     For many years, the manufacture and distribution of pickles in bulk has been, more or less, a regional business. The reasons for this largely relate to the manner in which the pickles are packaged and distributed. It has been customary practice that pickles sent directly to the end user, such as delis, restaurants, catering halls, etc, are packaged in bulk in ten-gallon plastic pails lined with a plastic bag. The pail is filled with cured pickles and a brine solution which prevents the pickles from drying out. Once filled, the top of the bag is ordinarily tied closed to hold the contents in place and to prevent contamination. The pails of pickles are then loaded on a truck and delivered to the end user. 
     The delivery of pickles in these ten-gallon pails has caused considerable problems for pickle manufacturers and distributors. Many of these problems stem from the common practice of filling each pail with cured pickles to a level above its upper rim. One problem this practice causes is that it prevents the pail from being closed with a tight-fitting lid. As a result, it has been possible to load only a single layer of filled pails on a truck for delivery at any one time. Any pails stacked on top of the first layer would be unsteady and would likely fall over as the delivery truck navigates its delivery route. Moreover, stacking any pails on top of the first layer of pails would damage the pickles in the first layer. Since it is impractical to load more than a single layer of pails of pickles in a truck for delivery, delivery costs for these pickles have been relatively high. Such high costs have made it uneconomical to make bulk deliveries of pickles in these pails beyond a local geographic area. 
     Another problem with the use of these ten-gallon pails is the relatively high cost of the pails themselves. In view of this high cost, pickle manufacturers typically charge their customers a deposit for each pail delivered. Although the customers ordinarily would have the deposit returned when they return the empty pail to the pickle manufacturer, the pails are frequently not returned. Rather, they are often conveniently put to a new use by the customer, such as for garbage, storing soups or sauces, storing other food products, etc. The failure of the customer to have their deposits for the pails returned raises the overall cost to the customer of the pickles. 
     The use of these plastic pails causes additional problems for pickle manufacturers. Firstly, while the pickles are ordinarily filled to a level above the upper rim of the pail, the brine solution can only be filled to the upper rim of the pail or lower. This causes the pickles in the topmost layer to dry out and lose their crispness. Also, the fact that the pails do not have a tight fitting lid, but rather are closed simply by tying the top of the inner bag, often results in the leakage and spillage of brine solution in the manufacturing plant and on the delivery trucks, as well as at the customer&#39;s establishment. Further, the pails require excessive handling since returned pails must be thoroughly cleaned before they may be reused. In addition, pickle manufacturers must maintain a costly inventory of these pails to replace those that are not returned or that become too damaged to be reused. 
     As an alternative to these large plastic pails, bulk pickles have been packaged in smaller five-gallon plastic tubs having a tight-fitting lid. In one such packaging arrangement, the tubs are filled with raw cucumbers and a brine solution, sealed closed, and shipped to a distributor or end user. During shipping, the cucumbers cure to a pickled state. 
     Although the curing of the cucumbers directly in their shipping tubs reduces handling by the manufacturer, the relatively high cost of the tubs themselves relative to the amount of pickles they are able to hold significantly increases the cost of the pickles to the customer. As a result, the use of these tubs has generally been limited to shipments over large distances. Moreover, when the empty tubs are thrown out, they occupy a relatively large volume, thereby incurring a high disposal cost to the customer. 
     A still further alternative for shipping pickles over a large distance has been to package them in small glass jars, with multiple glass jars packed in an outer cardboard case. These pickles are typically pasteurized before packaging to increase their shelf life, and therefore are not the fresh, bulk pickles desired by foodservice users. Moreover, the high packaging costs for the glass jars causes these pickles to be far too expensive for regular foodservice use. As a result, pickles in these containers are ordinarily sold through retail outlets. 
     There therefore exists a need for a container for delivering pickles in bulk which overcomes the problems associated with open top plastic pails. There further exists a need for a method which permits pickles to be shipped in bulk safely and economically over long distances. 
     SUMMARY OF THE INVENTION 
     The present invention addresses these needs. 
     One aspect of the present invention provides methods for manufacturing pickled products. According to these methods, a stock for pickling, such as cucumbers, is provided. Also provided is a cardboard box having a plurality of sides, a bottom and an open top. Preferably, the box is formed from a wax-impregnated cardboard so as to have a substantially rectangular profile. More preferably, the box has a volume sufficient to hold about ten gallons of the stock. The cardboard box has a liner with an open top, such as a plastic bag, and a selected quantity of the stock is placed in the liner. The liner may then be filled with a pickling solution, desirably, a brine solution, to a level which substantially covers the stock, after which the open top of the liner and the open top of the box may be closed. In a preferred arrangement in which the liner is a plastic bag, the open top of the bag may be closed by heat sealing, and the open top of the box may be closed by assembling a lid thereover. Once packaged as described, the stock cures to a pickled state. This curing may take place during the time the box is being shipped, or during storage either before or after shipping. 
     Desirably, a plurality of the boxes may be stacked on a pallet for shipping. The boxes may be stacked on the pallet so as to form at least two layers. 
     Another aspect of the present invention provides methods for packaging pickled products. According to these methods, a cardboard box is provided having a plurality of sides, a bottom and an open top. The box is lined, such as with a plastic bag having an open top, and a selected quantity of the pickled products is placed in the bag. The bag may then be filled with a liquid to a selected level, and both the open top of the bag and the open top of the box may be closed. In preferred methods, the liquid filled into the bag is a brine solution. Once packaged, the pickles may be shipped or conveniently stored for future shipment. During shipment or storage, a plurality of the boxes may be stacked on a pallet so as to form at least two layers on the pallet. 
     Pickles or other stock manufactured, packaged and shipped according to the foregoing methods provide many advantages over prior art manufacturing, packaging and shipping techniques. Firstly, the use of the cardboard boxes of the present invention enables a large number of units to be assembled in layers on a single pallet, thereby reducing overall shipping costs per unit of pickles and making it economical to ship bulk fresh pickles over large distances. Unit costs are further reduced by the relatively low cost of the cardboard boxes as used in the present invention as compared to the cost of the plastic pails and tubs presently in use. A still further advantage of the present invention is the relative ease of disposing of the cardboard boxes. Thus, not only may be the cardboard boxes be easily broken down so as to occupy a small disposal volume relative to the plastic pails and tubs, but they may be recycled, further reducing disposal costs. As a result of these and other advantages, fresh pickles may now be shipped in bulk more safely and economically, not only locally, but also over long distances. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete appreciation of the subject matter of the present invention and the various advantages thereof can be realized by reference to the following detailed description, in which reference is made to the accompanying drawings in which: 
         FIG. 1  is a plan view of a blank for forming a box for packaging and shipping pickled products in accordance with the present invention; 
         FIG. 2  is a plan view of a blank for forming a top for the box; 
         FIG. 3  is an enlarged partial view showing the end of the box in an assembled condition; 
         FIG. 4  is a perspective view of the box for packaging and shipping pickled products constructed from the blank of FIG.  1  and shown in an open and empty condition; 
         FIG. 5  is a perspective view of the box of  FIG. 4  filled with pickles and brine; 
         FIG. 6  is a perspective view of the filled box of  FIG. 5  with the inner bag sealed closed; 
         FIG. 7  is a perspective view of the filled box of  FIG. 6  closed for shipping; and 
         FIG. 8  is a schematic perspective view showing a plurality of the boxes of  FIG. 7  arranged on a pallet. 
     
    
    
     DETAILED DESCRIPTION 
     The methods of the present invention are described herein in connection with the pickling and shipping of cucumbers. However, it will be appreciated that the inventive aspects of these methods can readily be applied to processes in which other pickle stock is pickled in a brine or similar solution. In addition to cucumbers, such pickle stock may include fruits and vegetables such as green tomatoes, beets, cauliflower, pears and peaches. However, the pickling of cucumbers is the most prevalent. 
     The production of pickles from cucumbers in accordance with the present invention can generally be carried out using many of the conventional process steps known in the art. Generally, the process begins with whole, fresh cucumbers. The cucumbers as received by the pickle manufacturer may have been previously sorted by the supplier to fall within a certain size range. The cucumbers are then passed through a washing step to remove dirt and debris from their outer surfaces. If desired, the cucumbers may be further sized by the pickle manufacturer either before or after the washing step. 
     In one embodiment of the present invention, the washed cucumbers are then placed in a large barrel, covered with a pickling solution, typically a brine solution, and stored for a period of two weeks or more, during which time the cucumbers cure to a desired pickled state. Brine solutions for pickling cucumbers are well known in the art. Typical brine solutions may include, for example, water, salt, spices, garlic, and, optionally, a food preservative. It will be appreciated that brine solutions having different ingredients are contemplated herein, as are pickling compositions other than brine solutions. 
     Once they have cured to a desired state, the pickles are packed in a box for shipment. A box  10  specifically designed for shipping the pickles is illustrated in FIG.  4 . Box  10  is preferably constructed from a heavy duty corrugated cardboard so as to have sufficient strength to withstand the weight of the bulk pickles and brine solution held therein. Most preferred is a wax impregnated corrugated cardboard which can withstand moisture from the brine solution as the pickles are packed and subsequently used without a significant degradation in strength. Although box  10  may be formed with various dimensions to hold a desired volume of pickles, in a particularly preferred arrangement, box  10  is substantially rectangular and is dimensioned to hold about ten gallons of pickles. Thus, box  10  is a direct replacement for the ten gallon plastic pails conventionally used in the industry. A preferred arrangement to achieve this volume is to form box  10  with a length of about 15 inches, a width of about 12 inches and a height of about 13 inches. 
     In accordance with techniques which are generally known in the art, box  10  may be formed from a single cardboard blank which, when folded according to a predetermined pattern, will yield a box of the desired size and shape. One such blank  20  is shown in FIG.  1 . The broken lines depicted in  FIG. 1  represent lines along which the blank is creased, embossed or otherwise weakened so as to be folded into the final box shape. The thickened full lines represent slits cut through the entire thickness of the cardboard. 
     Blank  20  is divided by longitudinal fold lines  22  and  24  and transverse fold lines  26  and  28  into bottom panel  30 , side panels  32  and  34 , and three overlying panels defining each end of the box, inner panels  36  and  38  and outer panel  40  defining one end of box  10 , and inner panels  42  and  44  and outer panel  46  defining the opposite end of box  10 . Slits  48  and  50  separate outer panel  40  from inner panels  36  and  38 , respectively. Similarly, slits  52  and  54  separate outer panel  46  from inner panels  42  and  44 , respectively. Inner panels  36  and  38  each include a series of alternating tabs  56  and recesses  58  formed along one edge thereof, and an elongated opening  60  oriented substantially perpendicular to fold line  26 . Similarly, inner panels  42  and  44  are each formed with a series of tabs  62  and recesses  64  formed along one edge thereof, and an elongated opening  66  oriented substantially perpendicular to fold line  28 . 
     Outer panel  40  includes a flap  70  foldably connected along one edge thereof. A series of H-shaped slits  72  in outer panel  40  and flap  70  define alternating openings  74  and strips  76  when flap  70  is folded relative to outer panel  40 . A series of spaced folded lines  78  and  80  interconnect slits  72  to facilitate the folding of flap  70  relative to outer panel  40 . Panel  40  also includes an elongated opening  81  oriented substantially parallel to fold line  26 . Outer panel  46  includes the same structure. More particularly, outer panel  46  includes a flap  82  foldably connected along one edge, with a series of H-shaped slits  84  defining alternating openings (not shown) and strips  86  when flap  82  is folded relative to outer panel  46 . Spaced fold lines  88  and  90  interconnect slits  84  to facilitate the folding of flap  82  relative to outer panel  46 . An elongated opening  91  is formed in panel  46  and oriented substantially parallel to fold line  28 . 
     In forming box  10 , side panels  32  and  34  are bent upwardly along fold lines  22  and  24 , respectively, until they are substantially perpendicular to bottom panel  30 . Subsequently, inner panel  36  is folded inwardly along portion  26   a  of fold line  26  until it is substantially perpendicular to panel  32 , and inner panel  38  is folded inwardly along portion  26   c  of fold line  26  until it is substantially perpendicular to side panel  34  and against inner panel  36 . Outer panel  40  is then folded upwardly along portion  26   b  of fold line  26  so that inner panel  38  is sandwiched between inner end panel  36  and outer end panel  40 . Panels  36 ,  38  and  40  are held in this assembled position by folding flap  70  over the aligned tabs  56  and recesses  58  of panels  36  and  38 . In this folded condition, the aligned tabs  56  project through openings  74  and the strips  76  reside in the aligned recesses  58  to lock the end panels together. Also in this condition, openings  60  in panels  36  and  38  are in substantial alignment with opening  81  in panel  40  to define a hand hole for grasping one end of the box. 
     A similar procedure is used to form the other end of box  10 . That is, inner panel  42  is folded inwardly along portion  28   a  of fold line  28  until it is substantially perpendicular to panel  32 , and inner panel  44  is folded inwardly along portion  28   c  of fold line  28  until it is substantially perpendicular to side panel  34  and against inner panel  42 . Outer panel  46  is then folded upwardly along portion  28   b  of fold line  28  so that inner panel  44  is sandwiched between inner panel  42  and outer panel  46 . In this folded condition, openings  66  in panels  42  and  44  are substantially aligned with opening  91  in outer panel  46  to define a hand hole for grasping the other end of the box. Panels  42 ,  44  and  46  are held in this assembled condition by folding flap  82  over the aligned tabs  62  and recesses  64  of panels  42  and  44 . When so folded, the aligned tabs  62  project through the openings (not shown) formed by H-shaped slits  84 , and the strips  86  reside in the aligned recesses  64  to lock the end panels together. 
     Once box  10  has been formed from blank  20 , it may be lined with a liner, desirably moisture impervious, to protect the pickles and brine solution from contaminants and to prevent the brine solution from leaking. A preferred liner is plastic bag  100 , as shown in  FIG. 4 , although a molded plastic liner or other leak-resistant liner may be used. Referring to  FIG. 5 , the cured pickles P may be removed from their storage barrels and packed in boxes  10  to a level just below the upper edge of the boxes. Brine solution may be added to the box to a level substantially covering all of the pickles, after which bag  100  may be sealed closed, as shown in FIG.  6 . Although it is contemplated that bag  100  may be closed by any conventional method, including knotting the open end of the bag, or closing the open end of the bag with a twist tie, cable tie, string, clamp or the like, a particularly preferred technique is to apply a heat seal  102  to close the open end of the bag. Such techniques are preferred because they are fast, neat and because they seal the bag closed, thereby preventing loss of the brine solution through leakage or evaporation. 
     After bag  100  has been closed, the open top of box  10  may be closed. Box  10  may be of the type having a plurality of flaps foldably connected to the upper edges of the side and end panels of the box, and may be closed by folding these flaps over the top of the box into interengagement with one another. Alternatively, a lid may be provided to enclose the open top of box  10 . Although it will be appreciated that blank  20  may include an integrally formed portion foldable into a lid, the use of a separate lid is preferred since it may be removed entirely from box  10  so as to not interfere with the filling of the box with pickles or the removal of pickles from the box for use. 
     A blank  120  for forming a separate lid  110  is shown in FIG.  2 . Blank  120  is preferably formed from a heavy duty corrugated cardboard, and preferably the same heavy duty, wax impregnated corrugated cardboard from which blank  20  is formed. Longitudinal fold lines  122  and  124  divide blank  120  into a top panel  126  and side panels  128  and  130 . Each side panel includes a pair of fold lines for defining inner end panels of lid  110 . Thus, side panel  128  includes fold lines  132  and  134  defining inner end panels  136  and  138 , respectively, and side panel  130  includes fold lines  140  and  142  for defining inner end panels  144  and  146 , respectively. Blank  120  also includes a pair of transverse fold lines  148  and  150  for defining respective end wall members  152  and  154  foldably connected to top panel  126 . 
     To form lid  110 , side panels  128  and  130  are folded upwardly along fold lines  122  and  124 , respectively, until they are substantially perpendicular to top panel  126 . End panel  136  is then folded inwardly along fold line  132  until it is substantially perpendicular to side panel  128 , and end panel  144  is folded inwardly along fold line  140  until it is substantially perpendicular to side panel  130 . Subsequently, end wall member  152  is folded upwardly adjacent the outer surfaces of end panels  136  and  144  along transverse fold line  148 , and then downwardly adjacent the inner surfaces of end panels  136  and  144  along intermediate fold lines  156  and  158 . End wall member  152  is held in this folded position by inserting tabs  160  into respective elongated slots  162  formed in top panel  126 . 
     The opposite end of blank  120  is folded in a similar fashion. Thus, end panel  138  is folded inwardly along fold line  134  until it is substantially perpendicular to side panel  128 , and end panel  146  is folded inwardly along fold line  142  until it is substantially perpendicular to side panel  130 . End wall member  154  is then folded upwardly adjacent the outer surfaces of end panels  138  and  146  along tranverse fold line  150 , and then downwardly adjacent the inner surfaces of end panels  138  and  146  along intermediate fold lines  164  and  166 . End wall member  154  is held in this folded condition by inserting tabs  168  into respective elongated slots  170  formed in the top panel  126 . 
     One or more straps  180  may be applied tightly around box  10  in the lengthwise and/or widthwise directions to hold the box in the closed condition and to assume some of the outward stress exerted on the box by the pickles and brine solution packed inside. An example of a closed box  10  ready for shipment is illustrated in FIG.  7 . 
     The rectangular shape of box  10  makes it easy to assemble a plurality of these boxes on a standard pallet for shipment.  FIG. 8  schematically shows one arrangement in which twenty-four boxes  10  have been assembled on a pallet  190  in three layers. Pallet  190  occupies about the same amount of area as nine of the open-topped ten-gallon pails used in the prior art. Therefore, the use of the boxes  10  of the present invention enables about 240 gallons of pickles to be shipped in the same amount of floor space as had been previously used to ship about 90 gallons of pickles. 
     It will be appreciated that box  10  may be formed with dimensions for holding volumes of pickles other than ten gallons. For example, box  10  may be formed with smaller dimensions for holding about five gallons of pickles, and thus may serve as a replacement for the five-gallon plastic tubs presently in use. These five-gallon boxes provide all of the same advantages provided by the ten-gallon boxes described above. In addition, the five-gallon boxes may be made with a height which is much lower than height of the standard five-gallon tubs. This ability enables a greater number of five-gallon units to be held on a conventional storage shelf. That is, a conventional storage shelf can hold a pallet containing thirty-six of the five-gallon tubs stacked in three layers of twelve tubs each, for a total of 180 gallons of pickles. In contrast, when the five-gallon boxes are formed with a squat profile, a conventional storage shelf can hold a pallet containing fifty of such boxes stacked in five layers of ten boxes each, for a total of 250 gallons of pickles. This capability provides advantages to distributors since each of their storage shelves would be able to store fifty five-gallon units of pickles rather than the thirty-six units they were previously able to store, thus increasing storage capacity and enabling a greater number of “picks” from a pallet before it must be replaced. Yet a further advantage is that the five-gallon boxes have a hand hole on each end, making them easier to handle than the five-gallon tubs which typically have only a single handle. 
     In an alternate embodiment of the present invention, the cucumbers may be packed directly in box  10  after the washing step and substantially covered with a brine solution. The bag  100  and box  10  may then be closed as described above and the boxes assembled on a pallet. In accordance with this method, the cucumbers will cure to a pickled state during the time they are in transit from the manufacturer, through any distributor, to the end user. 
     Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.