PROCESS FOR FORMING PACKAGED SOLIDIFICABLE FOOD PRODUCTS, IN PARTICULAR HAND-HELD ICE-CREAMS AND CONTAINER FOR IMPLEMENTING THE PROCESS

Abstract: A process for forming packaged hand-held solidificable food products, in particular ice-creams, characterised by: forming from ice-cream impermeable material an openable enclosure (4, 29) provided with at least one aperture (6, 31) for feeding an ice-cream compound into it, filling said enclosure (4, 29) with the ice-cream compound, hermetically sealing said filled enclosure (4, 29), and cooling the thus filled and sealed enclosure until said compound has completely solidified.

Description: PROCESS FOR FORMING PACKAGED SOLIDIFICABLE FOOD PRODUCTS, IN PARTICULAR HAND-HELD ICE-CREAMS AND CONTAINER FOR IMPLEMENTING THE PROCESS This invention relates to a process for forming packaged solidificable food products, in particular hand-held ice¬ creams and a container for implementing the process. Hand-held ice-creams are currently produced by pouring the ice-cream compound, of liquid or semi-liquid consistency depending on the final product to be obtained, into a plurality of metal moulds maintained in a brine bath. Before the compound in the moulds completely solidifies, a stick of wood or plastics or edible material (sugar, liquorice etc.) is inserted into each of them so that when the compound has completely solidified the stick remains securely fixed to it. The ice-cream obtained in this manner is then extracted from the corresponding mould and deposited on a conveyor belt to be fed for packaging within a suitable paper container. This known process was previously carried out manually but is now performed by rather sophisticated machines which although able to automate the production cycle suffer from a series of drawbacks and limitations which it is the object of the present invention to overcome. One drawback of this known process is that it requires rather complicated and costly equipment (the moulds) which inter alia has to be changed each time the shape of the produced ice-cream is to be varied. A further drawback is that equally complicated and costly equipment is required for inserting the stick into the mould, and as this insertion has to be effected at a precise point during the ice-cream solidifying stage, the processing times have to be rigorously controlled, these varying in relation to the shape of the ice-cream to be obtained and the ice-cream compound used. A further drawback is that the transfer of the ice-cream to the packaging machine after extraction from the mould can involve problems regarding the rigorous maintaining of hygienic conditions, because of the exposure of the product to the external environment. A further drawback is that the shape of the ice-cream obtainable and hence of the mould used to produce it is subject to considerable limitations, in that undercuts must be totally avoided as they would prevent correct removal of the ice-cream from the mould. A further drawback is that during the consumption of the ice-cream, ie when the protective wrapper has been removed from the ice-cream and this is held by the consumer only by the stick, the hand of the consumer can be soiled because of the inevitable dripping of those parts of the ice-cream which progressively become liquid. All these drawbacks and other which will be apparent from the following description are overcome by a process for forming packaged solidificable food products, in particular hand-held ice-creams as described in claim 1. To implement this process the invention uses a container as described in claim 12. Some preferred embodiments of the present invention are described in greater detail hereinafter with reference to the accompaning drawings, in which: Figure 1 is a perspective view of an empty container used for implementing the process of the invention; Figure 2 is a schematic view thereof after its filling and sealing; Figure 3 shows it after tearing the enclosure when the ice¬ cream is to be consumed; Figure 4 is a plan development of the container of Figure 1; Figure 5 is a perspective view of the lower part of the container without ice-cream; Figure 6 shows a modified embodiment of the container of the invention in the same view as Figure 4; Figure 7 is a perspective view of the lower part of the container of Figure 6; Figure 8 shows a further embodiment of the container of the invention in the same view as Figure 4; Figure 9 is a perspective view of the lower part of the container of Figure 8; Figure 10 shows a further embodiment of the container of the invention in the same view as Figure 4; Figure 11 is a perspective view of the lower part of the container of Figure 10; Figure 12 is a perspective view of a different embodiment of the container of the invention; Figures 13a, 13b and 13c are plan views showing the complete plan development of the container of Figure 12 plus two successive stages in the folding of the part which is to form the internal appendix; Figures 14a, 14b and 14c are plan views showing the complete plan development of the container of Figure 12 plus two successive stages in the folding of the part which is to form a different internal appendix; Figures 15a, 15b and 15c are plan views showing the complete plan development of the container of Figure 12 plus two successive stages in the folding of the part which is to form another different internal appendix; Figure 16 is a perspective view of a further embodiment of the container according to the invention; Figure 17a shows the plan development of Figure 16; Figure 17b is a perspective view of the container of Figure 16 in its folded configuration; Figure 18 is perspective view of a further embodiment of the container according to the invention; Figure 19a shows the plan development of the container of Figure 18; Figures 19b and 19c are perspective views of the container of Figure 18 in two successive stages of folding; and Figure 20 shows in perspective view a container in a further embodiment. As can be seen from the figures the process of the invention uses as its essential element a container 2 of impermeabilized paper material, such as paper which has been plastic-coated, metallized or otherwise impermeabilized. It is formed by punching a continuous web of paper material, which is then subjected to a series of folds to form an enclosure 4 of the desired shape, comprising an upper aperture 6 and a lower appendix which extends downwardly outwards to form the gripping element 8 and upwardly inwards to form a locking element 10 for the solidified ice-cream 12, as will be apparent hereinafter. The shape of the container 2 is made stable after folding, by thermowelding, gluing or another method of joining together the edges of the enclosure. To implement the process of the invention, after the container 2 has been formed it is positioned with its aperture 6 facing upwards and made to pass, either alone or together with other similar containers, below one or more filling nozzles which pour into the enclosure 4 a predetermined quantity of ice-cream compound, ie a liquid or semi-liquid mixture of ingredients which after solidification form an ice-cream, a cake ice, an iced lolly or an analogous product. These products may consist of cream cheese, chocolate cube, caramel paste. This compound fills the enclosure 4 to a predetermined level, completely surrounding the locking element 10 and penetrating into a series of holes provided in it. When the container 2 has been sealed it can be transferred to a freezer in which the ice-cream 12 is completely solidified and can also be stored therein. It can also be used for products which are substantially solid at ambient temperature, these being poured into the enclosure 4 at a higher temperature, and hence in the liquid or pasty state. To consume the ice-cream the consumer firstly tears the enclosure 4, for which purpose in order to facilitate the operation the enclosure is provided with a tear-off tab 16, two preferential tear lines 18 also being provided in the enclosure 4. The position of the tab 16 is chosen so as to divide the enclosure 4 into an upper part which is completely removed, and a lower part which remains connected to the gripping element 8 to form a sort of cup 20 to prevent dripping of the ice-cream. Various forms of the container 2 are described hereinafter, all obtained from impermeabilized paper. Figure 4 shows the plan development of a punched paper web from which the container shown in Figures 1-3 can be obtained following a series of successive folds and final welding. By punching the continuous web 21 of impermeabilized paper, the plan development of the container 2 is obtained already provided with a plurality of folding lines 15, tabs 16 and preferential tear lines 18. The punched web 21 is then folded and welded along the contacting edges, shown hatched in Figure 1. After welding the edges the container 2 assumes the appearance shown in Figure 1 and can be filled with ice¬ cream compound. After filling, the aperture 6 is closed by sealing its edges and the whole product, which assumes the appearance of Figure 2, is then cooled. To consume the ice-cream 12 the tab 16 is torn off and the upper part of the enclosure 4 is removed, its lower part forming the gripping appendix 8 for the ice-cream and the cup 20 which retains any drips falling therefrom. Figure 6 shows a different form of the ice-cream container, the locking element 10 being a plurality of appendices 22. Figure 7 shows the lower part of the container 2, comprising the gripping appendix 8, the anti-drip cup 20 and the locking appendices 22 for the ice-cream 12. Figures 8 and 9 show a further embodiment in which the locking element 10 consists of a plurality of folds 23 provided in both the edges of ' the cup 20 and projecting inwards thereof. Figures 10 and 11 sho a further embodiment, in which the locking element 10 is in the form of signs (letters, numerals, designs in general) impressed into the impermeabilized paper and projecting inwards from the walls of the cup 20. Other signs (not shown on the drawings) can also be impressed in those paper regions forming the removable part, in order to form incisions and/or reliefs in that part of the ice-cream 12 which projects from the cup 20. Figure 12 shows a further sealed ice-cream container. It is again obtained from a punched, folded and welded paper sheet, its thickness determining the method of forming the inner locking appendix 10. For example Figures 13a, 13b and 13c shows three successive stages in the formation of an enclosure 4 in which the inner locking appendix 10 is obtained by twice transversely folding (horizontally in the drawings) a paper tab 24 forming the appendix 10. Complete formation of the enclosure is achieved by folding the sheet along the two vertical lines 26 and welding the contacting edges. If the paper used to form the enclosure is thinner, it may be necessary to fold three times the paper tab 24 forming the locking appendix 10. In this " respect Figures 14a, 14b and 14c show three stage in the formation of the enclosure 4, comprising firstly folding the tab 24 about two vertical lines to obtain an appendix 28 (Figure 14b) three times the thickness of the paper, which is then folded upwards through 180° to form the locking element 10 (Figure 14c) . If the paper is even thinner, or if a locking appendix 10 thicker than that obtainable by the present embodiment is required, a different system of folding the paper tab 24 forming said locking appendix 10 can be used. Specifically said tab 24, which is square (Figure 15a) , is firstly folded along one diagonal (Figure 15b) and then along the other diagonal (Figure 15c) and then upwards to form the appendix 10, which is four times the thickness of the paper. In the embodiment shown in Figures 16, 17a and 17b the container of the invention is substantially analogous to that shown in Figure 12, except that its lower and upper ends are of "bellows" form, as can be seen in Figure 17a showing the punched paper sheet, ie the container in plan development, and from Figure 17b showing the same sheet folded both in the part orming the locking appendix and in the part forming the actual enclosure. A further embodiment of the container according to the invention is shown in Figure 18. It is formed by firstly folding the punched outline of impermeabilized paper (Figure 19a) so that the two tabs forming the locking element 10 are superposed and joined along the folding line, whereas the two parts orming the two walls of the enclosure 4 are superposed but are free and not joined together (Figure 19b) . These two latter parts are then folded through 180° in opposite directions (Figure 19c) and are then welded along their edges to form the enclosure 4, internally containing the locking element 10 suitably provided with holes 14. After filling the enclosure 4 and sealing the aperture through which the ice¬ cream compound has been poured, the container is ready for cooling, and has the configuration shown in Figure 18. In all the embodiments heretofore described, the inner locking appendix 10 and the outer gripping appendix 8 are integral with the paper forming the enclosure 4. It is however possible for one or both of these appendices to be formed separately of the same or different material and then be joined to the enclosure 4 before or during its formation. In the embodiment shown in figure 20 the container consists of two thermoweldable material sheets 29 which, suitably shaped and joned each other to, form a cavity 30 corresponding to the shape of the ice-cream and an open duct 31 for the insertion of a stick 32 forming the inner locking appendix and the outer gripping appendix. Once the ice-cream compound, in the liquid or semi- liquid state, has been poured into the cavity, the stick 32 is partly embedded in the compound, and subsequently the upper end of the duct 31 is thermowelded so as to obtain an entirely sealed products which, when consumed, presents like a traditional hand-held ice-cream with stick. In a further embodiment not shown in the drawings two opposite walls of the enclosure 4 may be welded together in a limited zone so as to lock the ice-cream once has been poured therein. In addition all the described embodiments are obtained from impermeabilized paper, which is suitably punched, folded and welded along the contacting edges. It is however possible to form the container 2 of plastics material by conventional blow moulding or injection moulding techniques, which require more complicated equipment but eliminate the described operations on the paper. If the container is of thermoformed plastics material and hence more rigid than a paper container, the enclosure 4 is preferably sealed not by welding the edges of the aperture 6 but by applying a plastics "cap" the edge of which engages the inner wall of tlιe enclosure by friction. Furthermore it may also be possible to realize the container 2 in eatable material. Basically, independently of the particular embodiment and the method used for forming the container 2 , it represents a considerable modification to the conventional technique in that at one and the same time it forms the mould for the ice-cream compound, the sealed enclosure for transferring said compound from its place of filling to its place of cooling, the enclosure for storing the packaged ice¬ cream, the gripping element for the ice-cream during its consumption, and an antidrip cup, hence presenting numerous advantages because of these new functions, namely: - it substantially reduces the labouriousness of ice-cream packaging because the moulds into which the ice-cream compound is poured, the brine baths and the machines for inserting the sticks into the moulds during solidification of the compound are no longer required, - it consequently reduces the cost of equipment, and in particular of the moulds, which would have to be changed each time the shape of the ice-cream changes, - it results in totally hygienic production as the container is sealed immediately after its filling, - it allows ice-creams of any shape, including with undercuts, to be formed as the ice-cream no longer has to be removed from its mould, - it enables a relief design, variable from container to container, to be formed on the ice-cream by simply impressing the paper sheet, - because of the presence of the antidrip cup it enables the gripping appendix to be formed with a height less than that of traditional sticks, so substantially reducing the overall size of the packaged ice-cream, with consequent considerable saving in the space to be cooled, - it enables multiple packs to be formed, ie in the form of several individual packs joined together and separable on consuming, with substantial filling and transport simplification, - if certain ice-cream compounds are used (for example for forming iced lollies) it enables cold production to be dispensed with and allows the product to be solidified at the final point of sale or even by the consumer insted of immediately after filling the container.

Claims: C L A I M S 1. A process for forming packaged hand-held solidificable food products, in particular ice-creams, characterised by: - forming from ice-cream impermeable material an openabie enclosure (4,29) provided with at least one aperture (6,31) for feeding an ice-crea compound into it, - filling said enclosure (4,29) with the ice-cream compound, - hermetically sealing said filled enclosure (4,29), and - cooling the thus filled and sealed enclosure until said compound has completely solidified. 2. A process as claimed in claim 1 characterised by forming the enclosure with an outwardly projecting appendix (8) forming the gripping element for the packaged ice-cream. 3. A process as claimed in claim 1, characterised by forming an enclosure (4) provided with means for separating a removable part from a part (20) rigid with the gripping appendix (8) and provided with means for locking said ice¬ cream (12) . 4. A process as claimed in claim 3, characterised by forming an enclosure (4) provided with tear-off means for opening it. 5. A process as claimed in claim 3, characterised by forming an enclosure (4) , that part (20) of which rigid with the gripping appendix (8) comprises at least one inwardly projecting appendix (20, 22) lockable by said ice-cream (12) . 6. A process as claimed in claim 1 characterised in that at least two walls of the enclosure are partly connected each other to, to lock the solified product. 7. A process as claimed in claim 1 characterised in that, before hermetically sealing the filled enclosure (29) , through the opening (31) an appendix (32) is inserted a part of which is embedded in the ice-cream compound. 8. A process as claimed in claim 1, characterised by simultaneously filling a plurality of side-by-side enclosure (4). 9. A process as claimed in claim 1, characterised by sealing the enclosure (4) , filled with ice-cream compound, by welding the contacting edges of said aperture (6) . 10. A process as claimed in claim 1, characterised by sealing the enclosure (4) , filled with ice-cream compound, by means of a cap applied to the aperture (6) . 11. A process as claimed in claim 1, characterised by cooling the enclosure (4) immediately after it has been filled and sealed. 12. A container for implementing the proces claimed in one or more of claims 1 to 11, characterised by comprising an openabie enclosure (4,29) of impermeable material provided with at least one aperture (6,31) for feeding an ice-cream compound into it, said filling aperture (6,31) being sealable hermetically after the filling. 13. A container as claimed in claim 12 characterised in that the enclosure (4) comprises an outwardly projecting appendix (8) forming the gripping element for the packaged ice-cream. 14. A container as claimed in claim 12 characterised in that at least two walls are partly connected each other to to lock the solified product. 15. A container as claimed in claim 12, characterised by being provided with at least one appendix (10, 22, 23, 32) which projects into the enclosure, is connected to said gripping appendix (8) and is lockable by the ice-cream. 16. A container as claimed in claim 12, characterised in that the enclosure (4) is formed of impermeabilized paper. 17. A container as claimed in claim 12, characterised in that the enclosure (4) is formed of thermoformed plastics. 18. A container as claimed in claim 12, characterised in that the enclosure (4) is of the tearable type and is provided with a tab (16) for facilitating this tearing. 19. A container as claimed in claim 13 , characterised in that the edges of the aperture (6) in the enclosure (4) can be brought into contact for sealing the container. 20. A container as claimed in claim 12, characterised in that the enclosure (4) is formed of eatable material. 21. A container as claimed in claim 12, characterised in that the enclosure (4) is provided with a substantially rigid sealing element formed separately from the enclosure and engaging by means of its edge the inner wall of said enclosure surrounding the aperture (6) . 22. A container as claimed in " claim 13, characterised in that the appendix (10, 22, 32) lockable by the ice-cream (12) is formed separately from the enclosure (4) and is joined thereto during the enclosure formation. 23. A container as claimed in claim 13, characterised in that the appendix (10, 22, 23) lockable by the ice-cream is formed integrally with said enclosure (4) . 24. A container as claimed in claim 20, characterised by consisting of a punched sheet of impermeabilized paper which is folded into several parts defining the walls of the enclosure (4) and the gripping appendix (8) and is sealed along all its contacting edges with the exception of the portions defining the filling aperture (6) . 25. A container as claimed in claim 21, characterised in that the sheet of impermeabilized paper is folded into parts defining the walls of the enclosure (4) , the outer appendix (8) and the inner appendix (10, 22, 23). 26. A container as claimed in claim 22, characterised in that the inner appendix (10, 22) comprises a plurality of locking apertures (14) . 27. A container as claimed in claim 22, characterised in that the inner appendix consists of at least one rib formed in the sheet of impermeabilized paper and projecting inwards of the enclosure (4) . 28. A container as claimed in claim 12, characterised in that the enclosure (4) is divided into a first part (20) connected to the gripping appendix (8) and forming a collection cup for ice-cream droplets, and a completely removable second part, the inner appendix (10, 22, 23) being connected to said first part (20) . 29. A container as claimed in claim 12, characterised in that the enclosure (4) is of bellows formation. 30. A container as claimed in one or more of claims 12 to 26, characterised by consisting of a plurality of enclosures (4) formed in one piece and separable on consuming the ice¬ cream.

Inventors: TRANI GIORGIO, TRANI, GIORGIO
Applicants: TRANI GIORGIO, TRANI, GIORGIO
Application year: 1993
Main classification: B65D85
IPC codes: A23G9, B65D75, B65D85