Abstract:
A system and method for packing agricultural produce including functionality for: providing a container having at least one communications aperture formed in a wall thereof; providing at least one flexible controlled permeability bag within the container; providing at least one bag aperture in the at least one flexible controlled permeability bag in general registration with the at least one communications aperture; sealing the produce inside the at least one flexible controlled permeability bag within the container, while leaving the at least one bag aperture and the at least one communications aperture open; providing atmosphere treatment within the at least one bag via the at least one bag aperture and the at least one communications aperture; and sealing at least one of the at least one bag aperture and the at least one communications aperture.

Description:
REFERENCE TO CO-PENDING APPLICATION  
       [0001]    Applicants hereby claim priority of U.S. patent application Ser. No. 09/765,794, filed Jan. 19, 2001, entitled “A System For Packaging, Storing and Transporting Agricultural Produce”. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to methodologies and systems for packaging, storing and transporting agricultural produce generally.  
         BACKGROUND OF THE INVENTION  
         [0003]    There are known various techniques and systems for packaging, storing and transporting agricultural produce. The following US patents are believed to represent the state of the art: U.S. Pat. Nos. 5,421,138; 4,535,586; 4,981,007; 4,899,517. The known conventional techniques have significant limitations and disadvantages.  
         SUMMARY OF THE INVENTION  
         [0004]    The present invention seeks to provide improved methodologies and systems for packaging, storing and transporting agricultural produce, which result in significant efficiencies and cost savings, without sacrificing product quality.  
           [0005]    In the present specification and claims, the following terms are used: “bag” which relates to a container for agricultural produce in which a “Modified Atmosphere” condition is established by controlling the amounts and relationships of the appropriate gas components, which are required for extending the storage and shelf life of the agricultural product, for example agricultural produce, flowers and bulbs. “vapor” relates to liquids in the form of a gas or a gas with free floating water droplets, as for example, in condensation.  
           [0006]    “carton” relates to containers or boxes constructed from materials such as plastic, wood or metal, for storing agricultural products.  
           [0007]    “adhesive” relates to a sealing element for a venting closure system, by using such devices as a latch, cap-locking system or an adhesive sticker.  
           [0008]    There is thus provided in accordance with a preferred embodiment of the present invention a method for packing agricultural produce including the steps of:  
           [0009]    providing a container having at least one communications aperture formed in a wall thereof;  
           [0010]    providing at least one flexible controlled permeability bag within the container;  
           [0011]    providing at least one bag aperture in the at least one flexible controlled permeability bag in general registration with the at least one communications aperture;  
           [0012]    sealing the produce inside the at least one flexible controlled permeability bag within the container, while leaving the at least one bag aperture and the at least one communications aperture open;  
           [0013]    providing atmosphere treatment within the at least one bag via the at least one bag aperture and the at least one communications aperture; and  
           [0014]    sealing at least one of the at least one bag aperture and the at least one communications aperture.  
           [0015]    There is also provided in accordance with a preferred embodiment of the present invention, a system for packing agricultural produce including:  
           [0016]    at least one container having at least one communications aperture formed in a wall thereof;  
           [0017]    at least one flexible controlled permeability bag within the container, the at least one bag having an aperture in general registration with the at least one communications aperture and being adapted for containing the produce inside the at least one flexible controlled permeability bag within the container, while leaving the at least one bag aperture and the at least one communications aperture open;  
           [0018]    treatment functionality, operative for providing atmosphere treatment within the at least one bag via the at least one bag aperture and the at least one communications aperture; and  
           [0019]    sealing functionality for sealing at least one of the at least one bag aperture and the at least one communications aperture.  
           [0020]    According to a preferred embodiment of the present invention, the atmosphere treatment includes vacuum cooling.  
           [0021]    Additionally or alternatively, the atmosphere treatment includes at least one of fumigation or other gas treatment, such as ripening treatment.  
           [0022]    Preferably, the at least one communications aperture formed in a wall thereof is formed in a sealing layer adhered to a wall of the carton.  
           [0023]    In accordance with a preferred embodiment of the present invention, the flexible controlled vapor and gas selective permeability bag includes a gas impermeable bag, preferably a gas permeable bag having selected permeability characteristics adapted to a given type of produce.  
           [0024]    Preferably, the methodology of providing at least one bag aperture in the flexible controlled permeability bag in general registration with the at least one communications aperture includes:  
           [0025]    inserting the bag into the container;  
           [0026]    at least partially filling the bag with the produce;  
           [0027]    adhering the bag to the container adjacent the at least one communications aperture; and  
           [0028]    aperturing the bag generally in registration with the at least one communications aperture.  
           [0029]    Where the at least one communications aperture formed in a wall thereof is formed in a sealing layer adhered to a wall of the carton, the functionality of providing at least one bag aperture in the flexible controlled permeability bag in general registration with the at least one communications aperture includes:  
           [0030]    inserting the bag into the container;  
           [0031]    at least partially filling the bag with the produce;  
           [0032]    adhering the bag to the container adjacent the at least one communications aperture; and  
           [0033]    aperturing the bag and the sealing layer in a single operation.  
           [0034]    Preferably, the sealing at least one of the at least one bag aperture and the at least one communications aperture includes attaching an adhesive sticker or a cap over the at least one communications aperture from the outside of the container.  
           [0035]    There is also provided in accordance with a preferred embodiment of the present invention a box suitable for packing agricultural produce and including at least one sealable localized atmosphere communication aperture formed in a wall thereof.  
           [0036]    Preferably, the carton also includes a plurality of ventilation apertures formed in at least one wall thereof.  
           [0037]    In accordance with a preferred embodiment of the present invention, the carton also includes a gas impervious layer arranged for sealing engagement with the at least one sealable localized atmosphere communication aperture.  
           [0038]    Preferably, the box includes an interiorly disposed bag, which is preferably a modified atmosphere bag.  
           [0039]    Preferably, the sealing layer is an adhesive-coated plastic sticker and the bag is adhered to the adhesive-coated plastic sticker. In accordance with a preferred embodiment of the present invention, the bag and the adhesive-coated plastic sticker are both apertured adjacent the sealable localized atmosphere communication aperture, thereby to provide a fluid communication pathway between the interior of the bag and the exterior of the carton. A further gas impervious sealing layer may be employed for subsequently sealingly engaging the adhesive-coated plastic sticker, thereby sealing the interior of the bag from the exterior of the carton.  
           [0040]    Additionally in accordance with a preferred embodiment of the present invention, there is provided a method for loading a refrigerated container having a refrigeration unit producing a flow of forced air and a flow of return air under negative pressure in order to provide maximum loading and cooling efficiency, the method including:  
           [0041]    loading palletized ventilated cartons having ventilating apertures formed in walls thereof into a refrigerated shipping container in a manner such that there is defined a central plenum between rows of loaded pallets; and  
           [0042]    selectively blocking air passages inside the container such that the forced air flow is directed principally through the plenum and through interstices between ones of the ventilated containers and thus generally horizontally through the ventilating apertures.  
           [0043]    There is additionally provided in accordance with a preferred embodiment of the present invention, a loaded refrigerated container having a refrigeration unit producing a flow of forced air and a flow of return air under negative pressure in order to provide maximum loading and cooling efficiency, the loaded container also including:  
           [0044]    palletized ventilated cartons having ventilating apertures formed in walls thereof positioned in the refrigerated shipping container in a manner such that there is defined a central plenum between rows of loaded pallets and wherein  
           [0045]    air passages inside the container are selectively blocked, such that the forced air flow is directed principally through the plenum, through interstices between ones of the ventilated containers and thus generally horizontally through the ventilating apertures.  
           [0046]    In accordance with a preferred embodiment of the present invention, a forced air flow from the refrigeration unit is supplied along channels formed in a floor of the container and extending parallel to a longitudinal axis thereof; at least a portion of the forced air output rises through spaces between adjacent floor elements in the floor of the shipping container, except where physically blocked and relatively unimpeded from a channel underlying the plenum; and at least a portion of the forced air output rises relatively unimpeded from open ends of the channels at a back end of the container into back plenum defined rearwardly of the rows of pallets 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0047]    The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:  
         [0048]    FIGS.  1 A- 1 G are simplified pictorial illustrations of seven initial stages in packaging produce in accordance with a preferred embodiment of the present invention;  
         [0049]    FIGS.  2 A- 2 C are simplified pictorial illustrations of three stages in treating produce packaged in accordance with the embodiment of FIGS.  1 A- 1 G;  
         [0050]    FIGS.  3 A- 3 C are simplified pictorial illustrations of a methodology for loading a refrigerated container to provide maximum loading and cooling efficiency;  
         [0051]    [0051]FIG. 3D is a simplified cross-sectional view, taken along lines IIID-IIID in FIG. 3A, showing the location of a blocking element, in accordance with another preferred embodiment of the invention.  
         [0052]    [0052]FIG. 4A is a simplified illustration of a sealing element for packaging produce, in accordance with a preferred embodiment of the present invention; and  
         [0053]    [0053]FIG. 4B is a simplified illustration of another type of sealing element for packaging produce, in accordance with another preferred embodiment of the invention; 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0054]    Reference is made to FIGS.  1 A- 1 G, which are simplified pictorial illustrations of seven initial stages in packaging produce in accordance with a preferred embodiment of the present invention.  
         [0055]    As seen in FIG. 1A, a packing carton  10  is provided, preferably having side apertures  12  and end apertures  14  as well as at least one sealable localized atmosphere communication aperture  16 , preferably formed in an end  18  of carton  10 , near the top thereof. In accordance with a preferred embodiment of the invention, packing carton  10  need not be liquid impervious, such as a waxed container, and may thus be a relatively inexpensive uncoated and unwaxed cardboard box.  
         [0056]    In accordance with a preferred embodiment of the invention, as shown in FIG. 1B, the sealable localized atmosphere communication aperture  16  preferably is sealed by attaching thereover a gas impervious sealing layer  20 , typically a self adhesive-coated plastic sticker. Sealing of aperture  16  may take place at any suitable time or location. Typically it is carried out during manufacture of the carton. Normally it is carried out prior to filling of the carton.  
         [0057]    [0057]FIG. 1C shows insertion of a flexible bag  22 , such as a plastic bag, as a liner within carton  10 . The bag  22  is preferably a modified atmosphere bag, such as that described in assignee&#39;s U.S. patent application Ser. No. 08/918,584 to Moira M. Nir et al, assigned to StePac L. A., Ltd., Tefen Industrial Park, Tefen Western Galilee, Israel, the disclosure of which is hereby incorporated by reference. The bag  22 , and thus the carton  10 , is then filled with produce, as seen in FIG. 1D.  
         [0058]    As seen in FIG. 1E, subsequent to or concurrently with filling the bag  22  with produce and prior to sealing of bag  22 , the portion of the bag  22  which lies adjacent aperture  16 , when the carton is filled with produce, is adhered to sealing layer  20 .  
         [0059]    In the illustrated preferred embodiment of the present invention, where sealing layer  20  is an adhesive-coated plastic sticker, the adherence of bag  22  thereto may be achieved by manually pressing a suitable area of the bag  22  onto an adhesive-coated inside facing surface of sealing layer  20 , as shown in FIG. 1E.  
         [0060]    It is appreciated that if sealing layer  20  is adhered to carton  10  during manufacture of the carton or at any stage prior to filling of the carton with produce, the adhesive-coated surface thereof which overlies aperture  16  must be protected, as by a removable release layer (not shown), which can be readily removed prior to the stage shown in FIG. 1E, preferably following the stage shown in FIG. 1C, so as to avoid inadvertent, undesired adherence between the layer  20  and a location on the bag  22  which is not the desired location.  
         [0061]    Following adherence of the bag  22  to sealing layer  20 , or any equivalent adherence of the bag  22  to the carton  10  in the region of aperture  16 , the bag  22  and sealing layer  20  are apertured at aperture  16 , thereby defining an atmosphere communication pathway therethrough. One example of this functionality is illustrated in FIG. 1F, wherein a heated, preferably generally cylindrical aperturing element  24 , is inserted via aperture  16 , thus defining an aperture  25  through sealing layer  20  and the bag  22 . The aperture  25  is surrounded by an annular zone  26  of the sealing layer  20 . The bag  22  is sealed to sealing layer  20  at annular zone  26 .  
         [0062]    It is appreciated that there may exist a large variety of techniques for defining the aperture  25  in the sealing layer  20  and the bag  22  in registration with aperture  16 . While it is believed that the technique described hereinabove with reference to FIGS.  1 A- 1 F is preferred, the scope present invention need not be limited thereto.  
         [0063]    Following completion of the stage shown in FIG. 1F, the bag  22  is sealed, as shown in FIG. 1G, and the carton  10  is closed.  
         [0064]    Reference is now made to FIGS.  2 A- 2 C, which are simplified pictorial illustrations of three stages in treating produce packaged in accordance with the embodiment of FIGS.  1 A- 1 G.  
         [0065]    As seen in FIG. 2A, the filled cartons  10 , each having an open aperture communicating with the interior of bag  22 , are preferably palletized and inserted into a treatment chamber  30 , such as a vacuum cooling chamber, a fumigation chamber, a gas treatment chamber or a chamber providing multiple functions, such as vacuum cooling and gas treatment. The arrangement of the cartons  10  within treatment chamber  30  is such that apertures  16  and thus the interiors of bags  22  within cartons  10  are all in fluid communication with the interior of treatment chamber  30 . In such a way, the contents of the bags  22  within cartons  10  are exposed to the environment of the interior of the treatment chamber  30 , as seen in FIG. 2B for a vacuum cooling application.  
         [0066]    Following vacuum cooling and/or other treatment as shown in FIGS. 2A and 2B, but without requiring repalletization, the apertures  16  are preferably sealed by attaching a gas impermeable layer  40  onto the outside of the carton  10 , preferably over layer  20  as shown in FIG. 2C. This seals the interior of the bag  22  from the outside atmosphere, thereby enabling maintenance of a modified atmosphere within bag  22 .  
         [0067]    Reference is now made to FIGS.  3 A- 3 C, which are simplified pictorial illustrations of a methodology for loading a refrigerated container to provide maximum loading and cooling efficiency. As seen in FIGS.  3 A- 3 C, pallets  100 , having loaded thereon ventilated cartons  102 , having ventilating apertures  104  formed in walls thereof, are loaded into a container  106  in a manner such that there is defined a central plenum  108  between two rows of loaded pallets  100 .  
         [0068]    In a preferred embodiment of the invention, the interior width of the refrigerated container  106  is approximately 2.3 meters, the interior length of the container is approximately 11.6 meters and the pallets preferably have dimensions of 1 meter by 1.2 meters. The pallets  100  are preferably arranged in touching engagement with each other to define rows  110  and  112 , as seen in FIGS. 3A and 3B. Additionally, the pallets  110  and  112  are in touching engagement with the side walls of the container  106  (FIGS. 3A and 3B). The pallets in row  110  being arranged to have their relatively smaller dimension parallel to the longitudinal axis  114  of the container  106 , and the pallets in row  112  being arranged to have their relatively greater dimension parallel to the longitudinal axis  114  of the container  106  (FIGS. 3A and 3B).  
         [0069]    Forced air output from a refrigeration unit  116  is supplied along channels  120  (FIGS. 3A and 3C) formed in a floor  130  of the container  106  and extending parallel to longitudinal axis  114  thereof, as illustrated by arrows  122 . This forced air rises through spaces  124  between adjacent floor elements  126  in the floor of the container  106 , except where physically blocked.  
         [0070]    Thus, it may be appreciated that a major portion of the forced air rises relatively unimpeded from the channels  120 , underlying the rows  110  and  112 , through plenum  108  via elongate longitudinal openings  124  interconnecting channels  120  with plenum  108 , as indicated by arrows  134 .  
         [0071]    Forced air also rises relatively unimpeded from the open ends  140  of channels  120  at the back end of the container into a plenum  142  defined rearwardly of rows  110  and  112  of pallets  110 . Plenums  108  and  142  communicate with a plenum  144  at the top of the container above palletized cartons  102 , and which serves as an air return plenum communicating with the refrigeration unit  116 , as indicated by arrows  146 . Typically air in air return plenum  144  is sucked into the refrigeration unit  116  under negative pressure.  
         [0072]    Forced air also rises from various channels  120  via spaces  124  in a somewhat impeded manner via the interstices between adjacent palletized cartons  102  and eventually reaches air return plenum  144 .  
         [0073]    Additionally forced air rises alongside outer facing surfaces of palletized cartons  102  in vertical channels  150  typically formed by corrugations in the walls of the container  106  and reaches air return plenum  144 . This flow preferably is not allowed to extend directly from channels  120  but rather is a negative pressure flow which draws cooled air via the interstices between cartons  102 .  
         [0074]    It is a particular feature of the present invention that generally horizontal air movement is provided through the ventilation openings  104  in the cartons  102  for efficient cooling of the contents thereof. This is true both in the atmosphere treatment described hereinabove with reference to FIGS.  2 A- 2 C and in the refrigerated container loading and cooling arrangements described herein with reference to FIGS.  3 A- 3 C. In the embodiment shown in FIGS.  3 A- 3 C, the horizontal air movement is provided by suitable arrangement of the palletized cartons as described hereinabove and the definition of a plenum between rows of palletized cartons. Both the arrangement of the cartons on the pallets and the arrangement of the pallets in the container are important in this regard.  
         [0075]    The various forced air flows described hereinabove cause air to penetrate through ventilating apertures  104  in palletized cartons  102  and thus to communicate with the interior of the cartons  102 . In an embodiment where the cartons  102  contain a sealed bag therewithin, such as that shown in FIGS.  2 A- 2 C, the exterior of the sealed bags is exposed to cooled air, for providing suitable cooling of the interior of the bags.  
         [0076]    In accordance with a preferred embodiment of the present invention, spaces  124  which do not underlie pallets  100  are preferably blocked, as by provision of a flexible self-retaining blocking element, such as a closed cell sponge  160 . Similarly, the end of plenum  108  is blocked as by provision of a sponge  160  and the exposed edges of the most rearward positioned pallets  100  in rows  110  and  112  are similarly blocked by sponges  160 . This blocking and the above-described arrangement of pallets in the container  106  provides enhanced contact between air flows and the interiors of cartons  102  via apertures  104 .  
         [0077]    Reference is now made to FIG. 3D, which is a cross-sectional view of the container  106  and the pallets  100 , taken along lines IIID-IIID in FIG. 3A. In FIG. 3D it is seen that blocking elements  170  are attached to side walls  172  of the upper deck of the pallet  100 . On inserting the pallet  100  into the container  106 , the blocking elements  170  form tight seals between the pallets  100  and side walls  174  of the container  106 . The blocking elements  170  prevent the escape of the cooling air around the sides of the container  106  and ensures that the cooling air flows through the plenum  108  and the vertical channels  150  in order to provide efficient cooling to the produce contained within the cartons  102 , as described hereinabove.  
         [0078]    It is appreciated that the blocking elements  170  are preferably constructed of resilient material so as to provide adequate sealing between the carton rows  110  and  112  and the side walls  174  of the container  106 , as illustrated in FIG. 3D.  
         [0079]    Reference is now made to FIG. 4A, which shows a sealing element  50  for packaging produce in the carton  10 , in accordance with a preferred embodiment of the present invention. The sealing element  50  comprises a sealing device  52 , preferably in the shape of a ring. The sealing device  52  typically comprises locking elements  54  and  56  for sealing the bag  22  to the carton  10 , as shown in FIG. 4A. A plug member  58  with sealing member  60 , is pushed into the aperture  25 , as illustrated in FIG. 4A, to seal the inside of the carton  10  from the outside environment.  
         [0080]    Reference is now made to FIG. 4B, which shows another type of sealing element  70  for packaging produce in the carton  10 , in accordance with another preferred embodiment of the invention. The sealing element  70  comprises a clasp  72 , with a screw head  74 , which is inserted into the aperture  25 . A ring  76  is screwed onto the clasp  72  thus sealing the bag  22  to the carton  10 , as shown in FIG. 4B. A cover member  78  with a sealing member  80  is pushed into the aperture  25 , thereby sealing the inside of the carton  10  from the outside environment.  
         [0081]    It is appreciated that the shapes of the sealing elements described hereinabove are constructed so as to conform to the shape and dimensions of the carton  10 .  
         [0082]    It is also appreciated that the embodiments described hereinabove, for sealing the bag  22  to the carton  10 , are suitable for any type of receptacle, such as corrugated carton, plastic boxes or any type of agricultural storage container, which is used for packaging agricultural produce, as is known in the art.  
         [0083]    It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove as well as variations and modifications which would occur to persons skilled in the art upon reading the specification and which are not in the prior art.