Abstract:
A reuseable container is provided for storage and transport of prepared meat in log format. The container has a base, a pair of upwardly extending side walls, and a pair of upwardly extending end walls connected with the side walls to form a generally rectangular box. The box has four interior edges and four interior corners where the side and end walls join the base. The box is integrally formed of molded polyethylene. Each of the four interior edges and four interior corners has a rounded interior profile to prevent accumulation of material and facilitate sanitation between uses. A reuseable container system is also provided having a removable lid, and access panel.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims benefit of Canadian patent application number 2,929,342, filed May 9, 2016, which is herein incorporated by reference. 
       Field of the Invention 
       [0002]    The invention relates to containers for perishable food products, and more particularly relates to reuseable containers for shipping or storing bulk meat products especially those typically in log format. 
       BACKGROUND OF THE INVENTION 
     Description of the Related Art 
       [0003]    For many years, bulk meat has been shipped in reuseable open-top stainless steel containers, sometimes referred to as “coffins” (see “prior art”  FIGS. 1 and 2 ). The coffins used to ship processed meat logs for slicing in food service (e.g. processed deli turkey, deli chicken, or ham) are large and extremely heavy (over 500 lbs pre-loaded). Typically, in a processor plant, or warehouse, the coffins are transported by forklift. The scraping of the container feet on floors is loud and piercing and repetitive throughout a facility over the course of a day. Further, due to the construction of the stainless steel containers (typically made to order by a sheet metal fabricator), handling of the containers by employees can lead to injury. The sheets of steel are turned over or rolled at the tops and sides, but sharp burrs and corners persist, and these can lead to dangerous cuts. For all of these reasons, loading and handling of stainless steel “coffin” containers in the processed meat industry has come under scrutiny for occupational health and safety. 
         [0004]    Besides safe handling issues, the containers have other drawbacks. The containers themselves are not easy to clean, sanitize or maintain (e.g. patching when damaged). There are potential food safety issues due to build up of residue in the containers, which do not drain very efficiently. The fabricated inside edges and corners tend to trap material. For food safety, a container must be lined each time with a plastic polyethylene liner, and the loaded container must be covered on the top with a plastic polyethylene top sheet cover. This requires an additional packaging step and material expense (liner/wrap). 
         [0005]    It would be desirable to provide an alternative structure for such meat coffins which would address or mitigate the foregoing drawbacks. 
       SUMMARY OF THE INVENTION 
       [0006]    According to a first aspect of the invention, a reuseable container is provided for storage and transport of a perishable food product. The container has a base, a pair of upwardly extending side walls, and a pair of upwardly extending end walls connected with the side walls to form a generally rectangular box. The box has four interior edges and four interior corners where the side and end walls join the base. The box is integrally formed from a single piece of molded polyethylene (preferably, polyethylene foam). Each of the four interior edges and four interior corners has a rounded interior profile to prevent accumulation of material and facilitate sanitation between uses. 
         [0007]    At least one of the side or end walls may also include a window for receiving a removable access panel to facilitate loading and unloading of food product (e.g. meat logs). 
         [0008]    An upper edge of each of the side and end walls may be configured to receive a removable lid. 
         [0009]    At least one of the side or end walls may have a drainage hole proximate to the base. This drainage hole may be threaded. 
         [0010]    Preferably, the box is at least 5 feet in length, and at least 2 feet in width (and at least 2 feet deep). Preferably, the box has an interior volume of at least approximately 20 ft 3  (and more preferably, an interior volume of approximately 40-50 ft 3 ). In a typical embodiment, the walls are approximately 1 inch thick, while the base is generally slightly thicker. 
         [0011]    In one preferred embodiment, the box is rotationally molded. Preferably, the interior core of the material is polyethylene foam (injected polyethylene with a blowing agent), while the outer skins are of solid polyethylene. In another embodiment, the material is comprised of solid polyethylene with a hollow core. Other embodiments (e.g. solid or closed cell polyethylene) may also be possible, although the additional weight be undesirable in certain applications. 
         [0012]    The base may have feet. The feet are preferably spaced apart to provide gaps for receiving forks of a forklift. 
         [0013]    Preferably, the box has a weight of less than 400 lbs (and more preferably a weight of less than 350 lbs). 
         [0014]    According to a second aspect of the invention, a reuseable container system is provided for storage and transport of a perishable food product. A container is provided that has a base, a pair of upwardly extending side walls, and a pair of upwardly extending end walls connected with the side walls to form a generally rectangular box. The box has four interior edges and four interior corners where the side and end walls join the base. A removable access panel is defined in at least one of the side or end walls. A removable lid is provided that is sized to cover the container. The box, the access panel, and the lid are each integrally formed of molded polyethylene, and each has smooth interior surface to prevent accumulation of material and facilitate sanitation between uses. 
         [0015]    Preferably, the molded polyethylene of the box is a polyethylene foam having outer skins of solid polyethylene. At least one of the lid and the removable access panel may be hollow. 
         [0016]    The base may have feet. In this case, the lid may have alignment features that are disposed for receiving the feet of an adjacent base when the containers are stacked vertically. 
         [0017]    Preferably, the combined overall weight of the container, access panel, and lid is less than 500 lbs (and more preferably less than 400 lbs). 
         [0018]    The removable access panel may be defined within a window extending from an upper edge of the side or end wall to a lower edge disposed at a distance above the base. The window may be quadrilateral, e.g. trapezoidal, in shape. The window and access panel may have a tongue and groove arrangement. In one preferred embodiment, the removable access panel is slidably receivable in the window. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  shows a prior art shipping container of stainless steel. 
           [0020]      FIG. 2  shows prior art steel shipping containers in loaded state with plastic tarps to cover. 
           [0021]      FIG. 3A  is a front view of a preferred container according to the present invention (shown empty and with access panel removed). 
           [0022]      FIG. 3B  is a front view of the container of  FIG. 3A  (with meat logs). 
           [0023]      FIG. 3C  is a top view of the container of  FIG. 3A  in empty state showing interior rounded corners and edges. 
           [0024]      FIG. 3D  is a sectional view of the container of  FIG. 3C . 
           [0025]      FIG. 4A  is a front view of a preferred container according to the present invention (shown empty with access panel in place). 
           [0026]      FIG. 4B  is a front view of the container of  FIG. 4A , showing sliding entry of access panel. 
           [0027]      FIG. 5  is a top view of a lid for a container system. 
           [0028]      FIG. 6  is a front view of the assembled container system with lid and side access panel in place. 
           [0029]      FIG. 7  is a front view of assembled container systems in a stacked configuration. 
           [0030]      FIG. 8A  is a sectional view of a preferred layered molded polyethylene material used for the container box. 
           [0031]      FIG. 8B  is a sectional view of a preferred hollow molded polyethylene material used for the container lid and side access panel. 
       
    
    
     DETAILED DESCRIPTION 
       [0032]      FIGS. 1 and 2  show the prior art stainless steel coffins.  FIG. 2  shows the coffins stacked in a loaded state with polyethylene (stretch) cover wraps and liners to protect the product. The stainless steel containers are difficult to safely stack, and may not be able to be stacked at all for transportation. Some prior stainless steel coffins (such as those shown in  FIGS. 1-2 ) use a removable side panel which attaches using knobs. These knobs break easily and are sharp as they protrude from the container. Further, the edges and corners of the stainless steel containers are sharp and can lead to injury. This has been the situation for many years and has been tolerated due to a lack of viable alternatives. The meat product the boxes are designed to carry is heavy and of an awkward size. Wood and many plastics, which might be sufficiently strong, are not able to meet evolving food safety requirements. Wood in particular is porous and absorbs blood water, an obvious source of contamination and bacteria. 
         [0033]    In response, the present invention uses a lightweight polyethylene material that is 100% food grade resin. One presently preferred material is SAEPLAST° PE from RPC-Promens AS, which is a molded polyethylene featuring a closed cell exterior skin and closed cell foamed interior. Because the material is food grade, it can be contacted directly by the food product, avoiding the need for separate plastic liners and covers to protect the meat. 
         [0034]    As shown in  FIG. 3A , a five-sided box  100  is the basic container component. The box  100  has a base  110 , a pair of upwardly extending side walls  120 A,  120 B, a pair of upwardly extending end walls  130 A,  130 B connected with the side walls to form the box. Importantly, the walls and base are smoothly connected (preferably of a single piece of material) so that there is no accumulation of material in the corners and inside edges. 
         [0035]    One or both side walls  120 A,  120 B may include an access window  140  as shown to facilitate loading. This may be a quadrilateral window (preferably trapezoidal as shown, having a longer top “edge” than bottom edge, and upwardly tapering sides). This facilitates loading and unloading of meat logs  200 , which can be stacked inside the box, as shown in  FIG. 3B . 
         [0036]    The base  110  of the box preferably includes feet or posts  150  (preferably integral with the rest of the box) that have gaps  160  between them to permit safe and easy forklift access for lifting and stacking. Preferably, the design of the feet permits forklift access from any of the four sides. 
         [0037]    The box as shown may include at least one drainage hole  135  provided near the base so that fluid may drain away from the box interior. The drainage hole may be threaded to allow a threaded plug (not shown) to be securely attached. 
         [0038]      FIG. 3C  is a top view of the box showing interior radiused corners  170  and edges  180 . It is intended to avoid sharp corners or recesses on the interior or exterior surfaces which can allow for build up of contaminants between uses, and which are more difficult to access in cleaning.  FIG. 3D  also shows the radiused corners  170  and edges  180  in section. From  FIG. 3D , you can also see the optional tapering of the walls  120 A,  120 B (also in  130 A,  130 B not shown) having a narrowed point at the top edge  105  (allowing for insertion of the lid  300 ). Shouldered configuration of the feet  150  can also be seen. 
         [0039]      FIG. 4A  shows the box  100  with the access panel  190  in place. As shown in  FIG. 4B , the access panel is inserted and removed by simply sliding. The trapezoidal shape, as well as the tongue-and-groove features of the panel  190  and corresponding window  140 , lends strength to the overall assembly. As the features of the joint are inside, the outer surface does not need to have exterior hooks or knobs to secure the access panel, which can break or cause damage or injury. Accordingly, the boxes can also be placed in very close abutment for storage or shipping. 
         [0040]      FIG. 5  shows the lid  300  of the box. Shown is the top surface  310  of the lid. The lid seats snugly in the inner diameter of the upper edge  105  of the box  100  and upper edge of the access panel  190  (as shown in  FIG. 6 ). The lid  300  preferably includes alignment features  320 ,  325  on the top surface. These assist in inserting and removing the lid, as well as allowing stacking of the assembled container systems as shown in  FIG. 7 . For stacking, the feet  150  of an immediately upper box nest snugly with the alignment features  320 ,  325  of the lid  300  of the immediately lower box  100  to provide a secure stacked arrangement. As shown in  FIG. 3D , the feet may be shouldered to facilitate the nesting relationship with the features of the lid. 
         [0041]      FIG. 8A  shows a sectional view of the presently preferred wall and base material  500 . Molded polyethylene forms the outer skins  510 , and the interior core  520  is comprised of closed cell polyethylene foam. The overall structure is lightweight and durable. As shown in  FIG. 8B , a hollow variation of the material  550 , having outer skins  560  with a hollow core  570  (instead of a foamed core) may be used for the lid  300  and access panel  190  to save even more weight. 
         [0042]    The box  100 , access panel  190  and lid  300  can be manufactured using rotational molding. This process, also called rotomolding or rotocast, is a thermoplastic process for producing hollow parts by placing powder or liquid resin into a hollow mold and then rotating that tool bi-axially in an oven until the resin melts and coats the inside of the mold cavity. The interior foamed core is made by injecting polyethylene with a blowing agent which creates a foamed substance which thermally fuses with the walls of the skin. The finished walls, as is best seen from the exemplary slice in  FIG. 8A , have a sealed layered structure with closed cell skins on all outside surfaces. While polyethylene foam exhibits thermal insulation properties, its primary function is to provide rigidity, strength and robustness to the container providing a superior alternative to legacy products. 
         [0043]    The skins are thick and robust in their own right. Even without polyethylene foam, this would be a more durable product than a comparable product produced as a single wall, rotationally molded or injection molded. In the event the skin is compromised, it can easily be remedied through the process of plastic welding. Often a competitive single wall cannot be repaired and must be disposed of. 
         [0044]    Importantly, the access panel and lid of the system are separate components that are not attached using hinges, straps, latches or other hardware that can fail and/or be difficult to maintain or clean. 
         [0045]    The container can be made to include RFID, data loggers, bar codes/QR codes and other sensors (not shown) to improve traceability or to monitor cargo conditions. 
         [0046]    Preferably, the finished box is at least 5 feet in length, and at least 2 feet in width (and at least 2 feet deep). Preferably, the box has an interior volume of at least approximately 20 ft 3  (and more preferably, has an interior volume of approximately 40-50 ft 3 ). The walls are typically but not exclusively 1 inch in thickness whereas the base is generally thicker due to the rigors of the material handling process the container must withstand. 
         [0047]    Preferably, the combined overall weight of the container, access panel, and lid is less than 500 lbs (and more preferably less than 400 lbs). 
         [0048]    Because the container system is itself so much lighter than prior art coffins, the system allows for more meat weight to be transported, allowing for an overall transportation energy and cost savings. 
         [0049]    Moreover, the material, unlike stainless steel, has fewer employee hazards (smooth surfaces and edges, lighter weight for moving in a facility, soundless scraping), and easier cleaning and sanitizing. This promotes better food and employee safety. 
         [0050]    The scope of the claims should not be limited by the preferred embodiments set forth in the foregoing disclosure, but should be given the broadest purposive construction consistent with the description as a whole and having regard to equivalents set forth or implied. In particular, it should be noted that although “meat” and “meat products” are described herein as a preferred application for the container, the container will also have ready applications for other perishable and non-perishable food products.