Patent Publication Number: US-2011073556-A1

Title: Infant formula retort container

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention is related to the field of containers. In particular the present invention relates to containers adapted to be retortable and filled with infant formula. 
     2. Description of the Related Technology 
     Plastic blow-molded containers, particularly those molded of PET, have been utilized in hot-fill applications where the container is filled with a liquid product heated to a temperature in excess of 180° F. (82° C.), capped immediately after filling, and allowed to cool to ambient temperatures. Plastic blow-molded containers have also been utilized in pasteurization and retort processes, where a filled and sealed container is subjected to thermal processing and is then cooled to ambient temperatures. 
     Pasteurization and retort methods are frequently used for sterilizing solid or semi-solid food products, e.g., pickles and sauerkraut. The products may be packed into the container along with a liquid at a temperature less than 82° C. (180° F.) and then sealed and capped, or the product may be placed in the container that is then filled with liquid, which may have been previously heated, and the entire contents of the sealed and capped container are subsequently heated to a higher temperature. As used herein, “high-temperature” pasteurization and retort are sterilization processes in which the product is exposed to temperatures greater than about 80° C. 
     Pasteurization and retort differ from hot-fill processing by including heating the filled container to a specified temperature, typically greater than 93° C. (200° F.), until the contents of the filled container reach a specified temperature, for example 80° C. (175° F.), for a predetermined length of time. That is, the external temperature of the hot-filled container may be greater than 93° C. so that the internal temperature of a solid or semi-solid product reaches approximately 80° C. Retort processes may also involve applying overpressure to the container. 
     Plastic containers have replaced or provided an alternative to glass containers for many applications. However, few food products that must be processed using pasteurization or retort are available in plastic containers. The rigors of such processing present significant challenges for the use of plastic containers, including containers designed for use in hot-fill processing. For example, during a retort process, when a plastic container is subjected to relatively high temperatures and pressures, the plastic container&#39;s shape will distort. Upon cooling, the plastic container generally retains this distorted shape or at least fails to return to its pre-retort shape. Accordingly, there remains a need to provide plastic containers that can withstand the rigors of pasteurization and retort processing in order to take advantage of the cost savings that can be realized through manufacture and recycling. The lighter weight of plastic containers as compared to glass can also advantageously reduce shipping costs. 
     Much like glass containers, the usage of metal containers instead of plastic containers has many disadvantages. Metal containers may be more expensive to produce and the metal containers may ultimately weigh more during shipping. Furthermore, metal containers may dent or be damaged during shipping. Therefore, the usage of plastic in place of metal would also provide a benefit for producers of food products that typically use metal containers. 
     While using plastic containers is advantageous in the long run. The difficulty in producing such a container that also retains the look and shape of a container that has traditionally held the type of contents to be stored has proven difficult to achieve. Furthermore, with some products such as infant formula, there has not been a plastic container made that is adapted for the retort process so that it may be readily used by an infant or small child. That is to say there are not single serving plastic containers for infant formula that are retortable and ready to be grasped and used by an infant or toddler. Therefore there is a need in the field to produce a container that is sized to be held by an infant or toddler so that they can drink from the container, while also capturing the benefits of being constructed of plastic. 
     SUMMARY OF THE INVENTION 
     An object of the present invention may be a retortable container for infant formula. 
     Another object of the present invention may be a container adapted to retain a nipple. 
     Yet another object of the present invention may be a container having a body portion adapted to be retortable. 
     Still yet another object of the present invention may be a container having a body portion sized to be grasped by an infant. 
     Yet another object of the present invention may be a container with a plurality of flex panels. 
     An aspect of the present invention may be a plastic container comprising a top portion, wherein the top portion is dome shaped; a neck portion located below the top portion; a body portion constructed of a plastic material located below the neck; a base portion located below the body portion; and wherein the container is retortable and filled with infant formula. 
     Another aspect of the present invention may be a plastic container comprising: a top portion, wherein the top portion is dome shaped; a neck portion located below the top portion; a body portion constructed of a plastic material located below the neck portion, wherein the body portion comprises a plurality of flex panels; a base portion located below the body portion; wherein that body portion has a smaller diameter proximate to the neck portion than a diameter taken near the base portion and further wherein the body portion is sized to be grasped by an infant. 
     Still yet another aspect of the present invention may be a method of hot-filling a container comprising; providing a hot-fill container comprising a top portion having an upper top portion, a first bumper portion located below the upper top portion, and a lower top portion located below the first bumper portion; a body portion located below the lower top portion; and a base portion located below the body portion, wherein the base portion comprises a second bumper portion; gripping the container at the first bumper portion and the second bumper portion; hot-filling the container; and capping the container. 
     These and various other advantages and features of novelty that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an embodiment of a container constructed in accordance with the present invention. 
         FIG. 2  is a front view of the container shown in  FIG. 1 . 
         FIG. 3  is a side view of the container shown in  FIG. 1 . 
         FIG. 4  is a close up view of the flex panel shown in  FIG. 1 . 
         FIG. 5  is a cross sectional view of the container shown in  FIG. 1  taken along the line A-A. 
         FIG. 6  is a cross sectional view of the container shown in  FIG. 1  taken along the line B-B. 
         FIG. 7  is a perspective view of another embodiment of a container constructed in accordance with the present invention. 
         FIG. 8  is a front view of the container shown in  FIG. 7 . 
         FIG. 9  is a side view of the container shown in  FIG. 7 . 
         FIG. 10  is a close up view of the flex panel shown in  FIG. 7 . 
         FIG. 11  is a flow chart of the retort process. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S) 
     Referring now to the drawings, wherein like reference numerals refer to corresponding structure throughout and referring in particular to  FIG. 1 , wherein an isometric view of a container  100  is shown that is made in accordance with an embodiment of the present invention. 
     The container  100  may be a one-piece construction and may be prepared from a monolayer plastic material, such as a polyamide, for example, nylon; a polyolefin such as polyethylene, for example, low density polyethylene (LDPE), high density polyethylene (HDPE), polypropylene, a polyester, for example, polyethylene terephthalate (PET), polyethylene naphtalate (PEN), or others, which may also include additives to vary the physical or chemical properties of the material. For example, some plastic resins may be modified to improve the oxygen permeability. Alternatively, the container may be prepared from a multilayer plastic material. The layers may be any plastic material, including virgin, recycled and reground material. The layers may include plastics or other materials with additives to improve physical properties of the container. In addition to the above-mentioned materials, other materials often used in multilayer plastic containers may be used including, for example, ethylvinyl alcohol (EVOH) and tie layers or binders to hold together materials that are subject to delamination when used in adjacent layers. A coating may be applied over the monolayer or multilayer material to introduce oxygen barrier properties. In an exemplary embodiment, the present container is prepared from PET. 
     The container  100  is constructed to withstand the rigors of hot-fill processing, a retort process and/or pasteurization. The container  100  may be made by conventional blow molding processes including, for example, extrusion blow molding, stretch blow molding and injection blow molding. These molding processes are discussed briefly below. 
     In extrusion blow molding, a molten tube of thermoplastic material, or plastic parison, is extruded between a pair of open blow mold halves. The blow mold halves close about the parison and cooperate to provide a cavity into which the parison is blown to form the container  100 . As so formed, container  100  may include extra material, or flash, at the region where the molds come together. A moil may be intentionally present above the top portion of the container. 
     After the mold halves open, the container  100  drops out and is then sent to a trimmer or cutter where any flash of moil attached to the container  100  is removed. The finished container  100  may have a visible ridge (not shown) formed where the two mold halves used to form the container came together. This ridge is often referred to as the parting line. 
     With stretch blow molding a pre-formed parison, or pre-form, is prepared from a thermoplastic material, typically by an injection molding process. The pre-form typically includes an opened end, which becomes part of the closure of the container  100 . The pre-form is positioned between two open blow mold halves. The blow mold halves close about the pre-form and cooperate to provide a cavity into which the pre-form is blown to form the container  100 . After molding, the mold halves open to release the container  100   
     With injection blow molding, a thermoplastic material may be extruded through a rod into an injection mold in order to form a parison. The parison is then positioned between two open blow mold halves. The blow mold halves close about the parison and cooperate to provide a cavity into which the parison may be blown to form the container  100 . After molding, the mold halves open to release the container  100 . 
     As discussed above, the plastic blow-molded containers, particularly those molded of PET, may be utilized in hot-fill applications, retort processes and/or pasteurization. Hot-filling involves filling the container  100  with a liquid product heated to a temperature in excess of 180° F. (i.e., 82° C.), capped immediately after filling, and then allowed to cool to ambient temperatures. Pasteurization and retort differ from hot-fill processing by including heating the filled container to a specified temperature, typically greater than 93° C. (200° F.), until the contents of the filled container reach a specified temperature, for example 80° C. (175° F.), for a predetermined length of time. That is, the external temperature of the hot-filled container may be greater than 93° C. so that the internal temperature of a solid or semi-solid product reaches approximately 80° C. Retort processes may also involve applying overpressure to the container 
     In the construction of containers it is important to keep the container&#39;s top load and hot-fill, retort and pasteurization performance characteristics strong. The structural integrity of the container must be maintained after the hot-fill, pasteurization and/or retort process. Furthermore, consideration must be made for preventing bulging of the container  100  that can occur with some containers. When a container  100  is said to be adapted for a hot-fill process, retort process and/or pasteurization process, it is meant that the container  100  is designed and structured so as to withstand the heating and/or over pressuring that are involved in these processes without undergoing significant structural deformation. 
     The container  100  shown in  FIGS. 1-3  has a finish portion  12  that is located above the top portion  20 . The finish portion  12  may be threaded and adapted to retain a nipple for use with an infant. Below the finish portion  12  is the lower flange area  14  that together with the finish portion  12  accommodates the placement of the nipple. The nipple may be placed on the container  100  after removal of a cap that originally sealed the container  100 . 
     The top portion  20  as shown in  FIGS. 1-3  is dome shaped and located above the neck  18 . By “dome shaped” it is meant that the top portion  20  is generally a partially spherical structure that may also have vertically and/or horizontally sloped surfaces. The top portion  20  has a bumper portion  16  that provides a contact point for the gripping mechanism used on the processing line during the fill process. The bumper portion  16  functions to keep the container  100  straight while on the processing line. It should be understood that while the top portion  20  is shown as dome shaped that other shapes and geometries may be formed so long as there is sufficient structure that may operate as the bumper portion  16 . 
     Located below the neck  18  is the body portion  30   a . The body portion  30   a  shown in  FIGS. 1-3  is circular in shape and has a circumference. In the embodiment shown in  FIGS. 1-3  the body portion  30   a  is sloped so that the circumference of the body portion  30   a  increases as the base portion  40   a  is approached. The circumference of the body portion  30   a  is ideally of a size which is graspable by an infant or toddler. The container  100  shown in  FIGS. 1-3  is adapted to accommodate 8 oz. of fluid. 
     The body portion  30   a  has a flex panel  33   a  having an island  32   a . Located between two flex panels  33   a  is a column portion  35   a . The flex panel  33   a  may have a trapezoidal shape that has a narrower width towards the portion of the flex panel  33   a  closest to the neck  18  and a wider shape towards the portion of the container  100  closest to the base portion  40   a  of the container  100 . The flex panels  33   a  are described in more detail below. 
     In  FIGS. 1-3 , the body portion  30   a  may have six flex panels  33   a , as well as islands  32   a  and column portions  35   a . The column portions  35   a  also provide structure to which a label may be attached. The number of flex panels  33   a  facilitates the accommodation of container  100  having a circumferential arrangement. The flex panels  33   a  may also accommodate the vacuum absorption made necessary by the fill process. 
     The body portion  30   a  is located above and integrally connected to the base portion  40   a  via the groove  43 . The base portion  40   a  provides a base bumper portion  42  that provides a contact point for the gripping mechanism used on the processing line during the hot-fill process. 
       FIG. 4  is a close up view of the flex panel  33   a . The flex panel  33   a  is one of six panels on the container  100  shown in  FIGS. 1-3 . The flex panel  33   a  has a first width W 1  which is taken from the first side  36   a  of the flex panel  33   a  to the second side  37   a  of the flex panel  33   a . The width W 1  is taken proximate to the top side  38   a  of the flex panel  33   a . The width W 1  is less than the width W 2  shown in  FIG. 4 , which is taken from the first side  36   a  of the flex panel  33   a  to the second side  37   a  of the flex panel  33   a . The width W 2  is taken proximate to the bottom side  39   a  of the flex panel  33   a . The angle θ 1  formed between the first side  36   a  of the flex panel  33   a  and the bottom side  39   a  of the flex panel  33   a  is approximately between 89°-85°. 
     The island  32   a  is one of six islands on the container  100  shown in  FIGS. 1-3 . The island  32   a  has a width W 3  which is taken from the first side  45   a  of the island  32   a  to the second side  47   a  of the island  32   a . The width W 3  is taken proximate to the top side  46   a  of the island  32   a . The width W 3  is less than the width W 4  shown in  FIG. 4 , which is taken from the first side  45   a  of the island  32   a  to the second side  47   a  of the island  32   a . The width W 4  is taken proximate to the bottom side  49   a  of the island  32   a . The angle θ 2  formed between the first side  45   a  of the island  32   a  and the bottom side  49   a  of the island  32   a  is roughly between 89°-85°. In a preferred embodiment the angle θ 1  is equal to the angle θ 2 . 
       FIG. 5  is a cross sectional view of the container  100  shown in  FIG. 1  taken along the line A-A.  FIG. 6  is a cross sectional view of the container  100  shown in  FIG. 1  taken along the line B-B. The diameter D 1  of the container  100  taken along the line A-A is less than the diameter D 2  of the container  100  taken along the line B-B. 
     The container  200  shown in  FIG. 7  has a neck portion  12  that is located above the top portion  20  that may be threaded so as to accommodate the placement of a nipple. Below the neck portion  12  is the lower flange area  14  that together with the neck portion  12  accommodates the placement of a nipple, much in the same manner as the container  100  shown in  FIG. 1 . The top portion  20  as shown in  FIG. 7  is dome shaped and located above the neck  18 . The top portion  20  has a bumper portion  16  that provides a contact point for the gripping mechanism used on the processing line during the fill process. The bumper portion  16  functions to keep the container  200  straight while on the processing line. It should be understood that while the top portion  20  is shown as dome shaped that other shapes and geometries may be formed so long as there is sufficient structure that may operate as the bumper portion  16 . 
     Located below the neck  18  is the body portion  30   b . The body portion  30   b  shown in  FIG. 7  is circular in shape and has a circumference. In the embodiment shown in  FIG. 7  the body portion  30   b  is sloped so that the circumference of the body portion  30   b  increases as the base portion  40  is approached. In contrast to the body portion  30   a  shown in  FIG. 1 , the body portion  30   b  is sloped at an increased angle. The circumference of the body portion  30   b  is ideally of a size which is graspable by an infant or toddler. The container  200  shown in  FIGS. 7-9  is adapted to accommodate 6 oz. of fluid. 
     The body portion  30   b  has a flex panel  33   b  having an island  32   b . Located between two flex panels  33   b  is a column portion  35   b . The flex panel  33   b  may have a trapezoidal shape that has a narrower width towards the portion of the flex panel closest to the neck  18  and a wider shape towards the portion of the container closest to the base portion  40   b  of the container  200 . The flex panels  33   b  are described in more detail below. 
     In  FIGS. 7-9 , the body portion  30   b  may have six flex panels  33   b , as well as islands  32   b  and column portions  35   b . The column portions  35   b  also provide structure to which the label may be attached. The number of flex panels  33   b  facilitates the accommodation of container  200  having a circumferential arrangement. The flex panels  33   b  may also accommodate the vacuum absorption made necessary by the fill process. 
     The body portion  30   b  is located above and integrally connected to the base portion  40   b  via the groove  43 . The base portion  40   b  additionally has another groove  44 . The two grooves,  43  and  44 , in the base portion  40   b  provide additional structure for the base portion  40   b  in order to provide sufficient structure during the hot-fill process, while maintaining the overall aesthetic design. The base portion  40   b  also provides a base bumper portion  42  that provides a contact point for the gripping mechanism used on the processing line during the hot-fill process. 
       FIG. 10  is a close up view of the flex panel  33   b  used with the 6 oz. container  200 . The flex panel  33   b  is one of six panels on the container  200  shown in  FIGS. 7-9 . The flex panel  33   b  has a first width W 5  which is taken from the first side  36   b  of the flex panel  33   b  to the second side  37   b  of the flex panel  33   b . The width W 5  is taken proximate to the top side  38   b  of the flex panel  33   b . The width W 5  is less than the width W 6  shown in  FIG. 10 , which is taken from the first side  36   b  of the flex panel  33   b  to the second side  37   b  of the flex panel  33   b . The width W 5  is taken proximate to the bottom side  39   b  of the flex panel  33   b . The angle θ 3  formed between the first side  36   b  of the flex panel  33   b  and the bottom side  39   b  of the flex panel  33   b  is approximately between 89°-65°, and is preferably between 85°-75°. 
     The island  32   b  is one of six islands on the container  200  shown in  FIG. 10 . The island  32   b  has a width W 7  which is taken from the first side  45   b  of the island  32   b  to the second side  47   b  of the island  32   b . The width W 7  is taken proximate to the top side  46   b  of the island  32   b . The width W 7  is less than the width W 8  shown in  FIG. 10 , which is taken from the first side  45   b  of the island  32   b  to the second side  47   b  of the island  32   b . The width W 8  is taken proximate to the bottom side  49   b  of the island  32   b . The angle θ 4  formed between the first side  45   b  of the island  32   b  and the bottom side  49   b  of the island  32   b  is roughly between 89°-85°. In a preferred embodiment the angle θ 3  is equal to the angle θ 4 . 
     The containers  100  and  200  utilize the structure to withstand the heating process which may normally distort other containers made from the same material. The flexible panels  33   a ,  33   b  and column portions  35   a ,  35   b  add to the overall structure and permit it to retain its aesthetic shape during the retort process. The containers  100  and  200  have to go through a process where it is filled with an ambient liquid, gets capped, and is entered into a retort chamber, steamed and pressurized so as the liquid in the container is sterilized until it is safe. The internal liquid temperature can reach up to 255° F. or more. The shape then gets cooled back to room temperature and comes out looking like it did when it went in the retort chamber without distortion. 
       FIG. 11  is flow chart providing the steps of performing a retort process with the container  100 . The same method is applicable to each of the containers disclosed herein. In step  102 , the container  10  is provided. In step  104 , the container  100  is gripped by the fill machinery, similar to that used in the hot-fill process, which is a process that this container may also undergo. In step  106  the container  100  is filled, which in the present invention is preferably baby formula. In step  108 , the container  100  is heated to a specified temperature, typically greater than 93° C. (200° F.), until the contents of the filled container  100  reach a specified temperature, for example 80° C. (175° F.), for a predetermined length of time. That is, the external temperature of the hot-filled container may be greater than 93° C. so that the internal temperature of a solid or semi-solid product reaches approximately 80° C. In step  110 , an optional step of applying overpressure to the container  100  is performed. This step is performed sometimes when applying the retort process. In step  110 , the container  100  is capped. 
     It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.