Patent Publication Number: US-2016236814-A1

Title: Candy Manufacturing Support Pallet and Method of Use

Description:
INTRODUCTION 
     Some candies such as candy canes are seasonal with a bigger demand over the winter holidays. Many of those candies have shelf lives that are longer than a few months. Thus, the candies can be manufactured many months before they are shipped to be sold to consumers. Moreover, it may be advantageous or even required to manufacture candy canes year round due to economics and production limits. 
     Candy canes are fragile and have an odd shape that can be difficult to support. Manufacturing candy canes well before they are sold requires storage space and special supports that protects the candy canes but also allows for easy loading when the boxes are ready. Thus, a suitable support and storage system that is low cost, light weight, and minimizes space used is desirable. 
     The packaging for the candies may not be ready until just before the season begins. For instance, the design of a display on a box might be finalized weeks before the candies are shipped. However, a few weeks might not be enough time to manufacture all the candy to meet expected consumer demand. It is with respect to this general tension that the embodiments of the present application are directed. 
     SUMMARY 
     In summary, the present disclosure relates to a manufacturing support system that includes supporting, storing and displaying candy canes. 
     The manufacturing support system can include a support pallet that has a planar surface that defines a plurality of holding slots, where each holding slot is sized to receive and support a manufacturing insert tray. The support system can also include support rails that are positioned adjacent to the surface or that are connected to the surface. The holding slots may be rectangular and arranged such that the holding slots form a column on the support surface. More than one support pallet can be combined for use and be placed on a supporting carrier. 
     A method for manufacturing boxes is also disclosed. The method can include producing a consumer product, such as a candy cane, and placing the product in an insert tray. Then the tray can be positioned in a holding slot of a support pallet. The support pallet can then be stored in a location for days, weeks or months until the insert trays are removed and a display box is positioned over or around the insert tray. Multiple support pallets can be placed on a carrier, along with support rails, to facilitate moving and storing. The support pallet can also be used in a point-of-sale display. 
     These and various other features as well as advantages which characterize the systems and methods described herein will be apparent from a reading of the following detailed description and a review of the associated drawings. Additional features are set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the technology. The benefits and features of the technology will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following figures, which form a part of this application, are illustrative of described technology and are not meant to limit the scope of the claims in any manner, which scope shall be based on the claims appended hereto. 
       Referring now to the drawings, wherein like reference letters and numerals indicate corresponding structure throughout the several views: 
         FIG. 1  is a perspective view of a manufacturing support pallet according to a first example embodiment of the present disclosure; 
         FIG. 2  is a front view of a manufacturing support pallet according to a first example embodiment of the present disclosure; 
         FIG. 3  is a top view of a manufacturing support pallet according to a first example embodiment of the present disclosure; 
         FIG. 4  is a top view of a manufacturing support pallet according to a second example embodiment of the present disclosure; 
         FIG. 5  is a top view of a carrier with manufacturing support pallets according to the first example embodiment; 
         FIG. 6  is a top view of a carrier supporting manufacturing support pallets according to the second example embodiment; 
         FIG. 7  is a top front view of a manufacturing support pallet with an example candy product according to an example embodiment of the present disclosure; 
         FIG. 8  is a perspective view of a manufacturing support pallet with an example candy product according to an example embodiment of the present disclosure; 
         FIG. 9  is a block diagram illustrating a method of manufacturing a candy product package according to an example embodiment of the present disclosure; 
         FIG. 10  is a perspective view of a box loaded with candy canes according to the principles of the present invention; and 
         FIG. 11  a perspective view of an insert loaded with candy canes. 
     
    
    
     DETAILED DESCRIPTION 
     As briefly described above, embodiments of the present invention are directed to a candy product manufacturing support system, as well as a method for its use. In general, the system described herein includes a manufacturing support pallet that provides a holding structure to store candy products such as candy canes before the packaging is finalized. Although used between the manufacture of the product and the finalization of the packaging, it is within the scope of this disclosure to additionally use the support pallet during shipping and/or display of the finalized product. 
     As mentioned above, candy canes are generally brittle, easily broken and awkwardly shaped for storage and handling purposes. The use of the support pallet can enable the production of the candy canes at a convenient time based on the manufacturer&#39;s preferences and availability. In some circumstances, the manufactured candy canes can sit on the support pallet for weeks, months or longer before being placed into a finalized package. 
     In accordance with the present disclosure, an example manufacturing support pallet  100  is illustrated in  FIGS. 1-3 . As illustrated, the manufacturing support pallet  100  includes a support panel  102  with base surface  104  and holding slots  106 , as well as support rails  108  connected to support panel  102  along seam  110 . The manufacturing support pallet  100  can be stacked on top of other support pallets and/or arranged alongside other manufacturing support pallets  100 , as shown and described in more detail below with reference to  FIG. 5 . Other embodiments can include more or fewer components. 
     The manufacturing support pallet  100  can be made of any suitable material, such as corrugated cardboard, plywood, wood, aluminum, balsa wood, a plastic, etc. In embodiments, the support panel  102  and support rails  108  are typically made of the same material. 
     Example base surface  104  is substantially planar and is depicted as being oriented substantially parallel to the ground. In other embodiments, base surface  104  can be angled relative to the ground, for example, at an angle of between about 1° to about 60°. The base surface  104  can have varying thickness in different embodiments to provide the structure and support necessary to hold the product packages. 
     The example manufacturing support pallet  100  is shown with the base surface  104  positioned at approximately the bottom quarter of the support rails  108 . The distance of the base surface  104  to the bottom of the support rails  108  is shown in  FIG. 1  as height H. The manufacturing support pallet  100  can be designed with the base surface  104  positioned at a height H such that it accommodates the shape and size of the product package. In an embodiment of the example, the manufacturing support pallet  100  has a base surface  104  that is not fixed but is height-adjustable. 
     The base surface  104  defines one or more holding slots  106 . The holding slots  106  can be rectangular, as shown in the example. Alternatively, the holding slots  106  can have different cross-sectional shapes to accommodate differently sized product packages, such as square, circle, trapezoid, parallelogram, etc. As shown in  FIG. 3 , in some embodiments the holding slots  106  are aligned such that the centroids of the holding slots are linear. 
     In the embodiment shown, each holding slot  106  is congruent to the one or more other holding slots  106  defined by the base surface  104 . In other embodiments, the base surface  104  can define holding slots  106  with different shapes. The spacing between adjacent edges of the holding slots  106  can vary, for example, from about 0.25 inch to about 3 inches; with typical spacing being about 0.5 inch; about 0.75 inch; about 1 inch; about 1.25 inches; about 1.5 inches; about 2 inches; and about 2.5 inches. 
     The holding slots  106  can be arranged in a row along the length of the base surface  104 , as shown in  FIG. 3 . In a different embodiment of the example, the holding slots  106  can be rotated about 90° to be arranged in a row along the width of the base surface  104 . 
     As shown in the example in  FIG. 3 , a space L is disposed between the outer edges of the holding slots  106  and the inner surface of support rails  108 . In other embodiments, the space L is more or less than that shown in  FIG. 3 . 
     The example support panel  102  can be joined to each support rail  108  at seam  110 . In embodiments shown of  FIG. 3 , the two support rails  108  and the support panel  102  are separate pieces, for example, three pieces of corrugated cardboard. In those embodiments, the support panel  102  can be affixed to the support rails  108  using methods known in the art, for example, using an adhesive or fastener. In other embodiments, the support rails  108  and support panel  102  are made from one continuous piece. 
     The support rails  108  can also include one or more receiving cavities configured to receive and hold extensions from the support panel  102 . In that embodiment, the rails  108  can include receiving cavities at different heights H such that the support panel  102  can be positioned at different heights. For example, the extensions on support panel  102  can include a knob or other shape on the end. The receiving cavity on the support rail  108  can include a first portion sized to allow the knob or other shape to pass through and a narrower portion such that the extension can “snap” into place. 
     In accordance with the present disclosure, an example manufacturing support pallet  200  is illustrated in  FIG. 4  according to a second embodiment. As illustrated, the manufacturing support pallet  200  includes a support panel  202  with base surface  204  and holding slots  206 , as well as support rails  208 . Other embodiments can include more or fewer components. 
     The manufacturing support pallet  200  can be made of any suitable material, such as corrugated cardboard, plywood, wood, aluminum, balsa wood, a plastic, etc. In embodiments, the support panel  202  and support rails  208  are made of the same material. 
     The support panel  202  can stand on a surface without the help of support rails  208 . The support panel  202  can include rails that run lengthwise, widthwise, or both. The support panel  202  may also include four leg portions extending normal to the base surface  204 . The support panel  202  has an adjustable height. In other embodiments, the support panel  202  has a fixed height but different embodiments can have different heights. 
     Example base surface  204  is substantially planar and is depicted as being oriented substantially parallel to the ground. In other embodiments, base surface  204  can be angled relative to the ground, for example, at an angle of between about 1° to about 60°. The base surface  204  can have varying thickness in different embodiments to provide the structure and support necessary to hold the product packages. 
     The base surface  204  defines one or more holding slots  206 . The holding slots  206  can be rectangular, as shown in the example. Alternatively, the holding slots  206  can have different cross-sectional shapes to accommodate differently sized/shaped product packages, such as square, circle, trapezoid, parallelogram, etc. In the embodiment shown, each holding slot  206  is congruent to the one or more other holding slots  206  defined by the base surface  204 . In other embodiments, the base surface  204  can define holding slots  206  with different shapes. The spacing between adjacent edges of the holding slots  206  can vary, for example, from about 0.25 inch to about 3 inches; with typical spacing being about 0.5 inch; about 0.75 inch; about 1 inch; about 1.25 inches; about 1.5 inches; about 2 inches; and about 2.5 inches 
     The holding slots  206  can be arranged in a row along the length of the base surface  104 , as shown in  FIG. 3 . In a different embodiment, the holding slots  206  can be rotated about 90° to be arranged in a row along the width of the base surface  104 . 
     The support rails  208  can be u-shaped, similar to rails  108 . In other embodiments, support rails  208  are planar or substantially planar. 
     As shown in the example in  FIG. 3 , a space W is between the outer edges of the holding slots  106  and the outer edge of panel  202 . In other embodiments, the space W is greater or less than that shown in  FIG. 3 . 
     In contrast to the example embodiment shown in  FIGS. 1-3 , the example support pallet  200  has support rails  208  that are not connected to the panel  202 . Each support rail  208  can move independently from the panel  202  and, likewise, panel  202  can move independently from the rails  208 . 
       FIG. 5  illustrates an example embodiment of storage system  250 . The storage system  250  can also be used as an in-store display for the finished product packages. As shown in  FIG. 5 , the example storage system  250  includes a carrier  260  and a plurality of manufacturing support pallets  100 . Other embodiments can include more or fewer components. 
     The embodiment shown in  FIG. 5  includes three manufacturing support pallets  100  arranged side-by-side. However, the example embodiment carrier  260  can be sized to support any number of manufacturing support pallets  100 . For example, carrier  260  can be sized to support two, three, four, five, six, seven or eight, or more, manufacturing support pallets  100  side by side. Additionally, carrier  260  can be sized to support multiple columns of manufacturing support pallets  100 , for example, two columns each with three manufacturing support pallets  100  side by side. 
     The carrier  260  can be made of any suitable material, such as corrugated cardboard, plywood, wood, aluminum, balsa wood, a plastic, etc. In embodiments, the carrier  260  can have raised edges. 
     As shown in  FIG. 5 , the manufacturing support pallets  100  can be arranged in the carrier  260  such that there is space between each of the pallets  100  and the edges of the carrier  260 . In other example embodiments, the carrier  260  is sized such that the manufacturing support pallets  100  fit flush or snug to the edges of the carrier  260 , thereby substantially restricting any lateral movement of the manufacturing support pallets  100 . 
     One or more carriers  260  can be stacked on top of each other. In embodiments, rails  108  can provide support for the carrier  260  placed above. 
       FIG. 6  illustrates an example embodiment of storage system  270 . The storage system  270  can also be used to as an in-store display for the product packages. As shown in  FIG. 6 , the example storage system  270  includes a carrier  280  and a plurality of manufacturing support pallets  200 . Other embodiments can include more or fewer components. 
     The embodiment shown in  FIG. 6  includes three manufacturing support pallets  200  arranged side-by-side. However, the carrier  280  can be sized to support any number of manufacturing support pallets  200 . For example, carrier  280  can be sized to support two, three, four, five, six, seven or eight, or more, manufacturing support pallets  200  side by side. Additionally, carrier  280  can be sized to support multiple columns of manufacturing support pallets  200 , for example, two columns each with three manufacturing support pallets  200  side by side. 
     The carrier  280  can be made of any suitable material, such as corrugated cardboard, plywood, wood, aluminum, balsa wood, a plastic, etc. In embodiments, the carrier  280  has raised edges or another structure designed to limit lateral movement of the support pallets  200 . 
     As shown in  FIG. 6 , the manufacturing support pallets  200  can be arranged in the carrier  280  such that there is space between each of the pallets  200  and the edges of the carrier  280 . In other example embodiments, the carrier  280  is sized such that the manufacturing support pallets  200  fit flush or snug to the edges of the carrier  280 , thereby substantially restricting lateral movement of the manufacturing support pallets  200 . 
     One or more carriers  280  can be stacked on top of each other. In some embodiments, rails  208  can provide support for the carrier  280  placed above. As discussed above with reference to  FIG. 4 , rails  208  are not connected to panel  202  in manufacturing support pallet  200 . Thus, when multiple carriers  280  are stacked, a panel  202  can be removed from a carrier  280  without needing to remove the entire carrier  280  from the stack of carriers. 
     Referring now to  FIGS. 7 and 8 , an example manufacturing support pallet  300  is shown with an example product. As shown, the example manufacturing support pallet  300  includes a support panel  302  with base surface  304  and holding slots  306 , and support rails  308  connected to the support panel  302  at seam  310 . Other embodiments can include more or fewer components. 
     As shown, the example manufacturing support pallet  300  includes three separate cardboard pieces. Similar to the second example embodiment  200  shown in  FIG. 4 , the two support rails  308  are not connected to the panel  304 . However, in other embodiments not shown, the support rails are connected to the support panel  302  in manner similar to example embodiment  100  discussed above with reference to  FIGS. 1-3 . Also, as shown, the support rails  308  have a substantially upside-down “U” shaped cross section. In other embodiments of the example, the support rails can have a “closed” cross section that is substantially rectangular in shape. 
     The example manufacturing support pallet  300  is shown supporting two example product packages  400 . The example product packages  400  are candy cane insert trays that can be placed inside an outer display package as described in U.S. Patent Application 6______, the entirety of which is hereby incorporated by reference. 
       FIG. 10  shows a packaging system  20  configured for packaging candy and in particular for packaging and displaying candy canes  10 . The packaging system  20  includes a box  22  and insert  24  for supporting the candy canes  10  and configured to insert into the box  22 . As shown in  FIGS. 10 and 11 , an insert  24  is configured to support and retain the candy canes  10 . The candy canes  10  are supported with the elongate section  12  retained in the space formed between the first and second cross pieces  62 ,  64  and the back  52 . The hook section  14  passes over and around the top of the first cross piece  62  and the hook ends  16  extend downward over the front of the first cross piece  62 . Moreover, the bottom  60  extends forward beyond the sides  56  and the front formed by the cross pieces  62  and  64 . The bottom  60  can serve as a spacer when the insert  24  is placed in a box  22 . 
     With the configuration shown, it can be appreciated that the candy canes  10  may be stored in the insert  24  and do not immediately need to be placed in a box  22 . Therefore, production may continue throughout the year and changes may be made to update graphics and other information on the box after the candy canes  10  are produced and stored in the insert  24 . Moreover, versions of the box  22  having different graphics may be utilized with the same insert  24  and candy canes  10 . It will also be appreciated that although the insert  24  and box  22  shown in  FIGS. 10 and 11  are configured for holding twelve candy canes  10 , fewer or larger numbers of candy canes may be utilized with a narrower or wider insert  24  and box  22 . 
     Although the example manufacturing support pallet  300  is shown with only two holding slots  306 , it is within the scope of this disclosure that the base surface  304  defines many more than two slots  306  as discussed above with reference to  FIG. 4 . Further, the disclosure is not limited to supporting candy cane trays—any type of product package can be placed within the holding slots  306 . 
       FIG. 9  is a block diagram of an example method  500  for using an example manufacturing support pallet  100  or  300 . The example method  500  includes manufacturing product (step  505 ), manufacturing a product package (step  510 ), placing the product in the product package (step  515 ), positioning the product package in an example support pallet (step  520 ), arranging a support pallet in a carrier (step  525 ), and removing the product package from the support pallet (step  530 ). Other embodiments can include more or fewer steps. 
     The method  500  begins with manufacturing a product (step  505 ) and manufacturing a product package (step  510 ). The product can be a confectionary product such as candy. In other embodiments, the product can be any product that is placed in a package, including packages with display overlays. The product (step  505 ) and product package (step  510 ) do not need to be manufactured simultaneously. 
     After the product and product package are manufactured (steps  505  and  510 ), the product is placed in the product package (step  515 ). In one or more embodiments, step  515  can be performed by hand or automatically. 
     When the product has been arranged in the product package (step  515 ), the next step in example method  500  is to position the product package in the support pallet (step  520 ). At this point in the example method  500 , the support pallet and the product packages can be stored for later retrieval. 
     One or more support pallets can then be arranged in a carrier (step  525 ). Example arrangements of support pallets in a carrier are shown and described in more detail above with reference to  FIGS. 5 and 6 . One or more carriers can be stacked on top of each other. The one or more carriers with support pallets can next be stored or used for a consumer display. 
     The product package is next removed from the support pallet (step  530 ). The product package is removed hours, days, weeks, months or longer after it is arranged in the support pallet in the carrier (step  525 ). A cover or display wrapping can be added to the product package after removal (step  530 ). Then, the product package, with the cover or display wrapping, can be placed back in the support pallet, which can then go in the carrier. The carrier with the covered or wrapped product packages can then be used in shipping and/or a point-of-sale display. 
     As used herein, “about” refers to a degree of deviation based on experimental error typical for the particular property identified. The latitude provided the term “about” will depend on the specific context and particular property and can be readily discerned by those skilled in the art. The term “about” is not intended to either expand or limit the degree of equivalents which may otherwise be afforded a particular value. Further, unless otherwise stated, the term “about” shall expressly include “exactly,” consistent with the discussions regarding ranges and numerical data. Concentrations, amounts, and other numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 4 percent to about 7 percent” should be interpreted to include not only the explicitly recited values of about 4 percent to about 7 percent, but also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 4.5, 5.25 and 6 and sub-ranges such as from 4-5, from 5-7, and from 5.5-6.5; etc. This same principle applies to ranges reciting only one numerical value. Furthermore, such an interpretation should apply regardless of the breadth of the range or the characteristics being described. 
     The description and illustration of one or more embodiments provided in this application are not intended to limit or restrict the scope of the invention as claimed in any way. The embodiments, examples, and details provided in this application are considered sufficient to convey possession and enable others to make and use the best mode of claimed invention. The claimed invention should not be construed as being limited to any embodiment, example, or detail provided in this application. Regardless whether shown and described in combination or separately, the various features (both structural and methodological) are intended to be selectively included or omitted to produce an embodiment with a particular set of features. Having been provided with the description and illustration of the present application, one skilled in the art may envision variations, modifications, and alternate embodiments falling within the spirit of the broader aspects of the claimed invention and the general inventive concept embodied in this application that do not depart from the broader scope.