Patent Publication Number: US-11649100-B2

Title: Package for irregular shaped objects

Description:
FIELD OF THE INVENTION 
     The invention relates generally to the field of packing articles in packaging for sale. More specifically, the invention relates to a carrier package with a stabilizing footing for packing irregular-shaped products and includes use of the carrier package in a commercial process for assembling retail-ready or shelf-ready packaging. 
     BACKGROUND OF THE INVENTION 
     Irregular-shaped consumer products pose unique challenges regarding controlling, and uniformly and stably packing such products throughout the packing process, and later downstream when transporting and displaying the packaged product at the point-of-sale. 
     More specifically, the packing process for irregular-shaped, consumable products poses unique challenges because irregular-shaped products are difficult to handle and uniformly align in the packing process, making them difficult to efficiently and securely pack within the packaging. For example, placing an irregular-shaped product in a continuous flow wrap process can be time consuming because the product needs to be positioned properly within a container and generally immobilized from the time of placement through to sealing of the product within the package. 
     Another challenge with packing irregular-shaped products involves difficulties in effectively aligning and securing the products within the packaging to eliminate or avoid excessive movement of the products within the packaging once the packaging is sealed. Excessive movement of the products in packaging increases the risk of breakage, which can cause loss of product and/or a loss of sales due to poor consumer perception of product quality. 
     A further challenge unique to packing irregular-shaped products involves excessive empty space within the internal packing volume of the packaging, which arises because irregular-shaped products do not largely fill the total amount of internal packing volume inside packaging. The empty space is wasted space, and this adds up when multiple packages are packed within larger containers for shipment. Empty space can increase shipping costs because more containers must be shipped to ensure that enough product reaches the point of sale location to meet product demand. 
     One approach for packing irregular-shaped products includes loosely packaging the products in bulk, in a bag or box. However, bulk packaging fails to properly secure the products and can result in undesirable settling and breakage of the products in the bag or box during transport. Another approach includes securing irregular-shaped products in a container using blister packs, or bubble wrap or other packing material, within a container. Yet again, securely packaging or fitting product in any type of container using blister packs or bubble wrap is inefficient because it adds materials and time-consuming steps to the packing process. A further approach includes attaching irregular-shaped products to a hanging display, such as a flat piece of cardboard or other material. Unfortunately, this approach can result in product being inefficiently packaged in a bulky, an unwieldy, and/or a loose manner, which exposes product to breakage and fails to maximize use of internal packing volume in a package. While the previously-mentioned approaches for packing irregular-shaped products, e.g., bulk packing, unsecured packing, and individual packing, are well-known and used in commercial lines, these approaches fail to resolve the persistent challenges for packing irregular-shaped products. 
     Accordingly, there is a need for a carrier package with a footing for securely packing irregular-shaped products throughout a commercial packing process, as well as for stabilizing product during transportation and when displayed upright in retail-ready or shelf-ready packaging at the point of sale. There is a need for a carrier package that: (i) provides efficiency and uniform alignment in the packing process, while avoiding costly materials and time-consuming packing steps; (ii) securely packages irregular-shaped product within individual packages, as well as multiple packages within a display tray, to avoid breakage during transport and display at the point of sale; (iii) maximizes packed product density in a container, while conversely minimizing empty internal packing volume within each individual container; and (iv) adds convenience in distribution, handling, stacking, display and sale. 
     SUMMARY OF THE INVENTION 
     The invention overcomes one or more of the challenges of the traditional approaches to packing irregular-shaped products. To achieve solutions for the foregoing needs and to provide other advantages, and according to the purpose of the invention as embodied and described herein, the invention provides for uniform alignment and secure packing of irregular-shaped products in packaging with minimal empty internal packing volume. 
     The invention provides a carrier package containing at least one securely-aligned, irregular-shaped consumable product, and methods of assembly thereof. The carrier package includes a carrier formed from a foldable, rigid or semi-rigid, sheet material. The carrier has a footing and a vertical support member, the internal surfaces of which provide internal surfaces of a packing compartment. The carrier facilitates alignment and partial enclosure of the at least one irregular-shaped consumable product in the packing compartment of the carrier. The vertical support member has: (1) a pair of sidewalls, which are facing one another, that form lower edges at opposite ends of the footing, and (2) a rear wall having edges formed along the sidewalls and another edge along the footing. The footing and vertical support members provide a packing compartment. A wrap encloses the irregular-shaped product and the carrier. The wrap also secures the irregular-shaped, consumable product aligned within the carrier. The carrier also provides support to stand the irregular-shaped consumable product upright within the package for display at the point of sale. The footing, i.e., the stabilizing base, is operatively connected with the vertical support member and provides structure that supports the irregular-shaped product(s) aligned in the carrier to stand upright on a generally flat surface without tipping. 
     In various embodiments, the irregular-shaped product comprises an elongate shape. For example, the irregular-shaped product can be a consumable product like a pet chew or pet treat, or any other irregular-shaped consumable or non-consumable product for animals or humans. 
     In various embodiments, the sheet material used to make the carrier can be a paper-based material including, but not limited to, paperboard, cardboard, kraft board, corrugated cardboard, carton board, or paperboard laminates. The paper-based sheet material can be recycled and/or recyclable. The paper-based sheet material can have a coating or laminate applied to its surface that contacts the irregular-shaped product, whereby the coating prevents the transfer of ingredients, e.g., oil, flavor, or moisture, from the product to the sheet material. The carrier can also be made from a plastic material including, but not limited to, polypropylene (PP), polyethylene terephthalate (PET), high density polyethylene (HDPE), low density polyethylene (LDPE), polycarbonate, polystyrene, or polyvinyl chloride. The plastic material can be selected from food grade plastics. 
     In embodiments, the footing, the sidewalls, and the rear wall can form a generally 3-dimensional shape that can be square or rectangular. 
     In an embodiment, the wrap is made from a plastic material, which can also be selected as a food grade plastic. The wrap can also be transparent, printed with graphics or color, or a combination thereof. The wrap can be folded and/or sealed. 
     In an embodiment, the pair of facing sidewalls have tabs secured to the footing, and the pair of sidewalls form edges with the rear wall and the footing. 
     In an embodiment, the carrier can include a divider running substantially parallel to and between the sidewalls. The divider delineates two packing compartments for irregular-shaped products and prevents the products from contacting one another. 
     In an embodiment, a display tray is provided for holding multiple wrapped carriers that can be later packed in larger containers for transportation to, and display at, the point-of-sale. The display tray can be made from paper-based or plastic material. 
     In an embodiment, a retail ready packaging is provided comprising a display tray filled with from 2 to 5 carriers in an upright and parallel configuration. Each carrier comprises a packing compartment defined by a footing operatively connected to a vertical support member and the footing and a vertical support member align and partially enclose at least one irregular-shaped consumable product in the packing compartment of each carrier. The footing of each carrier enables each carrier to maintain the upright and parallel configuration with respect to every other carrier in the display tray. 
     A method for packing irregular-shaped, elongate consumable products is also provided. The method includes first placing at least one irregular-shaped product within a carrier comprising: a footing and a vertical support member, the vertical support member having a pair of sidewalls facing one another and forming lower edges where joined to opposite ends of the footing, and a rear wall having vertical edges joined to vertical edges of the sidewalls and a lower edge joined to the footing. Next, the method includes contacting an end portion of the irregular-shaped product against the footing and side portions of the product against the rear wall and at least one of the sidewalls. In an embodiment, the method includes placing a second irregular-shaped product within the carrier in contact with the first irregular-shaped product, whereby the two irregular-shaped products align and interlock with one another, i.e., nest together, within the packing compartment of the carrier. Then, the method includes forming a packaged product, i.e., carrier package, by securing the irregular-shaped product within the carrier using a wrap enclosing the carrier and the irregular-shaped product in a generally symmetric, uniform 3-dimensional shape having a minimum amount of empty packing volume. Consequently, the carrier package can stand upright on the footing, i.e., stabilizing base, whether alone or packaged with other carrier packages in a display tray or other container. 
     In an embodiment, the method includes hermetically sealing the wrap to enclose the irregular-shaped products in the packing compartment of the carrier. 
     In summary, the solutions provided by the invention maximize the density of the irregular-shaped product packed in the carrier with efficient use of internal packing space of the packing compartment, by aligning and securing the irregular-shaped products for storage, shipment, and display at a point-of-sale. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       Additional aspects, features, and advantages of the invention, as to its structure, assembly, and use, will be understood and become clearer when the invention is considered in view of the following brief description of the figures made in conjunction with the accompanying drawings, wherein: 
         FIG.  1    shows a front perspective view of a carrier for enclosing two irregular-shaped products. 
         FIG.  2    shows another front perspective view of the carrier of  FIG.  1   . 
         FIG.  3    shows a front view of the carrier of  FIG.  1   , and  FIG.  3   a    shows a cutaway view of a portion of  FIG.  3   . 
         FIG.  4    shows a rear view of the carrier of  FIG.  1   . 
         FIG.  5    shows a side view of the carrier of  FIG.  1   , whereby the opposite side view is a mirror image of  FIG.  5   . 
         FIG.  6    shows a top view of the carrier of  FIG.  1   . 
         FIG.  7    shows a bottom view of the carrier of  FIG.  1   . 
         FIG.  8    shows a front view of two irregular-shaped products nested together and aligned in the carrier of  FIG.  1   . 
         FIG.  9    shows a top view of two irregular-shaped products nested together and aligned in the carrier of  FIG.  1   . 
         FIG.  10    shows a side view of two irregular-shaped products nested together and aligned in the carrier of  FIG.  1   . 
         FIG.  11    shows a front view of two irregular-shaped products nested together and aligned in the carrier of  FIG.  1   , where the carrier and products are sealed with a wrap in a carrier package. 
         FIG.  12    shows a front perspective view of a display tray for holding multiple carrier packages. 
         FIG.  13    shows a rear perspective view of the display tray of  FIG.  12   . 
         FIG.  14    shows a top view of the display tray of  FIG.  12   . 
         FIG.  15    shows a front perspective view of the display tray of  FIG.  12    with two carrier packages placed therein. 
         FIG.  16    shows a rear perspective view of the display tray of  FIG.  12    filled with carrier packages. 
         FIG.  17    shows a front perspective view of an alternative of a carrier having a divider for enclosing two irregular-shaped, consumable products. 
         FIG.  18    shows a rear perspective view of the carrier of  FIG.  17   . 
         FIG.  19    shows a front view of the carrier of  FIG.  17   , and  FIG.  19   a    shows a cutaway view of a portion of  FIG.  19   . 
         FIG.  20    shows a rear view of the carrier of  FIG.  17   . 
         FIG.  21    shows a side view of the carrier of  FIG.  17   , whereby the opposite side view is a mirror image of  FIG.  21   . 
         FIG.  22    shows a top view of the carrier of  FIG.  17   . 
         FIG.  23    shows a bottom view of the carrier of  FIG.  17   . 
         FIG.  24    shows a front view of two irregular-shaped products aligned in the carrier of  FIG.  17   . 
         FIG.  25    shows a side view of two irregular-shaped products aligned in the carrier of  FIG.  17   . 
         FIG.  26    shows a top view of two irregular-shaped products aligned in the carrier of  FIG.  17   . 
         FIG.  27    shows a die-cut blank for the display tray of  FIG.  12   . 
         FIG.  28    shows a die-cut blank for the carrier of  FIG.  17   . 
         FIG.  29    shows a die-cut blank for the carrier of  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Illustrative and alternative embodiments of carrier  100 ,  200  with footing  110 ,  210  used for packaging irregular-shaped, consumable products are described in detail with reference being made to the figures of this application. While similar aspects of embodiments of the invention are featured throughout this disclosure, these similarities may be repeated within the context of the various embodiments of the invention. 
     Referring generally to  FIGS.  1 - 11   , carrier  100  is shown. Carrier  100  includes footing  110  that is either connected to, or contiguous with, the material used to form rear wall  120 , as shown, for example, in  FIGS.  1 - 11   . Footing  110  and rear wall  120  are either connected to, or contiguous with, a pair of opposite sidewalls  130 , as shown, in  FIGS.  1 - 11   . Carrier  100  is useful for aligning and securely packing irregular-shaped products  150  in a packing compartment and displaying products  150  for sale. Specifically referring to  FIG.  11   , carrier  100  enclosing irregular-shaped products  150  securely within wrap  180  forms carrier package  10 . 
     In the non-limiting embodiment shown, for example, in  FIGS.  1 - 3 A,  6  and  8   , tabs  140  are provided at ends of opposite sidewalls  130  and are adhered with an adhesive to, or structurally connected with, either the top (or bottom) surface of footing  110 . This operatively connects opposite sidewalls  130  with footing  110  and forms two corners at the lower, rear portion of carrier  100 . The corners provide carrier  100  with structural stability to align and to secure irregular-shaped products  150 . In certain embodiments, footing  110  and tabs  140  can be scored or have fold lines  142 , shown in  FIGS.  1 - 2  and  6 - 7   , that permit footing  110  and tabs  140  to be folded inward against an interior surface of rear wall  120 . 
     Referring to  FIGS.  8  and  11   , rear wall  120  and sidewalls  130 , which are structurally supported by the corners formed with footing  110 , provide a vertical support against which irregular-shaped product  150  can transfer lateral forces, i.e., lean, against, if carrier  100  and package  10  are placed upright. In the upright position, as illustrated in  FIGS.  8  and  11   , for example, a nested pair of irregular-shaped (e.g., curved) products  150  is shown, where each of the curved products has two ends, and where each end includes both a convexly-positioned nub and a concavely-positioned nub.  FIGS.  8  and  11    illustrate that the convexly-positioned nub on one end of a first irregular-shaped product  150  rests on footing  110 , while the concavely-positioned nub on the same end of the first irregular-shaped product  150  interlocks with and supports the convexly-positioned nub on an end of a second irregular-shaped product  150 . Irregular-shaped products  150  can also lean against rear wall  120  and/or one or more of side walls  130 . With irregular-shaped products  150  nested, at least 2 or more points of contact occur between irregular-shaped products  150  and the interior surface of carrier  100 . These points of contact are on footing  110 , rear wall  120 , and side walls  130 , as shown specifically in  FIGS.  8  and  11   , and align irregular-shaped products  150  in packing compartment of carrier  100 . 
     Referring now to  FIG.  11   , enclosing at least one irregular-shaped product  150  in carrier  100  with wrap  180  further stabilizes the structure of carrier package  10  and secures product  150  in carrier  100 . Wrap  180  is applied in a manner that permits carrier  100  to generally retain its 3-dimensional shape. 
     In certain embodiments, carrier  100  is adapted to provide for efficient stacking and packing of irregular-shaped product  150  for logistical purposes. For example, carrier  100  can promote maximizing the number of products  150  that can be packed in a shipping container. Such efficient stacking is not only beneficial from a logistical perspective—it also provides retail benefits. Referring to  FIGS.  15  and  16   , for example, two to five carrier packages  10  in an upright and parallel configuration can be loaded in display tray  400  that can be placed on a shelf for display at a point of sale and that permits viewing of products  150  inside carrier package  10 . Display tray  400  is sized and dimensioned relative to the size and dimension of carrier  100 ,  200 . 
     As discussed, carrier package  10  can include carrier  100  or carrier  200  shown, for example, in  FIGS.  1  and  17   . Carrier  100  includes packing compartment defined by footing  110  operatively connected to a vertical support member such as rear wall  120  and/or sidewall  130 , wherein footing  110  and the vertical support member align and partially enclose at least one irregular-shaped product  150  in the packing compartment of carrier  100 . Likewise, carrier  200  also includes packing compartments defined, in part, by footing  210  operatively connected to a vertical support member, such as rear wall  220  or sidewall  230 , wherein footing  210  and vertical support member align and partially enclose irregular-shaped product  250  in the packing compartments of carrier  200 . Such embodiments are adapted to enable carrier  100 ,  200  to maintain the upright parallel configuration with respect to every other carrier in display tray  400 , even if display tray  400  is not fully loaded with carrier packages  10 . 
     Referring specifically to  FIGS.  1 - 2 ,  3 , and  6 - 7   , footing  110  is rectangular and generally flat, but can be square or trapezoidal. Footing  110  is substantially perpendicular to rear wall  120 , as shown in  FIG.  5   , and footing  110  is also substantially perpendicular to the side walls  130 , as shown in  FIGS.  3 - 3     a . The depth of footing  110  is the distance from rear wall  120  to front edge  112  of footing  110 , as shown specifically in  FIGS.  1 - 2  and  6 - 7   . 
     Referring now to  FIGS.  3 - 5   , rear wall  120  is rectangular and generally flat, but can be square or trapezoidal. Rear wall  120  is substantially perpendicular to sidewalls  130 , as shown in  FIG.  6   , and to footing  110 , as shown in  FIG.  5   . Opposite sides of rear wall  120  are either connected to or contiguous with the material of sidewalls  130 , as shown, for example, in  FIG.  6   . The width of rear wall  120  is the distance between sidewalls  130 , as also shown in  FIG.  6   . The height of rear wall  120  is the distance from footing  110  to top edge  122  of rear wall  120 , as shown in  FIGS.  1 - 5   . 
     In certain embodiments, top edge  122  of rear wall  120  can be linear as shown in  FIGS.  1 - 4   , or curvilinear, between corners where top edge  122  intersects with sidewalls  130 , depending upon design configuration of carrier  100 , and particularly in view of the relative size of side walls  130 . 
     Referring to  FIG.  5   , sidewalls  130  are rectangular in this embodiment, but can be square or trapezoidal. Sidewalls  130  are substantially perpendicular to rear wall  120 , as shown in  FIG.  6   , and to footing  110 , as shown in  FIG.  3   . Sidewalls  130  can either be connected by tabs  140 , as shown in  FIGS.  1 - 3     a  to, or be contiguous with, the material of rear wall  120 . The depth of each sidewall  130  is the distance from front edge  132  of sidewall  130  to rear wall  120 , as shown in  FIGS.  1 - 2 , and  5   . 
     Referring to  FIGS.  1  and  2   , the height of sidewall  130  is the distance from footing  110  to top edge  134  of side wall  130 . In various embodiments, the height of sidewall  130  is about equal to the height of rear wall  120 , as shown, for example, in  FIGS.  3  and  4   . In other embodiments, the height of sidewalls  130  is greater than the height of rear wall  120 . In still further embodiments, the height of sidewalls  130  is less than the height of rear wall  120 . In even further embodiments, the height of a sidewall  130  is different than the height of an opposing sidewall  130 , whereby top edge  122  of rear wall  120  can be curvilinear or linear so that top edge  122  terminates substantially adjacent to top edge  134  of each side wall  130 . 
     In certain embodiments, top edge  134  of side wall  130  can be curved toward front edge  132 . For example, top edge  134  can be curved at its corners, i.e., where it intersects with front edge  132 . Conversely, top edge  134  can be curved along its entire width from its intersection with rear wall  120  and front edge  132 . 
     Carrier  100  provides a packing compartment defined, in part, by the interior surfaces of footing  110 , rear wall  120 , and side walls  130 . The packing compartment is configured relative to the dimensions of irregular-shaped product  150 , for example, as depicted in  FIG.  8   . Specifically, the packing compartment is configured along its height, width, and depth to account for a substantially-minimal, 3-dimensional, symmetrical space, e.g., square, rectangular, trapezoidal, etc., in which one or more irregular-shaped products  150  can fit. For example, in an exemplary embodiment shown in  FIG.  8   , the packing compartment is configured to hold 2 irregular-shaped products  150 , i.e., bent bone shape with two substantially flat surfaces, which are nested together to minimize the 3-dimensional size of the packing compartment. In this embodiment, the packing compartment is configured so that the depth of footing  110  and side walls  130  is either the same or greater than the depth of irregular-shaped products  150  placed in carrier  100 . In alternative embodiments of carrier  100 , the depth of footing  110  and side walls  130  can be equal to or less than the depth of products  150 . 
     Referring again to  FIG.  8   , the packing compartment of carrier  100  has a height that is generally about the same height as two irregular-shaped products  150  nested together in the packing compartment. In this embodiment, the width of rear wall  120  and footing  110  contributes to the proximity and relative positioning of two irregular-shaped products  150  next to one another, as shown, for example, in  FIG.  8   . This embodiment shows that the height of rear wall  120  and side walls  130  is greater than the width of rear wall  120  and footing  110 . In alternative embodiments of carrier  100 , the width of the packing compartment can be more than its height. 
     Referring generally to  FIG.  3   , the ratio of the width of rear wall  120  to the height of sidewalls  130  is about 3:5. In other embodiments, the ratio of the width of rear wall to height of sidewall may be adjusted to provide for uniform alignment and secure packing of irregular-shaped products  150  in carrier  100  with minimal empty internal packing space. 
     Referring generally now to  FIGS.  17 - 26   , an alternative embodiment of carrier  200  is shown. In this embodiment, rear wall  220  includes divider  260  that delineates two packing compartments, each of which is configured to house irregular-shaped products  250 . Divider  260  can be configured to project outward from rear wall  220  substantially perpendicular to rear wall  220 , as shown in  FIG.  22   , and substantially parallel with sidewalls  230 , as shown in  FIGS.  19  and  22   . In some embodiments, divider  260  can have the same or similar height of rear wall  220 , as shown in  FIGS.  19 ,  21 , and  24 - 25   . In other embodiments, the height of divider  260  can be less than the height of rear wall  220 . In still further embodiments, the height of divider  260  can be greater than the height of rear wall  220 . The depth of divider  260  can be the same or similar depth of the side walls  230 , as shown in  FIG.  22   . In an embodiment, divider  260  is located on substantially the centerline of the width of rear wall  220 , as shown in  FIGS.  19  and  22   . Referring specifically to  FIG.  28   , divider  260  is formed by folding two adjacent portions of die-cut blank  300 ′ onto themselves along central score line  262 . In an embodiment, divider  260  is contiguous with the material forming rear wall  220 . 
     Referring to  FIGS.  17 - 18 ,  21 , and  25   , top edge  234  of sidewall  230  can also be curved. For example, top edge  234  can be curved at its front corners, i.e., where it intersects with front edge  232 . Conversely, top edge  234  can be curved along its entire width from its intersection with top edge  222  of rear wall  220  to its intersection with front edge  232  of side wall  230 . 
     In a non-limiting embodiment shown in  FIGS.  17 ,  19 ,  19     a ,  22  and  24 , tabs  240  are provided at ends of opposite sidewalls  230  so that tabs  240  can be glued (or structurally attached) to either the top (or bottom) surface of footing  210 , wherein footing  210  comprises sub-footing  211  and sub-footing  212 . This operatively connects opposite sidewalls  230  with footing  210  and rear wall  220  and forms corners at the lower, rear of carrier  200  that provide structural stability to carrier package  10 . The bottom of a portion of sub-footing  212  can be affixed to the top of a portion of sub-footing  211 , as shown, for example, in  FIGS.  17 - 20   . Alternatively, the bottom of a portion of sub-footing  211  can be affixed to the top of a portion of sub-footing  212 . In certain embodiments, footing  210  and tabs  240  can have scoring or fold lines  242 , as shown in  FIGS.  17 - 18 ,  21 , and  25   , which allows divider  260  to be folded to the side, and footing  210  and tabs  240  to be folded inward against rear wall  220  to collapse carrier  200  for storage for use later in assembling carrier package  10 . This configuration allows for efficient fabrication of carrier  200 , and easy opening on commercial packing lines, e.g., flow wrap systems, for efficient product loading. 
     Referring now to  FIGS.  17 ,  19 ,  20 ,  22 , and  24   , carrier  200  provides packing compartments defined, in part, by the interior surfaces of footing  210 , rear wall  220 , side walls  230 , and divider  260 . The packing compartments are configured relative to the dimensions of irregular-shaped product  250 , as shown specifically in  FIGS.  24 - 25   . The packing compartments are configured along their height, width, and depth, to account for a substantially minimal 3-dimensional symmetrical space, e.g., square, rectangular, trapezoidal, etc., in which one or more irregular-shaped products  250  can fit. For example, in an exemplary embodiment shown in  FIG.  24   , each packing compartment is configured to hold one irregular-shaped product  250 , i.e., bent bone shape, which is aligned within a single packing compartment. In this embodiment, the packing compartment is configured so that the depth of footing  210  and side walls  230  is either the same or greater than the depth of irregular-shaped products  250  placed in carrier  200 . In alternative embodiments of carrier  200 , the depth of footing  210  and side walls  230  can be equal to or more than the depth of irregular-shaped products  250 , as shown in  FIGS.  24  and  25   . 
     Referring again to  FIGS.  24  and  25   , the packing compartments of carrier  200  have a height that is about the same height as irregular-shaped product  250 . In this embodiment, the distance between sidewall  230  and divider  260  contributes to the proximity and relative positioning of two irregular-shaped products  250  next to one another. This embodiment shows that the height of rear wall  220  and side walls  230  is greater than the width of rear wall  220  and footing  210 . In alternative embodiments of carrier  200 , the width of rear wall  220  and footing  210  can be more than its height. 
     Referring now to  FIG.  11   , wrap  180  can be made from a plastic material that can be transparent and can include a colorant or pigment. Other materials can be used for wrap  180  including foils, foil-lined plastics, foil-lined paper-based material, and the like. Suitable materials for wrap  180  can have a desired barrier property for moisture and air that can optionally be used to hermetically seal carrier  100 ,  200 , thereby securing one or more irregular-shaped products  150 ,  250  to prevent premature spoilage of products  150 ,  250  after packing with carrier  100 ,  200 . In certain embodiments, suitable plastic material for wrap  180  includes high density polyethylene (HDPE), polypropylene, polystyrene, polyvinylchloride, fluorinated ethylene propylene, acrylonitrile copolymer, polycarbonate, polytetrafluoroethylene (PFTE), cyclic olefin copolymer, polyethylene terephthalate (PET), and the like. 
     In certain embodiments, wrap  180  can be sealed around carrier  100 ,  200 , securing one or more irregular-shaped products  150 ,  250  using commercial methods including, for example, heat, mechanical force, or adhesives that can be thermosetting, or some combination of the foregoing. 
     Referring to  FIGS.  8 - 11  and  24 - 26   , irregular-shaped product  150 ,  250  includes food products. In certain embodiments, the food products may be pet food products or human food products. The irregular-shaped product can be bone shaped. 
     Referring generally to  FIGS.  12 - 16   , display tray  400  is provided for holding multiple carrier packages  10  that are packed into retail-ready or shelf-ready packaging, useful for both product promotions and positioning at point-of-sale displays. Display tray  400  provides technology for uniformly aligning and securely packing irregular-shaped products  150 ,  250  in carrier packages  10  and displaying them for sale. Footing  100 ,  200  of each carrier  100 ,  200  enables each carrier package  10  loaded in display tray  400  to maintain an upright, parallel configuration relative to other carrier packages  10  loaded in display tray  400 . Specifically referring to  FIG.  12 - 14   , container  400  comprises base  410  that is either connected to or contiguous with the material forming two opposite sidewalls  430 , rear wall  420 , and front wall  440 . Sidewalls  430  further connect rear wall  420  and front wall  440 . Retention arm  450  is connected to both sidewalls  430  at a distance between rear wall  420  and front wall  440 . 
     Referring generally to  FIGS.  15 - 16   , multiple carrier packages  10  are shown packed into a retail-ready or shelf-ready display tray  400 . More specifically, the display tray  400  shown contains from about 2 to 5 carrier packages  10 . Although not show in the figures, each carrier package comprises a packing compartment defined by a footing operatively connected to a vertical support member. The vertical support member itself is comprised of a rear wall and/or one or more sidewalls. The footing and a vertical support member align and partially enclose at least one irregular-shaped consumable product in the packing compartment of each carrier. In this arrangement, where each carrier package in the display tray  400  is oriented upright and inserted footing first into the display tray so that its footing is completely contained within the tray and adjacent to the tray base  410 , the footing associated with each carrier package  10  imparts vertical stability, enabling each carrier package to maintain an upright and parallel configuration with respect to every other carrier in the display tray. The upright and parallel configuration results in carrier packages that are uniformly aligned and securely packaged within the display tray. This is beneficial in a retail setting because it affects the appearance of the display, specifically increasing the overall neatness of the display which also increases the consumer&#39;s perception of product quality. 
     The parallel configuration a carrier package has relative to another carrier package in the display tray is measured as an angle formed between neighboring sidewalls of two adjacent carrier packages. This angle is determined by choosing one side of a filled tray containing carrier packages that are standing upright, drawing a line tangent to the sidewall of a first carrier package held within the tray, drawing another line tangent to the sidewall of a second carrier package held within the tray that is adjacent to the first carrier package, projecting these tangential lines onto a 2-dimensional plane, and then measuring the angle formed between the two lines. In certain embodiments the angle formed between neighboring sidewalls of two adjacent carrier packages is from about 0° to about 20°, preferably from about 0° to about 10°, more preferably from about 0° to about 5°, even more preferably from 0° to about 2°, and even more preferably from about 0° to about 1°. In certain embodiments the angle formed between neighboring sidewalls of two adjacent carrier packages is less than about 20°, preferably is less than about 10°, more preferably is less than about 5°, even more preferably is less than about 2°, and even more preferably is less than about 1°. 
     Referring generally to  FIG.  15   , retention arm  450  is adapted to further secure several carrier packages  10  upright in display tray  400 , even if display tray  400  is not fully loaded with carrier packages  10 . In certain embodiments, the ratio of the distance between (i) retention arm  450  and rear wall  420 , and (ii) retention arm  450  and front wall  400 , is about 2:3. In other embodiments, retention arm  450  is located at a substantially equal distance from rear wall  420  and front wall  440 . Referring to  FIGS.  15  and  16   , retention arm  450  can hold two carrier packages  10  upright in the rear of display tray  400 , while leaving room to hold three more carrier packages  10  upright to the front of retention arm  450  of display tray  400 . 
     Referring to  FIGS.  12 - 16   , the height of each front wall  440  is the distance from base  410  to top edge  442  of front wall  440 . The height of the retention arm  450  is the distance between top edge  452  of retention wall  450  and bottom edge  454  of retention wall  450 . Both top edge  452  and bottom edge  454  are connected to either sidewalls  430  or base  410 . Referring to  FIGS.  12  and  13   , the height of retention arm  450  is less than the height of sidewalls  430 . 
     Referring to  FIGS.  12  and  13   , the height of each sidewall  430  is the distance from base  410  to top edge  434  of side wall  430 . The height of retention arm  450  is the distance between (i) top edge  452  of retention wall  450  and (ii) bottom edge  454  of retention wall  450 . Both top edge  452  and bottom edge  454  are connected to either sidewalls  430  or base  410 . The height of retention arm  450  is less than or equal to the height of sidewalls  430 . 
     Carrier  100 ,  200  and display tray  400  can be made from paper-based sheet material including, but not limited to, paperboard, cardboard, kraft board, corrugated cardboard, carton board, paperboard laminates, or a combination thereof. Carrier  100 ,  200  and display tray  400  can made from any of the foregoing paper-based materials having a thickness of no less than about 16 point, i.e., 0.016 of an inch. In other embodiments, the thickness of the paper-based materials can be more than 16 point and up to about 20 point, i.e., 0.020 of an inch, or thicker, so long as the thickness provides the desired structural stability for carrier  100 ,  200 , as is consistent with the operability of the invention. 
     In alternative embodiments, carrier  100 ,  200  and display tray  400  can be made by a rigid or semi-rigid plastic material. 
     Carrier  100 ,  200  and display tray  400  can be die cut from paper-based or plastic materials into pre-formed blanks  300 ,  300 ′, and  300 ″, respectively, as shown in  FIGS.  27 ,  28   , and  29 , and then formed by adhering tabs  140 ,  240  to base wall  110 ,  210 . After being formed, carrier  100 ,  200  and display tray  400  can be folded down for efficient storage. Once formed and folded for storage, carrier  100 ,  200  and display tray  400  can be bundled and later unbundled and unfolded in preparation for assembly of carrier  100 ,  200  and display tray  400  during the packing process of irregular-shaped products  150 . 
     Carrier  100 ,  200  and display tray  400  can be configured with color and graphics that are aesthetically pleasing and eye-appealing to encourage consumers to view and consider the irregular-shaped  150 ,  250  products. Marketing communications and graphic design can be applied to the surface of carrier  100 ,  200  and/or display tray  400 , which may be coordinated with any graphics, color, and transparency of wrap  180 . 
     Referring now to  FIG.  27   , display tray  400  shown in  FIGS.  12  and  13    can be formed by the following steps. First, sidewalls  430  are formed by folding sidewalls  430  along the first fold lines  310 . Second, retention arm  450  is folded against rear wall  420  along second fold line  312 . Third, rear wall  420  is folded inward along third fold line  314 . Fourth, base  410  is formed from the tabs extending from front wall  410 , rear wall  420  and sidewalls  430 . Fifth, retention arm  450  is folded back along fourth fold line  316  and connected to sidewall  430 . 
     Referring now to  FIG.  28   , carrier  200  of  FIG.  17    can be formed by the following steps. First, divider  260  is formed by folding the two portions adjacent to central score line  262  onto themselves. Second, sidewalls  230  are folded up along first fold line  310 . Third, tabs  240  are folded inward toward each other along second fold lines  312 . Third, sub-footings  211 ,  212  are overlapped as footing  210  is folded up along third fold line  314 . Footing  210  can be secured to tabs  240  with a fastener, an adhesive, or both. In other embodiments, when it is desired that tabs  240  be secured below footing  210 , the third and fourth steps described above are reversed. Optionally, once carrier  200  is assembled, divider  260  can be folded to a side, and footing  210  and tabs  240  can be folded inward against rear wall  220  along score lines  142 , thereby collapsing carrier  200  for storage before later use in assembling carrier package  10 . 
     Referring now to  FIG.  29   , carrier  100  of  FIG.  1    can be formed by the following steps. First, sidewalls  130  are folded up along first fold lines  310 . Second, tabs  140  are folded inward toward each other along second fold lines  312 . Third, footing  110  is folded up along third fold line  314 . Footing  110  can be secured to tabs  140  with a fastener or with adhesive. In other embodiments, when it is desired that tabs  140  be secured below footing  110 , the second and third steps described above are reversed. Optionally, once carrier  100  is assembled, footing  110  and tabs  140  can be folded inward against rear wall  120  along score lines  142 , thereby collapsing carrier  100  for storage before later use in assembling carrier package  10 . 
     Also described herein are methods for packing irregular-shaped products  150 ,  250 . In a non-limiting embodiment, a method for packing carrier  100 ,  200  with at least one irregular-shaped product  150 ,  250  are provided with the invention. The method includes the step of either forming carrier  100 ,  200  (if not pre-formed as disclosed) or unfolding a pre-formed carrier  100 ,  200  into its predetermined 3-dimensional shape. 
     The next step of the method for packing the carrier  100 ,  200  includes placing at least one irregular-shaped product  150 ,  250  in the carrier  100 ,  200 , depending on the type of carrier  100 ,  200  used. If carrier  100  is used, then this step includes aligning a first irregular-shaped product  150  in the lower portion of packing compartment of carrier  100 , whereby an end of the product  150  contacts footing  110  and optionally a side wall  130 . This step includes aligning a second irregular-shaped product  150  in a position that is opposite that of the first irregular-shaped product  150 , whereby first and second irregular-shaped products  150  are interlocked, or nested together, in a manner than minimizes empty space in the packing compartment of carrier  100 . The two irregular-shaped products  150  can be nested before placement in packing compartment of carrier  100 . Alternatively, if carrier  200  is being used, then the step includes placing two irregular-shaped products  250  individually aligned and separated by divider  260  in each of the packing compartments. 
     The next step of the method for packing carrier  100 ,  200  includes enclosing carrier  100 ,  200  with irregular-shaped products  150 ,  250  aligned in packing compartments. The enclosing step comprises wrapping carrier  100 ,  200  with wrap  180  that is sized in a manner to secure irregular-shaped products  150 ,  250  in packing compartments, while maintaining the overall 3-dimensional shape of carrier  100 ,  200 . Wrap  180  can be a tube-shaped plastic material that surrounds carrier  100 ,  200 , and then is sealed at each end to form the carrier package. Alternatively, wrap  180  can be folded in a manner that is consistent with the shape and size of carrier  100 ,  200  to form carrier package  10 . 
     The next step of the method for packing carrier packages  10  includes packing multiple carrier packages  10  in a container. In an embodiment, multiple carrier packages  10  can be packaged in display trays  400 , which are then packaged in larger containers. 
     While the subject matter has been disclosed with reference to specific embodiments, it will be apparent that other embodiments and variations can be devised by those skilled in the art without departing from the true spirit and scope of the subject matter described herein. The appended claims include all such embodiments and equivalent variations.