Patent Publication Number: US-2020282708-A1

Title: Compostable food packaging material and method for producing

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
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     STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT 
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     REFERENCE TO AN APPENDIX” 
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     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to food packaging materials, specifically a compostable food packaging material for energy and protein bars. 
     2. Description of the Related Art 
     Cold-sealed food packaging materials are typically formed by sealing two layers of material together using pressure rather than elevated temperatures. Cold-sealable substrate materials are known for use in packaging products that would be adversely affected by exposure to heat, such as might occur during heat-sealing of substrate materials, after the food product has been produced. 
     In cold-sealing, two substrate layers are utilized. First, a clear film layer with reverse ink printing is introduced to a second layer, typically a metalized foil layer. These two layers are sealed together by a cohesive glue that fuses the two layers using pressure at the areas where glue is applied. Cold seal cohesive glues are used in a wide range of applications, including food wrappers, particularly packaging for protein bars and candy bars. For those applications in which food contact is possible, users must be certain the adhesive meets all FDA regulations. 
     When the first substrate coated with a cold seal cohesive comes into contact with itself or seal areas coated with the same cold seal cohesive, the bond results by using simple digital pressure. This differs from a heat seal adhesive that requires adhesive only on one substrate but must have a source of heat and pressure to make the bond. 
     Prior art in this field utilizes substrate materials that are not compostable. The market demand from consumers, food producers, and regulators is pushing packaging manufacturers to create substantially completely compostable food packaging materials. That is, there is a need in the industry for a ‘biodegradable’ packaging for food. 
     SUMMARY OF THE INVENTION 
     The present invention relates to packaging material for a food product that avoids, or at least reduces, some of the problems of the prior art materials. The invention provides food packaging material that is organically compostable and a method for manufacturing the material. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is view in perspective of a sectional view of the packing according to the present invention, with the single ply layer of compostable material displayed. 
         FIG. 2  is view in perspective of a sectional view of the packing according to the present invention, with the double ply layer of compostable material displayed. 
     
    
    
     In describing the preferred embodiment of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific term so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Looking at  FIG. 1 , one form of the present invention is shown in cross-sectional view.  FIG. 1  displays a flexible sheet material  10  for packaging food contents which is preferably a ‘protein’, ‘nutrition’ or ‘power’ bar. The flexible sheet material  10  has multiple layers comprised of a release coating layer  20  at the outermost layer, then an ink layer  30 , a layer of naturally organic material of packaging material  40 , and a cold seal layer  50 . 
     The cold seal layer  50  is the innermost layer enclosing the food contents. A storage space containing the contents is defined by the area within the sheet  10 . The storage space is sealed off from the surrounding environment and protects the food from the environment. 
     Looking at  FIG. 2 , another form of the present invention is shown in cross-sectional view.  FIG. 2  displays a flexible sheet material  110  for packaging food contents which also is a ‘protein’, ‘nutrition’ or ‘power’ bar. The flexible sheet material  110  has multiple layers comprised of a release coating layer  120  at the outermost layer, then a layer of first naturally organic material  125 , an ink layer  130 , a laminating adhesive layer  140 , a second layer of naturally organic material  150 , and a cold seal layer  160 . 
     The cold seal layer  160  is the innermost layer enclosing the food contents. A storage space containing the food is defined by the area within the sheet  110 . The storage space is sealed off from the surrounding environment and protects the food from the environment. 
     Machines for forming and sealing such materials  10  and  110  can be manufactured from machines that are available commercially. The present inventive process can be utilized may be based on a single ply or a doubly ply of the compostable materials  50  and  150 . Graphic indicia, in the form of non-toxic inks  30  and  130  are typically reverse applied to the outer surface of the laminating adhesive layers  40  and  140 , for indicating nutrition information, trademarks, and coloring. 
     The inks  40  and  140  are applied in discrete areas, thereby displaying color as a background but may instead be applied in a continuous layer. The inks  40  and  140  must be a conventional ink suitable for printing on food packaging and may be applied by printing processes known for the purpose. 
     In the preferred embodiment for the present invention, the food packaging product materials  10  and  110  are substantially completely compostable. For example, the materials  10  and  110  may be, in any combination, up to 100% biodegradable paper-based or vegetable fiber-based material, plant material, or similar natural material that readily degrades in the outdoor environment. 
     The cold seal coatings  50  and  160  may be continuous layers but preferably are pattern-applied at only those places where a seal is to be formed. That entails maintaining register between the back side with the coatings  50  and  160  and the front side with the printing. Preferably, the cold seal coating machine is a flexographic or rotogravure printing machine forming part of the same production line as, and is mechanically synchronized with, the printing press for disposing the inks  30  and  130 . 
     Flexographic and rotogravure printing machines are well known in the art and, in the interests of conciseness, will not be described here. The package forming and cutting machine can then be kept in register with the cold seal pattern in the same way as it is kept in register with the ink printing on the reverse side of the materials  10  and  110 . Methods of, and apparatus for, keeping subsequent machines in register with a printed pattern are well-known in the art and in the interests of conciseness will not be described here. 
     The method of production of the material  10  comprises the steps of first positioning the first layer of naturally organic material  40  for disposing the other layers upon it. Then the ink layer  30  is applied onto the adhesive layer  40 . After the ink  30  is applied, the release coating layer  20  is applied as the outermost layer. The cold seal layer  50  is pressed to the material  40  with layers  20 ,  30 , and  40  and spooled for transfer to the food manufacturing site, which will then further process the spooled packaging by adding the food. The release coating  20  is necessary to allow the packaging material  10  to become unspooled. 
     The method of production of the material  110  comprises providing the second naturally organic material  125 . The release coating is applied to the outer layer of the material  125 . The ink layer  130  is applied and the onto the underside of the material  125 , and then an adhesive layer  140  is applied to the ink layer  130 . The second naturally organic material  150  is then applied. After the second organic material layer  150  is applied, the cold seal layer  160  is pressed to the material  125  with layers  120 ,  130 , and  140  and spooled for transfer to the food manufacturing site, which will then further process the spooled packaging further. 
     In conclusion, the present invention in using the aforementioned structure has assuredly achieved anticipated effectiveness, moreover, contents of the present invention have not been publicly disclosed prior to this application, and novelty, advancement and industrial practicability of the present invention clearly comply with essential elements as required for a new patent application. Accordingly, a new patent application is proposed herein. It is of course to be understood that the embodiments described herein are merely illustrative of the principles of the invention and that a wide variety of modifications thereto may be affected by persons skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims.