Abstract:
A new and improved bulk sandwich package and method of packaging and merchandising is provided. A plurality of sandwiches are individually wrapped in gas permeable wrap and then bulk packaged in a modified atmosphere process, refrigerated and distributed to store locations or merchandisers where the bulk packages are refrigerated until needed, opened and placed in a refrigerated merchandiser for sale. The refrigerated merchandiser therefore provides consumers with a deli-style sandwich in stores without kitchen facilities, and permits the self-service purchase of the pre-assembled sandwiches.

Description:
The present application is a continuation-in-part of U.S. Ser. No. 09/045,006, filed Mar. 20, 1998 now U.S. Pat. No. 6,093,431. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to the packaging of pre-assembled sandwiches and methods for their distribution and sale. 
     A popular prepared food item is a sandwich or submarine sandwich, typically containing meat and/or cheese. Deli type restaurants or in-store deli counters prepare sandwiches on site, either to order, or daily in advance of the order, and then maintain the sandwiches in refrigerated holding bins or displays. Gas stations, convenience stores, quick service food marts, airport shops, food marts, vending machines and other small retail locations without kitchen facilities, compete for these sandwich sales. Heretofore, such locations have been unable to economically present the consumer with completely satisfactory sandwiches. The most typical competitive sandwich offerings have been sold in a refrigerated state to the consumer in sealed, clear plastic packaging, with one sandwich per package. Such sandwiches have sometimes been packaged in modified atmosphere packaging to extend their shelf life in a refrigerated store display or vending machine. 
     Alternative bulk packaging of 4,6,12 or even 24 sandwiches individually wrapped in regular atmosphere packaging and sold frozen in cardboard boxes for thawing by consumers in their homes also exist, and are most commonly sold in warehouse club type stores. These sandwiches rely upon freezing for their shelf life. No refrigerated bulk packaged sandwich products are known to be individually wrapped within a larger modified atmosphere package. 
     In order to present a satisfactory product, many factors must be addressed. The meat and cheese components of the sandwich must be selected such that they will have a substantial shelf life when properly packaged, and such that when opened from the bulk container and placed in a refrigerated merchandiser will not deteriorate too rapidly. In addition, bulk packaging for the sandwiches must be inexpensive, preferably transparent, flexible, and providing a barrier to oxygen and moisture, as well as sufficient toughness for casual handling and storage for a 3 to 5 week period. In addition, the sandwiches should preferably be individually wrapped with a clear shrink wrap film or other gas permeable wrapper for store and consumer convenience in handling the individual sandwich products. Finally, because demand is uncertain, the sandwich products must be maintained in a palatable condition during several days of display. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the invention to provide an improved sandwich for bulk packaging and subsequent individual sale from a refrigerated merchandiser. It is a further object of the invention to provide improved packaging for bulk sandwiches which are to be individually sold from a refrigerated merchandiser. 
     It is yet another object of the invention to provide an improved method of distributing and selling pre-assembled sandwiches from retail outlets that do not have on-site kitchen capabilities. 
     It is still another object of the present invention to provide bulk packaged, pre-assembled sandwiches for individual sale at a self-service counter food display station without requiring additional handling or assistance by store personnel. 
     It is a further object of the invention to provide bulk pre-assembled sandwiches with a refrigerated shelf life of at least about 30 days. In accordance with these objects of the invention, sandwiches with meat, cheese, or spread components and bread components are provided. These sandwiches are individually wrapped in gas permeable wrapper and placed in plastic web sleeves with modified atmospheres, wherein the sleeves provide barriers against moisture and oxygen sufficient to provide a refrigerated shelf life of at least 20 days. The packaged sandwiches are distributed to retail store locations and merchandisers with instructions describing display and placement of the product in a refrigerated merchandiser from which customers may make their selections without assistance by store personnel. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of an assembled sandwich ready for wrapping; 
     FIG. 2 is a perspective view of an individually wrapped sandwich; 
     FIG. 3 is a perspective view of a package of wrapped sandwiches in a plastic web sleeve according to the present invention; 
     FIG. 4 is a perspective view of a plurality of sandwiches placed for sale in a refrigerated merchandiser according to the present invention; and 
     FIG. 5 is a flow chart describing the method of packaging, distributing, and selling sandwiches according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 shows a typical sandwich  10 , comprising a bottom  12 , top  14 , and a meat portion  13  and a cheese portion  31  in between. The meat portion  13  will typically be turkey, chicken, roast beef or ham, and is already cooked at the time the sandwich is assembled. The sandwich may also be prepared with only a cheese portion, or with suitable spreads such as egg salad, chicken salad, tuna salad or pimento cheese The meat, cheese, and spread portions are collectively referred to as the fillings. The bread components  12 ,  14 , may be selected from any of a number of bread products, but preferably comprise a submarine type bun. The sandwich  10  in FIG. 1 is shown with a waxed paper type wrapper, and is shown in other Figures in gas permeable wrapping  11 , which is preferably a clear heat shrink film material. The wrapper  11  should be gas permeable to permit the later described modified atmosphere bulk packaging to perform most effectively. The wrapper  11  should have a pleasant tactile feel to the outer surface and insulate the sandwich from incidental handling contact. The assembled sandwich with meat and/or cheese and bread will preferably weigh between about 4 and 12 ounces. In FIG. 2, the sandwich  10  has been wrapped and the wrapped sandwich  18  is shown with wrapper  11  of clear heat shrink film. A sticker  15  designates the type of meat and/or cheese on the sandwich. The sticker  15  may be separate and placed on the wrapped sandwich  18  when heat shrink film is used, or may be preprinted on the outer surface of paper wrappers, together with a listing of ingredients and nutritional information. Preferably the sticker  15  will be on the bottom of the wrapped sandwiches  18 . 
     The wrapped sandwiches  18  are then bulk packaged in a container for distribution. As shown in FIG. 3, the preferable form of packaging is to place a plurality of wrapped sandwiches  18  in a plastic sleeve  20 , composed of a top web  21 , and a bottom web  22 . This is commonly referred to as form, fill and seal packaging. Preferably, approximately 3 to 12 sandwiches  18  are placed in a single sleeve  20 , with 5 to 8 sandwiches per package being the most desirable range. This represents a compromise between the convenience of the store operator in retaining and opening bulk packages of sandwiches, and the possible waste that will occur if sandwich sales do not achieve the level necessary to sell all of the sandwiches  18  in a package  20  within their opened refrigerated display shelf life. The number of sandwiches  18  placed in a single package  20  is not critical, however, and may be varied according to the equipment of the manufacturer and the size of the sandwiches  18 . 
     Preferably the packages  20  will be filled in a modified atmosphere process, with minimal oxygen content between about 0.2 to 0.5 percent to retard spoilage. Vacuum packaging with similar oxygen content may also be possible. Because the sandwiches  18  have gas permeable wrappers, the modified atmosphere or vacuum packaging also reduces the oxygen content within the individual sandwich, thereby controlling bacteria growth. 
     The top web  21  and bottom web  22  should be selected from appropriate materials to provide oxygen and moisture barriers, sufficient strength to resist puncture from handling, and preferably will be transparent, provide a peelable seal between the top  21  and bottom  22  webs, and permit the printing of graphics, instructions, and other necessary information on the packaging. In accordance with these requirements, the top web  21  is preferably a 50 gram SARAN-coated polyester film, with the top surface printed with contents and instructions  23  and the bottom surface having an adhesive and a 0.0025 inch peelable low-density polyethylene (“LDPE”) layer. This top web  21  is joined to the bottom web  22  which is preferably a 0.007 inch think 3-layer sandwich material, having a nylon outer layer, an ethylene vinyl alcohol copolymer (“EVOH”) center layer, and an LDPE inner surface which mates with upper web  21 . 
     Packages  20  of wrapped sandwiches  18  are then distributed to store locations. The packaging techniques employed should give the sandwiches  18  a packaged shelf life of at least 20 days, and preferably about 30 days. When properly prepared and refrigerated, bulk packaged sandwiches according to the present invention have achieved shelf lives of 42 days. Retail store locations typically possess substantial refrigerated storage space and a suitable refrigerated display  30  as shown in FIG.  4 . One suitable display is the Model CBM 2160 Cold Merchandiser available from Seaga Manufacturing, Inc. of Freeport, Ill. Refrigerated merchandisers preferably are thermostat-controlled, have a clear door or walls, may have a hinged or sliding door  33  to permit consumer access, and a top with an optional sign board location  34  for promotional purposes. Illustrated merchandiser door  33  has handle  36  and hinges to facilitate customer access to the sandwiches  18 . Alternative merchandisers may be built-in self-service refrigeration displays or displays where sandwiches are viewed and identified by the consumer and then retrieved and delivered to the consumer by store personnel. 
     Refrigerated packaging is particular attractive for resale through convenience stores which generally have ample refrigerated space but only a limited amount of freezer space. Furthermore, frozen sandwiches present difficulties in thawing that are not encountered with refrigerated product. 
     Stores are advised to keep the packaged sandwiches  18  refrigerated at approximately 35 to 40 degrees Fahrenheit until ready for use. When it is desired to offer sandwiches  18  for sale, a package  20  of sandwiches  18  is opened at the store location. The sandwiches  18  are then placed in a refrigerated display still wrapped in wrapping paper  11 . Instructions on the bulk package  20  of sandwiches provide that once the package is opened all sandwiches should be removed and placed in a sales location. In this fashion, partial opened packages of sandwiches will not inadvertently remain in the refrigerated storage areas and spoil. 
     In a store, refrigerated sandwiches  18  are usually placed in a cooler on a display shelf  35 . The thermostat of the refrigerated merchandisers  30  should be set to maintain the sandwiches  18  at a maximum 40 degrees Fahrenheit temperature. The display shelf life of the refrigerated sandwiches  18  in the merchandiser  30  is approximately 14 days. The extended shelf life after opening the modified atmosphere package is believed to be attributable to a substantial reduction in bacterial populations during the period of modified atmospheric storage. In a convenience store, the merchandiser  30  is preferably placed in full view, possibly near the store check out counter or coffee machine, and generates both directed and impulse sales. The customer who wishes to purchase a sandwich  18  may simply open the door  33  of refrigerated merchandiser  30 , and pick up a sandwich  18  and take it to the check out counter of the store. Not only does the wrapper  11  provide some protection from customer handling, but it also permits the store operator to handle the sandwiches  18  from package  20  to merchandiser  30  in a sanitary fashion without actually touching the sandwich  10 . 
     Condiments such as mustard and mayonnaise are not placed on the bulk package sandwiches during the assembly process. This is both to preserve customer choice and to prevent the absorption of excess moisture by the bread portions of the sandwiches. Packaged condiments may be made available for customers at the point of sale. 
     FIG. 5 provides a flow chart of the assembly and distribution process of the present invention. Specifically, bread is refrigerated in step  41 , and the cooked meat, cheese or spread to be placed in the sandwich is in refrigerated condition in step  42 . Bread and the filling are brought together in step  43  for assembly, which involves slicing the bread and inserting the filling between the bottom  12  and top  14  bread portions. In step  44 , the sandwiches  10  are wrapped in wrappers  11 , and thence proceed to step  45  for modified atmosphere packaging into sleeves  20  as described in connection with FIG.  3 . The sandwiches  18  packaged in sleeves  20  remain refrigerated for delivery to individual store locations  47  or to other merchandisers. When ready for use, packages  20  are opened at the store locations or by vending route personnel in step  48 . Then in step  49 , the wrapped sandwiches  18  are placed in the merchandiser  30 . 
     In the case of a vending merchandiser, packages  20  are opened as needed when vending machines are serviced and refilled, and any excess sandwiches  10  from an open package are kept refrigerated and placed in the next vending machine on the route  51 . Finally, step  50  shows the successful sale of the wrapped sandwiches  18  to consumers. 
     Although the present invention has been described with reference to certain preferred embodiments disclosed in detail, it is to be understood that this is for the purpose of illustrating the invention, and should not be construed as necessarily limiting the scope of the invention since it is apparent that many changes may be made to the disclosed components and procedures by those skilled in the art to suit particular applications.