US20060034986A1

US20060034986A1 - Food container and method

Info

Publication number: US20060034986A1
Application number: US10/917,912
Authority: US
Inventors: Kenneth Hynes
Original assignee: Carroll Sales Agency Inc
Current assignee: Carroll Sales Agency Inc
Priority date: 2004-08-13
Filing date: 2004-08-13
Publication date: 2006-02-16

Abstract

Disclosed is a food container. The food container can include a tube of thermoplastic material, the tube having an upper side and a lower side joined at a first edge and a second edge and a primary heat seal that continuously fuses the upper side and the lower side from the first edge to the second edge. In one embodiment, material of the food container defines an aperture between the primary heat seal and a closed end of the container and material disposed between the aperture and the closed end forms a handle for the container. Method of food preparation involving the container are also disclosed.

Description

TECHNICAL FIELD

The present invention relates generally to the field of food preparation and storage and, more particularly, to a container that is well suited for use in cook-chill food applications, a method of making the container and a method of handling the container during food product preparation.

BACKGROUND

Cook-chill systems and methods have been widely introduced to process food products for institutions such as schools, companies, hospitals, prisons, military bases, hotels, restaurants and so forth. Cook-chill food production works especially well for relatively “flowable” food products, such as soups, stews, chili, pastes and sauces. However, as used herein, the term cook-chill applies to any food production technique involving a bag-like container that is exposed to thermal and/or mechanical stresses.
Typically, cook-chill food production involves cooking the food product such that the food product is relatively hot, such as about 180° F. or higher. The hot food product is placed into a bag, which is typically made of plastic. The bag and its contents are then chilled to a temperature of about 38° F. to about 40° F. in a rapid cooling operation (e.g., within about 90 minutes). However, cooling to lower temperatures and freezing of the food product are also possible. A chiller device is often used to cool the food product by direct contact between the bag and a chilling liquid, such as cold water (e.g., about 38° F.). To more evenly cool the food product, most chillers mechanically act on the water and bag. For instance, tumbler-type chillers are used to tumble the bags of food product in the chilling liquid with a rotating tank, paddle-type chillers are used to stir the chilling liquid and bags of food product with a paddle, and jet chillers are used to pump chilling liquid that actuates the bags during chilling.
Once the bags of food product are chilled to a desired temperature, the bags of food product can be stored in a refrigerated environment and/or shipped to another location. When consumption of the food product is desired, the food product is typically reheated in the bag using a process referred to as rethermalization. Reheating of the food product typically involves raising the temperature of the food product to about 180° F. or higher, and can include boiling of the food product. Conventional rethermalization involves techniques such as submersing the bag(s) of food product in a heated medium (e.g., hot water) and placing the bag(s) of food product in a steam convention oven.
As can be appreciated, the process of introducing hot food product into a container bag, cooling the bag of food product while agitating and/or manipulating the bag, storing the bag of food product, transporting the bag of food product, and rethermalizing the bag of food product can place considerable strain on the bag.
Conventional bags are generally tubular in nature having a first end that is closed in advance of food product introduction and a second end that defines an opening, or open end. The open end is closed following introduction of the hot food product, but before chilling. In the past, one of two techniques have been selected for closing the ends of the bags, although both ends can be closed using the same technique or one end can be closed using a first of the techniques and the other end can be closed using a second of the techniques. The most common technique, which is referred to as clipping, is to collect the end of the bag together and bind the opening with a crimped metal clip.
The other technique for closing an end of the bag involves heat sealing the bag by pinching opposite sides of the bag with a heated bar to thermally fuse the bag together. Convention heat sealing uses a straight sealing bar disposed perpendicularly to a longitudinal axis of the bag and results in a seal formed generally at a right angle (e.g., about 90 degrees) with respect to an edge of the bag.
Applicants have found a number of disadvantages with conventional cook-chill bags. One disadvantage is that conventionally heat sealed cook-chill bags have a tendency to fail (e.g., develop a leak) at an interface of the heat seal and the edge of the bag, particularly during chilling of the bag and food product. Another disadvantage is that imperfect heat seals cannot be easily detected until significant failure of the seal occurs (e.g., by separation of the fused layers or “melt-through” of the seal). In this event, sudden loss of potentially hot food product from the bag can occur and this food product could come in contact with a worker's hands and/or forearms. Another disadvantage is that it is difficult to handle the bag. Conventional bags are intended to be grasped near the metal clip and/or heat seal by a worker who is wearing gloves to thermally insulate the worker's hands from the heated or chilled food product. However, in practice, it is found that many workers prefer not to wear gloves. These workers often become adept at handling the bags, but are vulnerable to direct contact with hot food product if the bag ruptures during handling before the food product is chilled or after the food product is rethermalized.
Accordingly, there is a need in the art for an improved cook-chill food storage container and methods of handling food product containers during the cook-chill process.

SUMMARY OF THE INVENTION

According to one aspect of the invention, a food container includes a tube of thermoplastic material, the tube having an upper side and a lower side joined at a first edge and a second edge; and a primary heat seal that continuously fuses the upper side and the lower side from the first edge to the second edge, the heat seal forms a junction with the first edge at an obtuse angle defined by the first edge and an edge of the heat seal proximal an open end of the container and the heat seal forms a junction with the second edge at an obtuse angle defined by the second edge and the edge of the heat seal proximal the open end.
According to another aspect of the invention, a food container includes a tube of thermoplastic material, the tube having an upper side and a lower side joined at a first edge and a second edge; a primary heat seal that continuously fuses the upper side and the lower side from the first edge to the second edge; and wherein the material defines an aperture between the primary heat seal and a closed end of the container and material disposed between the aperture and the closed end forms a handle for the container.
According to yet another aspect of the invention, a method of cook-chill food preparation, includes a) filling a container with heated food product, the container including: a tube of thermoplastic material, the tube having an upper side and a lower side joined at a first edge and a second edge; and a primary heat seal that continuously fuses the upper side and the lower side from the first edge to the second edge, the heat seal forms a junction with the first edge at an obtuse angle defined by the first edge and an edge of the heat seal proximal an open end of the container and the heat seal forms a junction with the second edge at an obtuse angle defined by the second edge and the edge of the heat seal proximal the open end; b) closing the open end; and c) chilling the food product in the container while agitating the food product with respect to the container.
According to still another aspect of the invention, a method of cook-chill food preparation, includes: a) filling the container with heated food product, the container including: a tube of thermoplastic material, the tube having an upper side and a lower side joined at a first edge and a second edge; a primary heat seal that continuously fuses the upper side and the lower side from the first edge to the second edge; and wherein the material defines an aperture between the primary heat seal and a closed end of the container and material disposed between the aperture and the closed end forms a handle for the container; b) closing the open end; and c) transporting the container by retaining the container by the handle.

BRIEF DESCRIPTION OF DRAWINGS

These and further features of the present invention will be apparent with reference to the following description and drawings, wherein:
FIG. 1 is a top view of a food container according to the present invention;
FIG. 2 is a partial top view of a food container according to another embodiment of the present invention;
FIG. 3 is a partial top view of a food container according to yet another embodiment of the present invention;
FIG. 4 is a schematic diagram of a machine for making the food container;
FIG. 5 is a schematic view of the food container during a cook-chill filling operation;
FIG. 6 is a schematic view of the food container at the conclusion of the cook-chill filling operation;
FIG. 7 is a schematic view of the food container at the conclusion of the cook-chill filling operation and having a heat seal at a fill end according to one embodiment of the present invention;
FIG. 8 is a schematic view of plural food containers during a cook-chill chilling operation;
FIG. 9 is a schematic view of plural food containers during a handling and/or storage operation; and
FIG. 10 is a schematic view of a food container during a cook-chill rethermalization operation.

DISCLOSURE OF INVENTION

In the detailed description that follows, like components have been given the same reference numerals, regardless of whether they are shown in different embodiments of the present invention. To illustrate the present invention in a clear and concise manner, the drawings may not necessarily be to scale and certain features may be shown in somewhat schematic form. Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.
Certain aspects of the present invention are directed to a food container. The food container can comprise a bag for use in “cook-chill” processing of a food product and is particularly well suited to receive relatively “flowable,” “pourable,” “dumpable” and/or “extrudable” (e.g., capable of being pushed out under pressure) food products, such as soups, stews, chili, pastes, vegetables and sauces. However, the bag can be used to receive alternative food items, such as meats, dairy products, baked goods and so forth, and does not have to be used in association with a cook-chill food production technique. The food container is formed from extruded stock material that has a generally tubular configuration. The stock material is cut to a desired length and heat sealed at one end. The heat seal extends continuously from one edge of the material to an opposite edge and intersects each edge at an obtuse angle with respective seal sections that are directed towards an adjacent end of the container. An aperture can be formed in the material of the bag so as to define a handle between the seal and the end of the container.
Without intending to be bound by theory, the geometrical configuration of the heat seal reduces stress points on the container so as to minimize the occurrence of holes and/or tears that may otherwise form at the intersection of the seal and edges of the container during exposure to the rigors of a cook-chill food preparation process. The handle arrangement provides a convenient means by which to manipulate and transport the container during various stages of the cook-chill food preparation process.
Referring now to FIG. 1, shown is a top view of a food container 10. The food container 10 has a first end that is closed by a manufacturer of the food container 10 and will be referred to herein as a closed end 12. The closed end is sometimes referred to in the art as the manufactured end. The opposite end of the food container 10 defines an opening 14 that is left open by the manufacturer of the food container 10 such that a food product maker, or processor, can introduce the food product into the container 10 through the opening 14. Accordingly, the end of the food container 10 defining the opening will be referred to as an open end, but is sometimes referred to in the art as the processor end. Nevertheless, after introduction of food product into the container 10, the open end is closed to the external environment as described in greater detail below.
The food container 10 between the closed end 12 and the open end 16 defines a cavity for receiving the food product. The cavity can be defined by generally tubular walls of the food container 10. In one embodiment, creases can be formed in the walls of the food container 10 such that the food container 10 has an upper side 18 and a lower side 20 joined at a first edge 22 and a second edge 24. The edges 22 and 24 are generally parallel to a longitudinal axis of the food container 10. As can be appreciated, the food container 10 of the illustrated embodiment can be made from an extruded tube of stock material and the edges 22 and 24 are formed by creasing the stock material. For instance, the stock material can be a multilayer coextrusion of thermoplastic material layers including, for example, one or more layers of nylon. In one embodiment, the stock material has five coextruded layers and has a thickness of about 4.5 mils. Alternatively, the food container 10 can be made from stock material that begins as two separate layers that have been joined by a seaming or sealing technique.
The closure of the closed end 12 can be formed by a primary seal 26. The primary seal 26 is preferably a heat seal formed by thermally fusing the upper side 18 and the lower side 20. As indicated, the primary seal 26 extends continuously from the first edge 22 to the second edge 24. The primary seal 26 has a first section 28 that forms an interface with the first edge 22 at an angle α (alpha). The angle α is an obtuse angle. In one embodiment, the angle α is about 135 degrees. Similarly, the primary seal 26 has a second section 30 that forms an interface with the second edge 24 at an angle β (beta) in the location of the second edge 24. The angle β is an obtuse angle. In one embodiment, the angle β is about 135 degrees. The angle α and the angle β can be the same or different angles.
Starting from the edges 22, 24, the first section 28 and the second section 30 are respectively directed towards the closed end 12 of the container 10. Without intending to be bound by theory, it is believed that the container 10 having obtuse angle interfaces between the primary seal 26 and the edges 22, 24 is less susceptible to stress compared to a container having a heat seal disposed perpendicularly to the edges 22, 24 and resulting in interfaces formed at about a right angle. More specifically, the container having right angle interfaces has stress points that may result in the formation of holes or tearing of the container material when filled with food product and undergoing the rigors of a cook-chill process.
In one configuration, the first section 28 and the second section 30 can meet each other between the first edge 22 and the second edge 24. In another configuration, such as the illustrated example, one or more intermediate sections 32 can be used to join the first section 28 to the second section 30. Although the sections 28, 30 and 32 are illustrated as being generally linear, the sections can be non-linear (e.g., curved). Junctions between various sections 28, 30, 32 of the primary seal 26 can be defined by curved transitions 34. Without intending to be bound by theory, curved transitions 34 have a lower tendency to form stress points than angled intersections that could lead to hole formation or tearing of the container material.
Material can be removed from the container 10 between the primary seal 26 and the closed end 12 to define an aperture 36. Remaining material adjacent the aperture 36 and the closed end 12 define a handle 38. For example, the handle 38 can be readily grasped by a worker by inserting the worker's fingers through the aperture 36 and closing the worker's hand around the handle 38 material disposed between the aperture 36 and closed end 12. Although workers handling the food container 10 should wear appropriate sanitary and protective equipment, the handle 38 allows for convenient grasping of the food container 10 in a location that is remote from the food product, which may be uncomfortably hot or cold. A hook, bar, rod or other retaining device can be inserted into the aperture 36 to hold the food container 10 in, for example, a hanging position. The sides 18 and 20 around the perimeter of the aperture 36 can be fused, such as by operation of a cutter tool used to form the aperture 36 or a heat sealing member.
Optionally, a second seal 40 can be formed to join the upper side 18 and the lower side 20. Like the primary seal 26, the second seal 40 can be a heat seal. In the illustrated embodiment, the second seal 40 extends continuously from the first edge 22 to the second edge 24 and forms perpendicular interfaces with the edges 22, 24. For example, the second seal 40 can be generally linear and disposed generally perpendicular to the edges 22, 24 and the longitudinal axis of the food container 10. The second seal 40 can provide strength to the handle 38. In addition, should the upper side 18 separate from the lower side 20 along the primary seal 26, the second seal 40 can provide closure redundancy to minimize escaping of the food product from the food container 10. Seepage of food product into a cavity defined by the upper side 18, the lower side 20, the primary seal 26, the second seal 40 and, if applicable, the fused perimeter of the aperture 36 can provide a visual indication that the primary seal has a discontinuity or is beginning to separate. This indication can signal possible greater separation or melt through of the sides 18, 20 along the primary seal 26 and the container 10 can be handled accordingly. Also, the aperture/handle is positioned with respect to a food product receiving cavity of the container 10 such that when a worker grasps the aperture/handle, leakage of the food product, if leakage occurs, is likely to drawn downward by gravity and away from the workers hand and forearm.
The food container 10 described herein has certain features to reduce wasteful leakage of food product from the container 10 and enhance ease of handling. While these features are believed to provide advantages over the prior art, there is always potential for injury when handling heated or chilled articles and the food container 10 is not intended to comprise a “safer” cook-chill food container than those found in the prior art or comprise a safety article.
It will be appreciated that the food container 10 can be sized to accommodate a desired amount of food product. In one embodiment, the food container is sized to accommodate about fifteen to about twenty pounds of food product. In such an embodiment, the container 10 can be about ten inches wide when measured from the first edge 22 to the second edge 24 and can be about 30.5 inches long when measured from the closed end 12 to the open end 16. The interfaces of the primary seal 26 with the edges 22, 24 can be located about six inches from the closed end 12 and the intermediate section 32 can be located about three inches from the closed section. In one embodiment, the primary seal 26 has a width of about 0.16 inches (e.g., about 5/32nds of an inch), and, in one embodiment, the primary seal 26 has a width of about 0.13 inches (e.g., about ⅛th of an inch) to about 0.5 inches. The second seal 40 can have a width in the range of about 0.13 inches (e.g., about ⅛th of an inch) to about 0.5 inches. The aperture 36 can have a width of about 0.75 inches and a length of about 3.5 inches.
With additional reference to FIG. 2, shown is a partial top view of a food container 10′ according to another embodiment of the present invention. Similar to the above-described embodiment, the container 10′ has a primary seal 26 that forms interfaces with edges 22, 24 of the container that respectively have obtuse angles α and β. In addition, an aperture 36 can be formed in the container 10′ to define a handle region 38. To reinforce the perimeter of the aperture 36 and to increase the amount of fusing between the upper side 18 and the lower side 20 around the aperture 36, the container has a heat seal 42 disposed around the perimeter of the aperture 36. In the illustrated embodiment of FIG. 2, a second seal 40′ is present. The second seal 40′ is arranged in similar fashion to the primary seal 26 such that the second seal 40′ forms interfaces with edges 22, 24 of the container that respectively have obtuse angles. As should be appreciated, the presence of the seal 42 and/or second seal 40′ is optional.
With additional reference to FIG. 3, shown is a partial top view of a food container 10″ according to another embodiment of the present invention. Similar to the above-described embodiments, the container 10″ has a primary seal 44 that forms interfaces with edges 22, 24 of the container that respectively have obtuse angles α and β. In addition, an aperture 36 can be formed in the container 10″ to define a handle region 38. To reinforce the perimeter of the aperture 36 and to increase the amount of fusing between the upper side 18 and the lower side 20 around the aperture 36, the container has a heat seal 42 disposed around the perimeter of the aperture 36. In the illustrated embodiment, a second seal for the container 10″ is omitted. However, a second seal can be added to the container 10″ and/or the heat seal 42 can be omitted.
The primary seal 44 for the container 10″ includes a cusp region 46. The cusp region 46 can have rounded corners to reduce the formation of stress points. The cusp region 46 can be cut, such as along dashed line 48 with scissors or a knife, to form an opening in the food container 10″ through which food product contained therein can be dispensed. The shape of the cusp region 46 can provide a built-in funnel-like constriction to the dispenser opening. As should be appreciated, alternative shapes for the cusp region 46 other than the illustrated shape and alternative means for forming a dispenser opening in the container 10″ can be made and are considered to fall within the scope of the present invention as defined by the claims appended hereto.
With reference now to FIG. 4, shown is a schematic diagram of a food container manufacturing assembly 50 for making a food container according to the present invention. In the illustrated example, the assembly 50 is configured to make the food container 10 illustrated in FIG. 1. Modifications to the assembly to make the food container 10′ of FIG. 2, the food container 10″ of FIG. 3 or any other similar food container will be apparent to one of ordinary skill in the art.
The manufacturing assembly 50 can include, a feeding assembly 52, a sealing assembly 54 and a cutting assembly 56. Other assemblies that are not illustrated, but will be apparent to one of ordinary skill in the art, can include a stock supply assembly, a tensioning assembly, a take-up assembly, an out-feed assembly, a packaging assembly for placing plural assembled food containers 10 in a package for delivery to a food producer, a waste product removing assembly (e.g., to dispose of stock material removed when forming the aperture 36), and so forth.
Stock material 58 can be stored in the form of a roll. As indicated, the stock material 58 can be in the form of a flat-lying creased tube of thermoplastic material, such as the above described multilayer coextrusion. Stock material 58 can be taken off of the roll and directed to the sealing assembly 54 using rollers of the feeding assembly 52.
The sealing assembly 54 includes a heated sealing bar 60 corresponding to the primary seal 26. To make the seal 26, the stock material 58 is appropriately positioned with respect to the sealing bar 60 and the sealing bar 60 is actuated to contact the stock material 58 and pinch the stock material 58 between the sealing bar 60 and a platen 62. Alternatively, the stock material 58 can be pinched between the sealing bar 60 and a second corresponding sealing bar located under the stock material 58. The sealing bar 60 contacts the stock material 58 with sufficient pressure, temperature and duration to fuse the upper side 18 (FIG. 1) of the stock material 58 to the lower side 20 (FIG. 1) of the stock material 58, thereby forming the primary seal 26.
As will be appreciated, the sealing bar 60 has a shape that corresponds to the desired configuration of the primary seal 26 such that the interfaces of the primary seal 26 and the edges 22, 24 form respective obtuse angles α and β. In one embodiment, the sealing bar 60 has sections that correspond to the first and second sections 28, 30 of the primary seal 26. These corresponding sections of the sealing bar 60 can laterally extend beyond the edges 22, 24 of the stock material 58. For example, an overall length of the sealing bar 60 can be longer than the width of the stock material 58 as measured from the first edge 22 to the second edge 24. In this manner, the primary seal 26 can be formed continuously from first edge 22 to second edge 24, even if the lateral placement of the stock material 58 varies during production.
The sealing assembly 54 can further include a cutter 64 for forming the aperture 36. The cutter 64 can be heated and/or include a sharpened edge. To make the aperture 36, the stock material 58 is appropriately positioned with respect to the cutter 64 and the cutter 64 is actuated to contact the stock material 58 and pinch the stock material 58 between the cutter 64 and the platen 62 or other corresponding member. The cutter 64 contacts the stock material with sufficient pressure, temperature and duration to remove a section of stock material 58 corresponding to the aperture 36. As indicated, the action of the cutter 64 may tack the upper side 18 to the lower side 20 to produce a closure around the aperture 36. The width of this closure is confined to a very narrow area around the aperture 36. In another embodiment, the cutter 64 can be combined or used in conjunction with a sealing bar to form a wider and/or stronger seal (e.g., seal 42 of FIG. 2) around the aperture 36.
The sealing assembly 54 can further include a heated sealing bar 66 corresponding to the second seal 40. Similar to formation of the primary seal 26, the second seal 40 can be formed by appropriately positioning the stock material 58 with respect to the sealing bar 66. The sealing bar 66 is actuated to contact the stock material 58 and pinch the stock material 58 between the sealing bar 66 and the platen 62 or other member (e.g., a cooperating sealing bar). The sealing bar 66 contacts the stock material 58 with sufficient pressure, temperature and duration to fuse the upper side 18 of the stock material 58 to the lower side 20 of the stock material 58, thereby forming the second seal 40. The sealing bar 66 can laterally extend beyond the edges 22, 24 of the stock material 58 so that the second seal 40 can be formed continuously from first edge 22 to second edge 24, even if the lateral placement of the stock material 58 varies during production.
In the illustrated example, the primary seal 26 is formed, then the aperture 36 is formed and then the second seal 40 is formed. However, this formation order can be modified and/or more than one of the primary seal 26, the aperture 36 and the second seal 40 can be formed concurrently or with partial concurrence.
The feeding assembly 52 can direct the stock material such that the primary seal 26, aperture 36 and second seal 40 pass a cutter 68 of the cutting assembly 56. The cutter 68 can be heated and/or include a sharpened edge. Upon desired positioning of the stock material 58, the cutter 68 can be actuated to contact the stock material 58 and pinch the stock material 58 between the cutter 68 and the platen 70 or other corresponding member. The cutter 68 contacts the stock material with sufficient pressure, temperature and duration to sever a portion of the stock material 58 corresponding to the food container 10 from the remainder of the stock material 58. Action of the cutter 68 may tack the upper side 18 to the lower side 20 to produce a closure along the closed end 12. The width of such a closure is confined to a very narrow area along the closed end 12. In another embodiment, the cutter 68 can be combined or used in conjunction with a sealing bar (e.g., sealing bar 66 or other sealing bar member) to form a wider and/or stronger seal along the closed end 12.
In an alternative embodiment, the cutter 68 is used to perforate the stock material 58, but not separate each container 10. The perforated stock material 58 can be re-rolled. Thereafter, individual containers 10 can be separated from the roll of perforated stock material by tearing or cutting along the perforation. Such separation can be accomplished by hand or by an automated apparatus.
As will be appreciated, the containers 10 can be made in a highly automated fashion. In addition, plural containers 10 can be packaged in a stacked arrangement (e.g., lied flat, one on top of another) in a larger container (e.g., a box) and distributed to food producers. The stacked arrangement reduces the volume consumed by the containers 10 over containers that have been closed with a metal clip.
Referring now to FIG. 5, shown is a schematic view of the food container 10 during a cook-chill filling operation. As indicated, cook-chill food preparation techniques involve preparing a food product 72 and filling the container 10 with food product while the food product is relatively hot, such as about 120° F. or higher. In many cases, the food product 72 enters the container 10 at a temperature of about 180° F. or higher. The food product 72 can be pumped (e.g., through a pipe 73) or gravity fed into the container 10 through the opening 14 at the open end 16 of the container 10. Due to the elevated temperature of the food product 72, the material of the container 10 may undergo some softening and stretching during the filling operation and subsequent handling.
With additional reference to FIG. 6, shown is a schematic view of the food container 10 at the conclusion of the cook-chill filling operation and after the open end 16 has been closed. Closing of the open end 16 can involve constricting the opening 14 and crimping a metal clip 74 around the food container 10. Optionally, excess container 10 material can be removed. In another embodiment, the open end 16 can be heat sealed using a conventional heat seal disposed generally perpendicularly to the longitudinal axis of the container 10.
With additional reference to FIG. 7, the open end 14 of the container 10 can be closed with an open end heat seal 76 configured to have features of the primary seal 26 located adjacent the closed end 12. For example, the seal 76 can have a first section 78 forming an interface with the first edge 22 at an obtuse angle and a second section 80 forming an interface with the second edge 24 at an obtuse angle. Starting from the edges 22, 24, the first section 78 and the second section 80 are respectively directed towards the open end 16 of the container 10. Optionally, the heat seal 76 can have a cusp that defines a food dispenser when cut. If desired, excess material can be removed from the food container distal to the seal 76 as shown in the illustrated example.
Referring now to FIG. 8, shown is a schematic view of plural food containers 10 during a cook-chill chilling operation. The containers 10 have been placed in a chiller apparatus 82 used to lower the temperature of the food product 72 contained within the container 10. Chillers and chilling techniques are relatively well known in the art and will not be described in detail. Example chillers include tumbler chillers, paddle chillers, jet chillers and forced air chillers, but are not limited to these types of devices. As indicated above, conventional cook-chill bags have been known to develop holes and/or tears at the intersection of a conventional heat seal and edge of the bag. Without intending to be bound by theory, it is believed that the interfaces formed by the primary seal 26 and the open end heat seal 76 described herein are less susceptible to the thermal and mechanical stresses experienced during chilling. Accordingly, the food containers described herein are advantageously less likely to develop holes and/or tears.
With additional reference to FIG. 9, shown is a schematic view of the food container during a handling and/or storage operation. The handling operation can be carried out before chilling of the food product 72 (e.g., transporting the filled containers 10 from a filling station to the chiller) or subsequent to chilling of the food. In one example, the filled food containers 10 can be hung from hangers 84 having a hook-like structure inserted through the aperture 36. The hangers 84 can be connected to a support 86. The support 86 can be moveable under force exerted by a worker or a mechanized source (e.g., a motor) so as to convey the filled containers 10 to a desired location. As should be appreciated, the use of a moveable conveyor system for the filled containers 10 can be used to transport the filled containers between and among any of the following exemplary locations: a filling station, a chiller, a freezer, a refrigerated chamber, a storage location, a packaging station for loading plural filled containers 10 into larger containers (e.g., a box), a loading dock (e.g., for transfer of the filled containers 10 into a vehicle), and a rethermalizer.
The filled containers 10 can be stored in a refrigerated environment. Optionally, the filled containers 10 can be frozen to extend the storage duration of the food product 72. The filled containers 10 optionally can be stored on the hangers 84, which are supported by a moveable support 86 or a fixed support 86 during storage.
With additional reference to FIG. 10, illustrated is a schematic view of the filled food container 10 undergoing rethermalization (e.g., reheating of the food product while disposed in the container 10) using a rethermalizer 88. The illustrated rethermalizer 88 is simply a container (e.g., pot) containing heated liquid (e.g., water heated to about 180° F. or higher). The food container 10 is immersed in the heated liquid so that the food product 72 contained within the food container 10 becomes heated. As should be appreciated, other types of rethermalizers can be used and include, without limitation, a steam convection oven, a microwave and so forth. Although only one container 10 is shown in FIG. 10, it will be appreciated that plural filled containers 10 can be rethermalized simultaneously.
During rethermalization, the food container 10 can be hung from a bar 90 or other member. For example, the bar 90 can be inserted through the aperture 36. The bar 90, in turn, can be supported by support members 92. Depending on the configuration of the rethermalizer, the bar 90 and/or support members 92 can form part of rethermalizer or be brought into association therewith.
In one embodiment, the food container 10 can be placed in the rethermalizer in an unsupported arrangement. A worker can use a tool or hand-held hook to retrieve the rethermalized food container 10 from the rethermalizer by inserting a distal end of the tool or hook through the aperture 36.
Although particular embodiments of the invention have been described in detail, it is understood that the invention is not limited correspondingly in scope, but includes all changes, modifications and equivalents coming within the spirit and terms of the claims appended hereto.

Claims

1. A food container, comprising:

a tube of thermoplastic material, the tube having an upper side and a lower side joined at a first edge and a second edge; and

a primary heat seal that continuously fuses the upper side and the lower side from the first edge to the second edge, the heat seal forms a junction with the first edge at an obtuse angle defined by the first edge and an edge of the heat seal proximal an open end of the container and the heat seal forms a junction with the second edge at an obtuse angle defined by the second edge and the edge of the heat seal proximal the open end.

2. The food container according to claim 1, wherein the tube and primary heat seal define a cavity for receiving food product through an opening defined by the container at the open end.

3. The food container according to claim 2, further comprising a second seal to close the opening after food product has been received in the cavity.

4. The food container according to claim 3, wherein the second seal is a heat seal that continuously fuses the upper side and the lower side from the first edge to the second edge, the heat seal forms a junction with the first edge at an obtuse angle defined by the first edge and an edge of the heat seal distal the open end of the container and the heat seal forms a junction with the second edge at an obtuse angle defined by the second edge and the edge of the heat seal distal the open end.

5. The food container according to claim 1, wherein the material defines an aperture between the primary heat seal and a closed end of the container and material dispose between the aperture and the closed end forms a handle for the container.

6. The food container according to claim 5, further comprising a second heat seal disposed between the aperture and the closed end, the second heat seal continuously fuses the upper side and the lower side from the first edge to the second edge.

7. The food container according to claim 5, further comprising a heat seal disposed around a perimeter of the aperture to fuse the upper side to the lower side around the aperture.

8. The food container according to claim 1, further comprising a second heat seal disposed between the primary heat seal and a closed end of the container, the second heat seal continuously fuses the upper side and the lower side from the first edge to the second edge.

9. The food container according to claim 1, wherein the primary heat seal has a first section forming the junction with the first edge, a second section forming the junction with the second edge and an intermediate section joining the first and second sections.

10. The food container according to claim 9, where transitions between the first section and the intermediate section and between the second section and the intermediate section have curved transitions.

11. The food container according to claim 1, wherein the primary seal includes a cusp that when cut defines a food dispenser for removing food product from the container.

12. A food container, comprising:

a tube of thermoplastic material, the tube having an upper side and a lower side joined at a first edge and a second edge;

a primary heat seal that continuously fuses the upper side and the lower side from the first edge to the second edge; and

wherein the material defines an aperture between the primary heat seal and a closed end of the container and material disposed between the aperture and the closed end forms a handle for the container.

13. The food container according to claim 12, further comprising a second heat seal disposed between the aperture and the closed end, the second heat seal continuously fuses the upper side and the lower side from the first edge to the second edge.

14. The food container according to claim 12, further comprising a heat seal disposed around a perimeter of the aperture to fuse the upper side to the lower side around the aperture.

15. The food container according to claim 12, wherein the tube and primary heat seal define a cavity for receiving food product through an opening defined by the container at an open end.

16. The food container according to claim 15, further comprising a second seal to close the opening after food product has been received in the cavity.

17. The food container according to claim 12, wherein the primary seal includes a cusp that when cut defines a food dispenser for removing food product from the container.

18. A method of cook-chill food preparation, comprising:

a) filling a container with heated food product, the container including:

a primary heat seal that continuously fuses the upper side and the lower side from the first edge to the second edge, the heat seal forms a junction with the first edge at an obtuse angle defined by the first edge and an edge of the heat seal proximal an open end of the container and the heat seal forms a junction with the second edge at an obtuse angle defined by the second edge and the edge of the heat seal proximal the open end;

b) closing the open end; and

c) chilling the food product in the container while agitating the food product with respect to the container.

19. The method according to claim 18, further comprising reheating the food product in the container.

20. The method according to claim 19, wherein the material defines an aperture between the primary heat seal and a closed end of the container and material dispose between the aperture and the closed end forms a handle for the container and the container is hung by the handle during reheating.

21. The method according to claim 18, wherein the material defines an aperture between the primary heat seal and a closed end of the container and material dispose between the aperture and the closed end forms a handle for the container.

22. The method according to claim 21, further comprising transporting the container by grasping the handle and lifting the container thereby.

23. The method according to claim 21, further comprising transporting the container by a mechanical conveyor that retains the container by the handle.

24. The method according to claim 18, wherein the closing includes forming a second heat seal that continuously fuses the upper side and the lower side from the first edge to the second edge, the heat seal forms a junction with the first edge at an obtuse angle defined by the first edge and an edge of the heat seal distal the open end of the container and the heat seal forms a junction with the second edge at an obtuse angle defined by the second edge and the edge of the heat seal distal the open end.

25. The method according to claim 18, wherein the primary seal includes a cusp that when cut defines a food dispenser for removing food product from the container and further comprising removing food product from the container via the food dispenser.

26. A method of cook-chill food preparation, comprising:

a) filling the container with heated food product, the container including:

wherein the material defines an aperture between the primary heat seal and a closed end of the container and material disposed between the aperture and the closed end forms a handle for the container;

b) closing the open end; and

c) transporting the container by retaining the container by the handle.

27. The method according to claim 26, wherein transporting the container includes hanging the container by the handle during reheating of the food product in the container.

28. The method according to claim 26, wherein transporting the container includes grasping the handle and lifting the container thereby.

29. The method according to claim 26, wherein transporting the container includes moving the container by a mechanical conveyor that retains the container by the handle.

30. The method according to claim 26, wherein transporting the container includes hanging the container by the handle during storage of the container.

31. The method according to claim 26, wherein the primary seal includes a cusp that when cut defines a food dispenser for removing food product from the container and further comprising removing food product from the container via the food dispenser.