WO2003082690A2

WO2003082690A2 - Packaging system

Info

Publication number: WO2003082690A2
Application number: PCT/CH2003/000210
Authority: WO
Inventors: Alain Guigan
Original assignee: Alain Guigan
Priority date: 2002-04-02
Filing date: 2003-04-01
Publication date: 2003-10-09
Also published as: WO2003082690A3; AU2003212178A1

Abstract

Container (1) comprising a bottom (14), a panel (3) and a lid (2), said lid (2) comprising a groove (4) adapted to receive the panel open end (16), whereby the interlocking zone (5, 15) defined by said panel open end (16) and said groove (4) is not completely included in the same plane.

Description

Packaging System

The present invention relates to a packaging system including a packaging and a device for filling and refilling said packaging.

Packaging materials represent more than 50% of household refuses in developed countries like Switzerland.

Any system, which helps reduce the amount of packaging brought home by the consumer from the retailer, shall therefore be considered positively by an evermore environmentally conscious, "Packaging Aware" consumer.

An object of the present invention is to provide a packaging system which reduce the amount of packaging.

This is achieved by the use of a new container, a new distribution system and a new distribution system as defined in claims 1 to 9.

The invention also concerns a new distribution method which in particularly suitable for supermarkets.

The packaging system according to the invention is an attempt to contribute to the global effort of reducing the amount of packaging materials used for retail distribution, handling and storage of food (and non-food) items.

Detailed embodiments of the invention will be discussed hereafter with the support of the following figures : Fig. N°

1. Container with open "lip" Side View

2. Container base sealed with "Operculum" Top View

3. Container with closed "lip", stick-on label & Chip Front View

4. Container with closed "lip", with stick-on & Info labels Top View

5. Container base family Side View

6. Container base family Front View

7. Container with removable slide-on handle Side View

8. Stacked container base (showing slide for remov. handle) Side View

9. Stacked container base Front View

10. Container with soft pouch Side View

11. Additional control buttons on scale to enter tare weight of container

12. Dry-products "Distributor" principle Side View

13. Dry-product Self-Service System principle Side View

14. Dry-product Self-Service System principle Front View

15. Storage bin re-filling System (from the 1^st floor) principle Side View

16. Storage bin re-filling System (from the alley) principle Side View

17. Container "Shopper" for 4 full / 12 empty containers Top & Side Views

Containers (Fig. 1 to 10)

(Fig. 1) A container 1 consists of a (possibly colored) plastic lid 2 interlocking with a transparent (or translucent) plastic or glass container panel 3, which is produced in various sizes (for example: 0.5, 1.0, 1.5 and possibly 2.0 liters in countries using metric measurements). The container 1 also include a spout 7 which is oriented downwards.

The interlocking system consists of the usual groove 4 of the top, locking with the panel open end 16 of the container, like in existing container systems manufactured and distributed since years by Tupperware, Rubbermaid, etc.

The container differs however from known containers in that the interlocking zone 5,15 is not completely included in the same plane.

These spout 7 and groove 4 are vertical on the side walls of the container base, but possibly angled or even horizontal on the back wall, so as to prevent the (accidental) opening of the container from the back.

(Fig. 2) The groove 4 is however wide enough so that a flat flange allows for the hot sealing of an "operculum" 6, effectively closing the container base 3.

The special design of the container, constituted of only 2 parts (i.e. the combined lid 2 and panel 3), allows for the easy opening at the spout level.

At this place, the spout 7 can be closed or opened, simply by respectively pressing or pulling on the corresponding top interlocking part 8.

A "bump" 9 is provided for in the container's top over the spout 7 so that it opens widely when it is pulled open. The panel 3 and bottom 14 of the container 1 are made of the highest grade of plastic (or possibly tempered, unbreakable glass) resisting to very high temperature, to be able to withstand repeated washing and sterilization (possibly at UHT) and hot sealing of an "operculum" 6 (without melting) as well as to tear and wear and to ultra- violet rays, so that it may look "as new" after several cycles, and possibly to very low temperature, to allow it to be used as a container for frozen goods.

The container base and the top could also be hinged, i.e. fixed to each other, in which case they could be either made of the same material or, more likely, of different materials and glued (or attached in another manner) together.

(Fig. 5, 6, 8 & 9)The transparent container panel 3 is rectangular-shaped, with inclined front and side walls, so that they be stackable, and all the angles are rounded, so that it is easily washable.

The panel 3 is fitted with an engraved (or, possibly printed) volume scale, and possibly with scales indicating the corresponding approximate weights for such common products as sugar, flour, rice, etc.

One of the widths of the container base's bottom is compatible with that of a "Tetrabrik" (i.e. 9.6 cm) at a height of approx. 8 cm, so that it may fit into a refrigerator's door.

The other width will be small enough so that the container can be grasped by hand properly.

(Fig. 7 6 8) This can be eased by the shaping of (recessing) the top part of the back and side walls of the container base (which should also help increase the container's rigidity) or by a removable handle 9 sliding on a rail 10 fitted on the same location or on the top of the container base. This point is important since it will condition the container's height and the feasibility of having a 2 liters container compatible with the maximum height acceptable in a refrigerator.

The special design of the containers allows for the easy handling and storage (and airtight closure between servings) of liquids.

(Fig. 2) In the production plants, the container base can be machine-filled directly with the liquid, usually sterilized, such as for example milk, and is then sealed by an "operculum" 6 (like yogurt pots) and covered by the container top 2.

The "operculum" 6 is itself protected by the container lid 2.

Indeed, this combined closure is keeping the contents sterile and preventing any accidental leakage of the container, as well as any tampering with the product.

The "operculum" 6 could be fitted with a slip 11 next to the container's spout 7 so that it may be partially removed without prior removal of the container top.

These container bases and/or tops could be new or possibly already used.

The used containers would be those returned by the clients against reimbursement of a deposit and would be thoroughly machine-washed in the same manner as for glass or reusable PET bottles.

Since only the "operculum" 6 would not be reusable, such a packaging would be very environment friendly. In case of liquids altered by light, such as milk or vegetable oils, the containers could be stored, transported and displayed in specially-designed trays (inspired by those used for example for yogurt pots), which would prevent light from reaching the transparent container bases and would show the client only the container top with the label(s).

(Fig. 10) Alternatively, liquids, specially those which are altered by an exposure not only to light but also to air/oxygen, could be factory pre-conditioned in soft, biodegradable pouches 12, in order to save on packing materials, as compared to "Tetrapak" or similar types of packaging.

Indeed, in case such a pouch 12 is used, its closure between servings would not only be air-tight but the pouch would remain air-free, thereby reducing the oxidization of the product after opening, which is a big shortcoming with the rigid "Tetrapak" type packing, even those fitted with airtight closing systems.

These soft pouches 12 would probably need to have a special design, so that they fit into the containers, and to have a spout 13, which can fit and be lockable into the container's spout 7.

Possibly, in case the pouch's 12 design remains unchanged the container spout 7 would need to be designed so that the pouch doesn't fall back into the container 1 when the spout 7 is in the "open" mode.

Anyhow, this new design of the pouch 12 would still make it usable without the container, in the existing standard pouch holders or in the container 1 without using the top, which means that only one design of pouches 12, possibly declined in the 3 or 4 a/m sizes, would need to be produced and displayed. In practice, the consumer should preferably put the pouches 12 into the containers 1 only after paying for the goods, so that the cashier may read easily the barcode printed on the pouch 12, which might not be very readable through the plastic wall of the container 1.

The pouch 12 would preferably be partially transparent, so that the liquid level be visible on the container's volume scale.

The liquids sold in operculated containers or in pouches could be edible, such as, for example, pasteurized milk and juices, vegetable oils, or (why not) "table wine" and, more generally any product currently being packed into pouches, glass or plastic bottles, "Tetrapak" or other so called "modern" material... provided they are not carbonated, nor UHT (unless the "operculum" or pouches are made of multi-layer UHT compatible material, which are then probably not biodegradable...).

This same system could also be used for non-edible, such as shampoo or liquids soaps "refills", lubricating oil, etc... provided the corresponding container bases 3,14 and tops 1 are clearly identifiable, so that they are not used in direct contact with edible products after that.

This identification could be done easily by marking with a permanent marker (or by scratching, etc.) a specific location on the container's side rim and a matching location on the top, in case the container is used once for non-edible products (or has been used too many months (to be determined, probably with the container manufacturer) after the production date of the container base or top.

The case of direct liquid filling of a container 1, without it being sealed by an "operculum" 6, is more aimed at home-use, due to the fact that the spout 7 closure, even if air tight when the container is standing vertically, could start leaking or even open, in case the container falls or is pressed. Should it appear through thorough testing that the spout 7 closure can be designed to withstand such problems, the direct filling of liquids by the consumer and their self- service retail purchase could be considered, in the same manner as those of free- flowing dry-products studied hereunder.

The same containers 1 can indeed also be used by the consumer for the self-service retail purchase, handling and storage of Rice, Semolina, Pulses, Beans, Lentils and other dry vegetables as well as Sugar, coffee in beans, etc... and generally all edible free-flowing dry materials sold in volumes.

It may also be used for non-edible free-flowing dry materials sold in volumes, and particularly washing powders, or break-bulk materials sold by weight, such as screws, nuts, nails, etc., subject to the same a/m precautions being taken as for the non-edible liquids.

It is to be noted that the stated fact that it is supposed only to handle free-flowing items means that it should normally not be used for too-finely ground products such as flour, coffee, chocolate, etc... which would have a tendency to flow around in a messy manner and to resist flowing through the lips.

Self-Service System (Fig. 11 to 17)

One is familiar with the self-service distribution system for fresh fruits and vegetables currently in favor in even the smallest Supermarkets, at least in developed countries.

The client takes a thin, transparent poly-bag from a free dispenser and fills it with the fresh product of his choice.

He then weighs the bag on a special scale (made by "Bizerba", for example) and, after pressing the button showing the product or its reference number, sticks on the bag the sticker produced by the scale.

This label indicates the name of the product, its unit price and the weight and price of the contents of the bag, as well as their code-bar transcription, readable by the cashier, and whatever relevant info the retailer may have set into the scale's program, and particularly those required by law, such as the origin, quality, production/expiry dates, price per unit, etc... of the product.

The advantages of using such a system versus the traditional system of having the shopkeeper do the same thing, or having the same goods pre-packaged, are numerous:

The main one is of course the induced laborsaving, since no one pays the client for doing the job.

The second one has to do with the shelf life of the product, and the perception that the client has that an unpacked product is more natural and fresher. This is for example illustrated by the well-known case of the (shell-protected) eggs, which sell better when displayed in a basket than the same eggs prepackaged in a nice polyurethane box, even labeled with the origin, the day it was laid, etc...

- The other advantages are more subtle, such as giving the client the choice of selecting the best quality product in the bin. This leaves of course the next client with lower quality products but also... less choice.

It is somewhat not surprising that the same system is not used until now on other types of products and particularly dry products, where prepackaging by the producer or by the supermarket chain is the rule.

This brings another element into the picture, which is the product branding.

Actually, the appeal of a brand for the most commodity-like, volume products such as sugar, flour, rice, etc... is very limited, which led the supermarket chains to prepackage under their own (or no) brand these high volume, low cost/margin "generic" products.

However, these "generic" products are seen by the consumer as "products without origin", which goes into the opposite direction as the general trend i.e. the consumer's wish to be able to trace the origin of the product.

Another probable reason why the a/m self-service system is not applied to dry products is that it would require more of that evermore precious shelf-space than the prepackaged product, specially that the cheaper generic products are generally stored on the lower shelves. Finally, the problem of hygiene is certainly not foreign to the decision of not letting the customer help himself with these products, which are not ("naturally") protected by a reel, rind, etc... unlike most of the fruits and vegetables.

This problem is overcome in some of the larger supermarkets in Switzerland, for example, where the bench of olives and other pickles provides for the supply of ladles and throwaway gloves.

The proposed Self-Service System is not only overcoming all the a/m obstacles, but also saving a lot of unnecessary packaging material.

It also saves product (and money) for the retailer compared to the prepackaged products, which need to be overweight to be able to guarantee the minimum guaranteed weight written on the label and need to be sold before a (production or packing) date written on the package.

(Fig. 13 & 14) To summarize the Self-Service System, one could state that it is composed of vertical silo-type storage bins 20 (one for each product) made of stainless steel and/or other food grade composite materials (possibly lined with "Teflon" type self-lubricating material, to ease their emptying), hanged under the ceiling of the supermarket, over the highest reachable shelf 21 , i.e. at a location unusable for sales purposes until now.

(Fig. 12) Between the bin's 22 base and the "distributor" 23 the product flows through a pipe 24, with a partially transparent last section 25 covering for example 1 liter of the product, possibly fitted with an enlarging lens 27, so that the client may actually chose and see for himself the exact product he is going to purchase. The base of this pipe 24 is fitted with a removable, interchangeable, manually (or electrically) operated "distributor" 23, adapted to the physical characteristics of each type of product.

In most cases, the clients will use the containers 1 as a "standardized" reusable packaging.

For that purpose, the "distributor" 23 is fitted with a specially designed mouthpiece 28 and slide 29, which allows the connection, tight fitting and opening of the container's spout.7 to the distributor 23, so that the container 1 may be filled without leakage or spoilage.

This "distributor" 23 is designed in a way to deliver, gently, say the equivalent of about 0.25 liters of that product for each turn of a crank 30, powering usually an endless screw 31 (or a piston in case of liquids, for example), which moves the product out of the silo's pipe 24.

These "distributors" 23 are very simple mechanism, easily to wash and sterilize (at the end of the day or whenever appropriate), in which case a built-in sliding plate 32 (put in place automatically by the removal of the "distributor") prevents the emptying of the silos.

The "distributors" 23 are located over a (waist level) "working" table, where the client can prepare his containers for filling and closing, before weighing (an labeling) them on the scale positioned nearby.

The "distributors" 23 are equipped laterally with two "hooks", on which the client can easily hang the handles of the same thin, transparent poly-bag used for the fruits and vegetables (but not perforated with holes larger than the products), in case he wishes not to use a container 1, for example if he did not bring along an empty container 1 and does not want to procure one, or in case he wishes to buy a larger quantity of a product than the standard container volumes.

The client then turns the crank 30 (or presses the necessary number or amount of time on a button, in case the distributor is electrically powered) until he gets the approximate quantity he needs (This can also be automated, for example by the use of a level switch which stops the feeding motor when a certain level is reached in the container).

A scaled ruler, positioned in an appropriate manner next to the volume scale engraved on the container base, indicates the actual approximate corresponding weight of the distributed product.

(Fig. 4) The client can then possibly collect, next to the "distributor", a small pre- printed label 31 corresponding to the product and bearing the product's full name, quality, country of origin, producer's name, etc... as well as possibly the crop, the batch number, and any other information coming from the shipping or other documents which accompanied the bags/goods, as well as the logo/ brand/trademark and coordinates of the retailer and/or of the actual producer/supplier, and possibly storage and preparation guidance, a cooking recipe...

(Fig. 3 & 4) This non-sticking label 31 , possibly printed on both sides and in color, could be sized so as to fit the top 2 of the container 1, where it could be secured after weighing with an angle of the stick-on weighing label 32.

The same information would be supplied to the customer on an enlarged copy of that label, displayed next to the corresponding distributor, possibly together with (or a copy of) an empty bag, which contained the goods actually fed in the silo 22. (Fig. 11) After filling and closing the container 1 (and/or the poly-bag), the customer then proceeds in the same manner as for the fruit and vegetables for the bag weighing and labeling, on a scale fitted with some additional buttons 34 corresponding to the 3 or 4 tare weights corresponding to the various sizes of containers and possibly to the free, thin poly-bag.

It is to be noted that this scale (with additional buttons 34 for the tare weights) could also be used to weigh fresh fruits and vegetables in bags, as usual, or in containers, specially the smaller and/or more fragile species, such as cherries and berries, tomatoes, mangoes (and other very fragile tropical fruits), etc... as well as nuts, olives and pickles, etc...

The tare weight of the selected container 1 (or bag) will normally be fed into the scale, by the client, by pressing a button 34 corresponding to the container (and corresponding tare weight) used, the default button being either the 1 liter container or the poly-bag.

This identification could be further eased, by color-coding the tops. Indeed, since all tops are normally similar, their color can be used as a coding system for the corresponding capacity of the container base (For example yellow for 1 liter, blue for 1.5 liter, etc..) and/or for other purposes.

This entering of the tare weight could actually be done automatically, for example trough some bar (or other) code or shape interfacing between the container and the scale, for example by the positioning of a hole/or a slip on the container base, which would activate a sensor in the scale.

(Fig. 3) The product loaded inside the container could also be memorized automatically, for example through the use of an electronic chip 33, similar to those embedded in credit cards, embedded for example in the container base's, under the spout7.

This chip, which would be pre-programmed with the size of the container 1 , would load and memorize at the "distributor" 23 level the information on the product filled and then at the scale the other info, without the need for an intervention by the client, nor the mistyping errors expectable from him.

This chip could also be used to memorize its production date, location and batch number of the container base and any info on its history (including for example its use for the purchase of a non-edible product) to be able to trace a quality problem with the container and/or to phase it out, to perform statistics, etc...

The label produced by the scale could include all the information on the product actually bought by the client, including not only the same a/m standard markings as for the fruits and vegetables but also the tare weight used (So that the cashier may check it and compare to the type of packaging presented) and the weight of 0.1 liter of product (So that the client may evaluate the weight of product corresponding to the volume graduations engraved on the container).

(Fig. 3) The stick-on label 32 would need to be applied over the container's lip, as a kind of seal, to prevent its accidental opening (or tampering).

It could therefore remain square, provided it is (possibly printed) and applied as a lozenge, with the angle overlapping the spoutshowing the full product name and packing date, so that these be readable when the containers are stored vertically on an upper shelf (Fig. 3).

By the way, the best guarantee that the client removes earlier labels is that the weight stated on these would otherwise be counted as product and charged as such! (Fig. 12) It is to be noted that, with this chip 33 system, the actual weighing of the product and issuance of the label could also be done either at the same location as the "distributor" 23, on a reading interface 35, or by the cashier equipped with a chip reader.

Furthermore, by using the embedded chip system in coordination with a telling machine, reading a cash or credit card (possibly proprietary to the retailer) bearing the name, coordinates and(/or only) the account number of the owner of the container, possibly accessible (and changeable) after typing a password, one could save on labels and handling time and automate the whole process, opening the way for decentralized cashier-free distribution centers.

Ultimately, the use of the embedded chip system, together with a "home chip reader", could allow additional information such as detailed information on the country of origin, the producer, as well as recipes, serving suggestions, etc. as well as advertising for the product, the store, coming promotions, etc. and relevant web addresses, etc., to be loaded on the chip at the time of filling by the "distributor" interface 35 and read at home on the family computer.

In certain cases where the retailer (or the distribution center) cannot or doesn't want to make available to his clients free, thin poly-bags and/or containers, a scoop could be used, to receive the product from the "distributor" and to weigh it on the scale, adjusted to take into account the scoop's tare weight, which would be preferably the same as containers (The scoop could actually be a container base with a top glued under its bottom, the weight of the glue being offset by cutting-off a small part of the top).

The client could then empty the scoop in his own packaging and stick on it the label produced by the scale. In the case of coffee in beans, either the "distributor" would be fitted with a grinder, or the grinding could be done by the client, after the cash-register (like it is done now in some Swiss supermarkets), in which case the existing grinders might need to be fitted with the same mouthpiece as a "distributor".

The scale's program will indicate at any time the filling status of each silo, and therefore would indicate in advance when a silo needs to be refilled.

It will also, in combination with the cash register's program, allow the storekeeper to view in detail (and possibly act to correct) the discrepancies evidencing the eventual errors (deliberate or not) done by the clients.

(Fig. 15) The bin refilling would be done preferably directly from a bag storage, in a hopper 36 to be located on a floor positioned just over the silos or, for the larger installations, via an air-blow refill system, similar to that used on the trucks used to deliver flour to the bakeries.

(Fig. 16) This refill could also be done by bringing down the Silos into the alley, with a simple lift mechanism and pouring in the contents of bags of the relevant product.

In such a case the capacity of the silos should be large enough to prevent too frequent refills during opening hours.

The contents of the silos could be protected from pests and germs through the use of an adequate stainless steel grate and possibly through the use of fumigation and/or gas injection.

It should also be noted that part of or all the Self-Service System and Containers can also be used for other distribution outlets, for example for (emergency) food distribution, by consumer cooperatives, or by the catering industry, for example to store (in bins) and distribute "portions" of solid or liquid raw materials.

One could for example install the silo bins directly in the kitchen of a large restaurant or of a catering company.

In addition to the benefits of avoiding unnecessary packaging and/or spoilage, the Self-Service System would also offer to the catering company a better inventory planning and accounting than with a traditional system.

In such cases, the plastic containers could be replaced by a range of stainless steel containers, with a wider volume range (for example, from 0.25 liters to 5 liters), since the actual product weighing would be secondary, i.e. would not be required.

The Self-Service System could actually be used in any location where there is a need for distribution of liquids or free-flowing solids in "standardized" portions, such as for example coin-operated or industrial laundries, to distribute washing powders and liquids, etc....

Claims

1. Container (1) comprising a bottom (14), a panel (3) and a lid (2), said lid (2) comprising a groove (4) adapted to receive the panel open end (16), characterized by the fact that the interlocking zone (5,15) defined by said panel open end (16) and said groove (4) is not completely included in the same plane.

2. Container (1) according to claim 1 furthermore comprising a spout (7), said lid (2) being designed to also cover said spout (7).

3. Container (1) according to claim 2 wherein the spout interlocking zone (5) is not in the same plane as the remaining interlocking zone (15).

4. Container according to claim 3 wherein said spout interlocking zone (5) is curved downwards.

5. Container according to anyone of the previous claims wherein the lid (2) is designed to be easily removed or partially removed and easily replaced on the panel open end (16) in order to close the container (1).

6. Container according to anyone of the previous claims wherein the panel (3) is made of transparent material and comprises marks which indicate the volume and/or the weight of common products such as sugar, flour or rice.

7. Distribution system designed for filling or refilling a container as defined in any of the previous claims wherein said distribution system comprises a silo-type storage bin and a distribution line such as a pipe, the free end of said distribution line being adapted to dispense said container with the stored content.

8. Distribution system according to claim 7 wherein said free end is designed to be tightly fixed to the container so that the container may be filled without leakage or spoilage.

9. Distribution network particularly designed for supermarkets comprising containers such as the ones defined in previous claims 1 to 6 and at least one distribution system such as the one defined in previous claims 7 or 8.

10. Distribution method for distribution stores such as supermarkets, said method consisting in using containers as defined in previous claims 1 to 6 and at least one refilling system as defined in previous claims 7 or 8 wherein the clients fill or refill their containers with the distribution system and then pay the corresponding quantity retrieved.