Modified Atmosphere Packaging Unit, Method for Manufacturing Such Unit, and Use Thereof

Abstract

The present invention relates to a modified atmosphere packaging unit, and method for manufacturing such unit and the use thereof. A modified atmosphere packaging unit according to the invention comprises: a product receiving body configured for holding a product, and having a bottom part and a wall part; a flange configured for attaching a seal thereon for closing the product receiving body; a seal or lid that is attached to the flange, wherein the product receiving body and the flange are a moulded fiber product comprising: an amount of plant-based fiber material; an amount of wet strength agent; and wherein the product receiving body and the seal or lid is provided with a biodegradable barrier-coating and/or a biodegradable barrier-film.

Claims

1. A modified atmosphere packaging unit comprising: a product receiving body configured for holding a product, and having a bottom part and a wall part; a flange configured for attaching a seal thereon for closing the product receiving body; and a seal or lid that is attached to the flange, wherein the product receiving body and the flange are a moulded fiber product comprising: an amount of plant-based fiber material; and an amount of wet strength agent, wherein the product receiving body and the seal or lid is provided with a biodegradable barrier-coating and/or a biodegradable barrier-film.

2. The modified atmosphere packaging unit according to claim 1, wherein at least a part of the amount of plant-based fiber material is microfibrillated cellulose.

3. The modified atmosphere packaging unit according to claim 2, wherein the amount of microfibrillated cellulose is in the range of 1.2 wt % to 10 wt % of the moulded fiber product.

4. The modified atmosphere packaging unit according to claim 1, wherein the moulded fiber product comprises an amount of biodegradable aliphatic polyester.

5. The modified atmosphere packaging unit according to claim 4, wherein the biodegradable aliphatic polyester comprises an amount of one or more of PBS, PHB, PHA, PCL, PLA, PGA, PBST, PBAT, PHBH and PHBV.

6. The modified atmosphere packaging unit according to claim 4, wherein the amount of biodegradable aliphatic polyester in the moulded fiber product is in the range of 0.5 wt % to 20 wt. %.

7. (canceled)

8. The modified atmosphere packaging unit according to claim 4, wherein the amount of biodegradable aliphatic polyester in the moulded fiber product is in the range of 0.1 wt % to 12 wt % of the unit.

9. The modified atmosphere packaging unit according to claim 1, wherein the plant-based fiber material comprises an amount of non-wood fiber material, wherein the non-wood fiber material comprises material from the family of Poaceae.

10. (canceled)

11. The modified atmosphere packaging unit according to claim 9, wherein the amount of non-wood fiber material is at least 5 wt. %.

12. The modified atmosphere packaging unit according to claim 1, further comprising an amount of calcium carbonate and/or calcium bicarbonate.

13. The modified atmosphere packaging unit according to claim 1, wherein the moulded pulp material comprises an amount of fibers, wherein at least 80% of the fibers has a length above 1.1 mm.

14. The modified atmosphere packaging unit according to claim 1, wherein the barrier-coating is a silicon based coating, wherein the silicon based coating comprises a silicon oxide and/or silane.

15. (canceled)

16. The modified atmosphere packaging unit according to claim 1, wherein barrier-coating comprises an amount of graphene, chitosan, alginate, wax, polyethylene, or silica gel.

17. The modified atmosphere packaging unit according to claim 1, wherein the product receiving body comprises a biodegradable multi-layer that is provided on the inner surface of the modified atmosphere packaging unit and comprising: an inner cover layer comprising an amount of a biodegradable aliphatic polyester; a first intermediate layer of a biodegradable material for connecting and/or sealing adjacent layers; a functional layer comprising a vinyl alcohol polymer; a second intermediate layer of a biodegradable material for connecting and/or sealing adjacent layers; and an outer cover layer comprising an amount of a biodegradable aliphatic polyester.

18. The modified atmosphere packaging unit according to claim 17, wherein the thickness of the individual layers is within the range of 1.5 to 50 ?m.

19. The modified atmosphere packaging unit according to claim 17, wherein the functional layer is positioned asymmetrically in the multi-layer.

20. The modified atmosphere packaging unit according to claim 1, wherein the product receiving body comprises a coating that comprises an amount of graphene.

21. A method for manufacturing a modified atmosphere packaging unit, the method comprising the steps of: providing a modified atmosphere packaging unit comprising; a product receiving body configured for holding a product, and having a bottom part and a wall part; a flange configured for attaching a seal thereon for closing the product receiving body; and a seal or lid that is attached to the flange, wherein the product receiving body and the flange are a moulded fiber product comprising: an amount of plant-based fiber material; and an amount of wet strength agent, wherein the product receiving body and the seal or lid is provided with a biodegradable barrier-coating and/or a biodegradable barrier-film; filling the product receiving body with the product; and sealing the product receiving body.

22. The method according to claim 21, wherein the step of providing the modified atmosphere packaging unit comprises dry forming using a dry fluffy pulp.

23. A method for using a modified atmosphere packaging unit comprising: a product receiving body configured for holding a product, and having a bottom part and a wall part; a flange configured for attaching a seal thereon for closing the product receiving body; and a seal or lid that is attached to the flange, wherein the product receiving body and the flange are a moulded fiber product comprising: an amount of plant-based fiber material; and an amount of wet strength agent, wherein the product receiving body and the seal or lid is provided with a biodegradable barrier-coating and/or a biodegradable barrier-film.

Description

[0088] FIG. 1A illustrates an embodiment of the packaging unit according to the present invention;

[0089] FIG. 1B illustrates a bottom view of the packaging unit of FIG. 1A;

[0090] FIG. 1C illustrates a stack of packaging units illustrated in FIG. 1A-B;

[0091] FIGS. 2A-B illustrates different views of an alternative packaging unit according to the present invention;

[0092] FIGS. 3A-B shows different embodiments of multi-layer that can be applied to the packaging units of FIG. 1 or 2 and further figures;

[0093] FIG. 4 illustrates an alternative packaging unit according to the invention for margarine according to the invention;

[0094] FIG. 5 illustrates a plate-shaped packaging unit according to the present invention;

[0095] FIG. 6 illustrates a ready-to-eat meal tray according to the present invention;

[0096] FIG. 7 illustrates a cup-shaped packaging unit according to the present invention; and

[0097] FIG. 8 illustrates a meat tray according to the present invention.

[0098] Packaging unit 2 (FIGS. 1A-C) comprises bottom 4 and side wall 6. Side wall 6 is provided with rim 8 that provides a surface for the top seal or lid (not shown). The corners of wall 6 are provided with supports 9 that also act as denesting features. Bottom part 4 is provided with additional supports 12 enabling the products to rest on supports 12 and provide an open space between bottom part 4 and the product in packaging unit 2.

[0099] In the illustrated embodiment height H of packaging unit 2 is about 32 mm. Packaging units 2 can be nested in stack 14. Pitch distance P between two packaging units 2 in stack 14 is in the illustrated embodiment about 3.5 mm. Height S of supports 12 is about 3.5 mm. Due to the angled side wall 6 and supports 9, side walls 6 of nested packaging units 2 are provided at a small distance d of about 0.3 mm. This enables effective denesting of packaging units 2 from stack 14. The inner surface of side wall 6 is provided with multi-layer barrier 10, 20 or coating 25.

[0100] Alternative packaging unit 22 (FIGS. 2A-B) is also provided with bottom part 24 and side walls 26. Side walls 26 and bottom 24 are provided with multi-layer film 10, 20, or coating 25.

[0101] In the illustrated embodiment laminated multi-layer 10 (FIG. 3A) comprising first cover layer 10a, first intermediate layer 10b, central functional layer 10c, second intermediate layer 10d, and second cover layer 10e. It will be understood that other layers can be added to multi-layer 10. It will be understood that laminated multi-layer 10 can be applied to the (illustrated) packaging units or to further alternative embodiments that are not illustrated.

[0102] An alternative biodegradable laminated multi-layer 20 (FIG. 3B) comprises first cover layer 20a, first intermediate layer 20b, first functional layer 20c, second intermediate layer 20d, central flexible layer 20e, third intermediate layer 20f, second functional layer 20g, fourth intermediate layer 20h, and second cover layer 20i. It will be understood that other layers can be added to multi-layer 20. It will be understood that laminated multi-layer 20 can be applied to the packaging units that are illustrated or are not illustrated.

[0103] Multi-layer 10,20 may comprise different materials and combinations as is described earlier. These embodiments have been tested and appear to fulfil the requirements in relation to the desired barrier properties. The thickness of individual layers can be determined taking into account the product that needs to be brought into the packaging unit, whereby it is possible to apply functional layer(s) that is/are positioned asymmetrically (i.e. somewhat out of the center of layer 10,20) in multi-layer 10,20.

[0104] Further alternative packaging unit 32 (FIG. 4) comprises bottom 4 and side wall 6. Food product 7 relates to margarine or butter. The inner surface of packaging unit 32 is provided with multilayer 10, 20 or coating 25. Opening 5 is covered by top seal 11 comprising multi-layer 10 being connected to flange 8, and optionally comprising another paper layer or other suitable layer. Additionally, lid 13 is provided that optionally can be positioned over seal 11.

[0105] Plate 42 (FIG. 5) is provided with bottom 4, sidewall 8 and flange 8 to which is connected seal 11. Lid or seal 11 can be manufactured from a multi-layer 10, 20, for example. Wall 6 and bottom 4 can be provided with multi-layer 10, 20 or alternative food with a coating 25 that in the illustrated embodiment preferably comprises an amount of graphene and/or is silicon based.

[0106] Ready-to-eat meal tray 52 (FIG. 6) comprises bottom or side walls 6. The inner surface of packaging unit 52 is provided with multilayer 10, 20 or coating 25. Connected to flange 8 is seal or lid 11 preferably from multi-layer material 10, 20 that in the illustrated embodiment is provided with window 54. Optionally, lid 11 is provided with an extension 56 to enable the user to remove seal or lid 11 from flange 8.

[0107] Cup 62 (FIG. 7) comprises bottom 4, wall 6, flange 8 and attached thereto seal or lid 11. Seal 11 and the inner surface of wall 6 and bottom 4 are provided with a multi-layer 10, 20 and/or coating 25. Optionally, extension 66 is provided to enable a user to open packaging unit 62.

[0108] Meat tray 72 (FIG. 8) provide with bottom 4, wall 6, product support 12 that supports food product. In the illustrated embodiment seal 11 is a transparent seal that comprises multi-layer 10, 20 and/or coating 25. Wall 6 and bottom 4 are provided with multi-layer 10, 20 and/or coating 25.

[0109] The MAP unit illustrated in FIG. 1A-C is used in a test. The surface of these packaging units is about 0.031 m.sup.2, such that 1 m.sup.2 of film equals 32 trays in total surface. Under normal conditions the barrier(s) limit the OTR to a maximum of 10 ml O.sub.2/m.sup.2.24 h, and limit the WVTR to a maximum of 6.4 g/m.sup.2.24 h.

[0110] Further tests with these packaging units were performed with the packaging unit comprising different multi-layers with EVOH as a functional layer. The top seal is manufactured from the same multi-layer. Results are shown in Table 1, including results after deep drawing the film, wherein the film comprises PE-EVOH-PE layers with intermediate tie layers.

TABLE-US-00001 TABLE 1 Multilayer PE/EVOH/PE Thickness OTR WVTR Thickness Multilayer micron EVOH ml/m2*24 h g/m2*24 hr 60 5 0.54 4.8 90 10 0.3 2.48 With the thinning factor 0.63 (after lamination) 37.70 3.14 0.9 8 56.55 6.30 0.5 4.1 *OTR at 23? C. and 0% RH *WVTR at 38? C. and 90% RH (tropical conditions)

[0111] To achieve a further increase in shelf life, depending on the food type and specific conditions, the EVOH barrier layer can be increased to 15 micron, for example.

[0112] Further tests have been performed with different embodiments of modified atmosphere packaging units. These tests were performed with different amounts of MFC, and are provided with or without the use of additional chemicals, specifically Xerolex and/or AKD.

[0113] Tests were performed with several MFC types, including with Bang & Bonsomer/Betulium MFC, two type MFC25 and MFC65 (sugar beet residue based), and MFC from COSUN/Duynie (sugar beet residue based) and MFC from Graanul, Biotech in Estonia (wood based). Stiffness and strength improvements in tensile strength were measured, in RCT Ring crush compression test (important cardboard parameter), in burst index and tear strength resistance. The improvement effects at dosage levels of 2% MFC (as received. 8-20% dry matter, so 0.16-0.4% wt %) are in the range of 10-30% improvement. The possible increase in roughness (Bendsten) for the packaging units that comprise MFC as compared to the reference packaging unit could be compensated by applying calcium carbonate or clay as filler. In particular, an increase of 10-30% (in ml/min at 0.74 kPa) was measured.

[0114] The results show the applicability of the packaging unit as MAP units.

[0115] The present invention is by no means limited to the above described preferred embodiments thereof. The rights sought are defined by the following claims, within the scope of which many modifications can be envisaged.