Packaging and method for plant matter

Abstract

Described is a packaging, and method and system for packaging an individual and single serving of plant matter, such as a cannabis flower. Also described are a method of making and using for the packaging.

Claims

1. A method for packaging and storing fresh plant matter in a single-use consumer package unit having a bottom component and a top component, wherein the bottom component includes an upper planar flange surrounding a plurality of molded compartments, the molded compartments being configured for and forming a plurality of separable single-use consumer package units for receiving and containing the fresh plant matter, said method comprising the steps: a) providing the bottom component comprising the plurality of molded compartments formed therein for receiving and containing a unit of fresh plant matter; b) providing the unit of fresh plant matter processed to fit within the molded compartments formed in the bottom component; c) placing the unit of fresh plant matter into said molded compartments of the bottom component; and d) vacuum sealing the package using a film component sealably affixed to the planar flange of the bottom component, whereby the film component forms the top component of the package unit.

2. The method of claim 1 further comprising the step of: washing and air-drying the fresh plant matter prior to placing the unit of fresh plant matter into said molded compartment.

3. The method of claim 1, wherein the method comprises the step of: spraying or fogging the plant matter with a preservative prior to sealing.

4. The method of claim 1, wherein the plant matter is cannabis.

5. The method of claim 1, wherein the plant matter is fruit prepared in single-serving slices.

6. The method of claim 1 wherein the shelf-life of the fresh plant matter is extended compared with the shelf-life of fresh plant matter that is not packaged by the method of claim 1.

7. A single-use consumer package unit having a bottom component and a top component, the bottom component comprising a plurality of molded compartments formed therein and a peripheral edge surrounding the molded compartments, the molded compartments being configured for receiving and storing fresh plant matter processed to fit within the molded compartments and wherein the single-use consumer package unit is vacuum sealed by a semi-permeable film forming the top component of the single-use consumer packaging unit.

8. The single-use consumer package unit of claim 7, wherein the semi-permeable film is releasably affixed to the planar flange formed on the peripheral edge of the bottom component surrounding the molded compartment.

9. The single-use consumer package unit of claim 7, wherein the fresh plant matter is cannabis.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a Product Data Sheet for a material used to manufacture the bottom forming film layer of the packaging.

(2) FIG. 2 is Product Data Sheet for a material used to manufacture the top non-forming film layer of the packaging.

(3) FIG. 3A is a plan view of a pocket formed in a bottom component or layer of the packaging;

(4) FIG. 3B is a top view of a pocket formed in a bottom component or layer of the packaging;

(5) FIG. 3C is a perspective view of a pocket formed in the bottom component or layer of the packaging.

(6) FIG. 4A illustrates a roller mechanism for forming a plurality of pockets in a sheet of bottom component material;

(7) FIG. 4B illustrates a molded pattern of a plurality of pockets formed in a section of bottom component material;

(8) FIG. 4C is an enlarged view of the inset B in FIG. 4B.

(9) FIG. 5 shows packaging specifications for a citrus fruit wedge, and illustrates an unsealed lip on one edge of the pocket for removing the top non-forming film layer from the bottom component for accessing a citrus wedge contained therebetween.

(10) FIG. 6 shows measurement of moisture content for the samples, stored in various packaging under various conditions.

(11) FIG. 7 shows a comparison of the ratio of THCA/THC for each sample.

(12) FIG. 8 shows a comparison of the total cannabinoid.

(13) FIG. 9 shows total terpene concentrations.

DETAILED DESCRIPTION OF THE INVENTION

(14) This invention relates to a packaging for storing, preserving, or serving individual units of fresh plant matter so that plant matter can be stored without appreciable degradation or deterioration of the plant matter, which can result in loss of natural flavor, appearance, texture, color, aroma, nutrients or other compounds preferably retained in the plant matter. The invention also relates to a method of and system for packaging fresh plant matter in individual units or a plurality of individual units. The packaged fresh plant matter single-use unit or plurality of units, and method of using the individual units of packaged fresh plant matter also form part of the subject invention.

(15) The term fresh plant matter as used in this application refers to plant matter immediately following harvest, or plant matter that has been harvested within a time period before packaging wherein the plant matter has not undergone substantial degradation or deterioration such that the degradation or deterioration negatively affects the desired quality or characteristics of the plant matter. The degree of freshness of the plant matter can depend on the type of plant, the conditions of harvest or storage conditions immediately following harvest, and other environmental factors that affect degradation or deterioration of the plant matter to be packaged. Preferably fresh plant matter is harvested plant matter that is packaged within a week of harvest, more preferably within about 72 hours of harvest; even more preferably within about 48 hours of harvest, still more preferably within about 24 hours of harvest, and most preferably from immediately following harvest to within about eight hours of harvest. The packaging and methods described herein are described using as an example the packaging of cannabis, more specifically, a cannabis flower, or a citrus fruit wedge, such as a lemon wedge. However, it would be understood that the method, system or packaging described herein can be applied to other plant matter susceptible to rapid loss of freshness or at risk of contamination due to handling, such as spices or herbs or other fresh fruits or vegetables, without detracting from the scope or concept of the invention.

(16) The subject invention concerns a packaging comprising a first bottom component or layer, or forming film having formed or molded therein a recessed area or pocket for receiving a single unit of fresh plant matter. In a preferred embodiment, the recessed pocket is formed in a shape substantially and depth conforming to the shape and dimensions of the fresh plant matter. In a preferred embodiment, the forming film layer is a plastic sheet material, approximately 3.0 to 5.0 mils in thickness so that it can be molded into and retain a desired shape by a heating process, known in the art as thermo-formed. The shaped pocket is formed using a mold designed for forming the desired shape and size of the pocket. This bottom component of the packaging can be conveniently referred to as the tray portion of the packaging.

(17) It would be understood that the bottom component or tray formed thereby can be a flexible film material, a semi-rigid plastic layer, or a rigid plastic layer, so long as a pocket can be readily formed in the material, e.g., by a mold process. The thickness and rigidity of the bottom component or tray is limited only by what is practicable for use with fresh plant matter; and dimensions and rigidity limited by weight considerations for shipping and storage.

(18) One embodiment of the subject invention includes a bottom component comprising a laminated material such as rollstock forming film having specifications as described and shown in FIG. 1.

(19) F LBN 3.5 M is a coextruded flexible forming film for protective packaging of products which need medium barrier to oxygen. F LBN 3.5 M is a high performance multilayer film designed for vacuum pack applications and is ideal for gassy cheese products. The film clarity allows for visibility of package contents. The Metallocene LLDPE sealant provides a low seal initiation temperature with a broad process window. The nylon skin and core layers provide strength and durability with intermediate oxygen barrier. Packaging equipment include Thermoformable HFFS equipment (Multivac, Triomat, Rapidpak, Hopper, Mahaffey & Harder, etc).

(20) The bottom component, when formed, can be formed to retain a planar flange on its peripheral edge onto which is sealingly disposed and affixed a top component, or non-forming film layer, following filling of the pocket with a unit of the fresh plant matter. In a preferred embodiment, the top component is about 2 to 3 mils in thickness and is semi-permeable, meaning that the top non-forming film layer is impermeable to harmful organisms and moisture, but may be permeable to gases so that natural emanations from the unit of fresh plant matter do not build up inside the sealed pocket. In addition, the top non-forming film layer can be releasably affixed to the planar flange of the bottom forming film layer, or tray, such that the top component may be removed for accessing and serving an individual unit of fresh harvested plant matter. Specifications for a laminate film useful for the top component of the packaging are exemplified in FIG. 2.

(21) The laminate film is a clear-seal non-forming film which is a flexible web designed for frozen products. The film provides optimal oxygen permeability for vacuum packaged steaks which are quickly frozen to maintain bloomed color throughout distribution. The clarity of this film allows for visibility of package contents. Clear Metallocene Plastomer sealant is suitable for use with a wide variety of forming films. It is designed to provide strength and durability with ideal Oxygen permeation. Packaging Equipment include Thermoformable HFFS equipment (Multivac, Tiromat, Rpidpak, Hooper, Mahaffey & Harder, etc).

(22) The pocket formed in the bottom component of the packaging is illustrated in FIG. 3A, FIG. 3B and FIG. 3C. FIG. 3A illustrates the atypical depth of the pocket formed in the bottom component to hold a single wedge of lime. FIG. 3B shows a top view illustrating the shape and dimension of the pocket opening, and FIG. 3C illustrates the pocket in perspective view.

(23) In a more preferred embodiment, and as illustrated in FIGS. 4A and 4B, the bottom forming film component is manufactured to comprise a plurality of recessed areas or pockets, each for receiving a single slice of citrus wedge. The plurality of pockets can be formed in a single sheet of material, as illustrated in FIG. 4A. The bottom forming film component can be perforated or relief cut for separating the plurality of pockets into individual rows of trays (see ZZ CUT in FIG. 4B), or individual trays, each having a releasably sealed or resealable top component disposed onto the corresponding bottom component. Alternatively, the top component can be permanently sealed to the bottom component, whereby access to the individual unit of fresh plant matter contained within the pocket is gained by cutting or tearing of the top component material. Pre-formed perforations or weakened areas can be provided in the top component to facilitate easy access to the contents. FIG. 4C shows a close-up of inset B in FIG. 4B, illustrating a printing free area for photocell detection.

(24) The method of packaging fresh plant matter according to the subject invention includes the following steps: 1. Freshly harvested plant matter is sorted into individual units capable of conforming to the size of the molded compartment formed within the bottom component of the packaging. 2. The sorted fresh plant matter can optionally be washed and dried, or further processed. For example, individual units of fresh plant matter can be cut or sliced, weighed or subjected to other pre-packaging techniques and apparatus known in the art. The individual units of fresh plant matter are then disposed into the thermo-formed, molded compartment of the bottom component of the packaging. Preferably, the molded compartment is consistent with the size and shape of the individual unit of fresh plant matter so that the whole individual unit of fresh plant matter fits within the molded compartment and the molded compartment is deep enough to prevent the unit of fresh plant matter from extending upwardly past the peripheral edge or flange of the bottom component. This can provide the advantage of a substantially flat or planar upper surface of the packaging, even when filled, that can allow for convenient stacking, storage, and shipping of a plurality of packaged plant matter units. 3. Prior to sealing the packaged unit of fresh plant matter with the cover material, the fresh plant matter can optionally be sprayed or fogged with a preserving agent. Preferably, the preserving agent comprises all natural ingredients and is compatible with the packaging material and its contents. For packaging of fruit wedges, for example, the preserving agent can be a blend of citrus juice capable of being applied via a fogging system.

(25) In use, for example, a licensed cannabis dispensary can obtain a plurality of cannabis flowers packaged individual single serving pouches or pockets in accordance with the subject invention.

(26) When a customer requests a certain amount of cannabis flowers, sealed packages containing single cannabis flowers may be provided for use by the customer. The customer may therefore use a single cannabis flower without exposing the rest to contamination or deterioration.

(27) The licensed dispensary is also not required to choose an individual cannabis flower from a container filled with individual cannabis flowers which may have been exposed to contamination and deterioration caused by exposure to air, humidity, heat, and light.

(28) Similarly, a restaurant can obtain a plurality of citrus wedges packaged individual single serving pouches or pockets in accordance with the subject invention. When a restaurant customer requests a lemon wedge for her iced tea, a sealed package containing a single lemon wedge is provided and is opened for use by the customer. The restaurant server is not required to slice a lemon to obtain the wedge, nor is the server required to obtain a single wedge from a bin filled with pre-sliced wedges which may not be fresh and may have been exposed to contamination from others.

EXAMPLES

Example 1Evaluation of Shelf-Life of Cannabis Flower in Specialized Packaging

(29) The shelf-life for cannabis flower was evaluated against various storage parameters, with ambient air (Ziploc bag), with specialized packaging under vacuum, with and without UV exposure, and room temperature or elevated temperature conditions. In addition, storage under refrigeration (4 C.) and freezer conditions (20 C.) were also considered. For the study, three key quality factors were used to assess the product stored under these conditions: cannabinoid concentration (CN), terpene concentrations (TP), and water activity or moisture analysis (WA). The sample and testing matrix are shown below in Table 1.

(30) Results from this testing are compared to data collected for an initial sample, collected at time zero, to monitor changes over time.

(31) TABLE-US-00001 TABLE 1 Sample and Testing Matrix Packaging Temperature UV Exposure 1 month 2 months 3 months Ziploc Bag ambient light CN, TP, WA CN, TP, WA CN, TP, WA Vacuum Packaging ambient light CN, TP, WA CN, TP, WA CN, TP, WA Vacuum Packaging 40 C. dark CN, TP, WA CN, TP, WA CN, TP, WA Ziploc Bag 4 C. dark CN, TP, WA Vacuum Packaging 4 C. dark CN, TP, WA Ziploc Bag 20 C. dark CN, TP, WA Vacuum Packaging 20 C. dark CN, TP, WA CN = cannabinoid analysis, TP = Terpene Analysis, WA = Water activity (moisture analysis)
Packaging Methods

(32) Prior to all packaging, sufficient cannabis flower to complete all testing was sourced and homogenized, to ensure product consistency between the various packaging and storage conditions. Homogenized cannabis flower was separated into aliquots of approximately 2 grams, enough to complete testing at each time point. Nine flower samples were placed into individual Ziploc bags for the study. The remainder of the samples were packaged under vacuum in special packaging material.

(33) For the vacuum packaging, forming temperatures of 85 C. (upper preheat) and 90 C. (lower preheat) were used. Packaging was heated for 1.0 second, then formed for 1.5 seconds, with a seal time of 2.0 seconds using a total flat seal plate which was set to 140 C. The vacuum pressure was set to 200 mlb, with ball valves used to restrict or soften the vacuum to an actual level of approximately 75-80 mlb, with an upper vent delay of 0.05 seconds.

(34) Once all packaging was complete, samples were stored under the prescribed conditions. An additional aliquoted sample was submitted for immediate testing to establish the initial baseline values for cannabinoids, terpenes and moisture content, which will be used for comparison.

(35) Analysis Methods

(36) Cannabinoid analysis was performed using Ultra-Performance Liquid Chromatography (UPLC), with a photodiode array detector. Cannabinoid signals were verified by retention time in addition to UV spectral matching against a spectral library for reference compounds. Quantitation was performed against a calibration curve prepared from certified cannabinoid reference materials.

(37) Terpene analysis was performed by Gas Chromatography with Mass Spectrometric detection (GCMS). Samples were introduced into the chromatographic system using a Head-Space auto-sampler, for which the samples were incubated at elevated temperature to evolve volatile terpene constituents prior to injection into the GCMS. Terpene signals were verified by retention time in addition to mass spectral matching against a NIST spectral library for reference compounds. Quantitation was performed against a calibration curve prepared from certified terpene reference materials.

(38) Moisture analysis was performed using a dew point moisture analyzer to measure water activity (Aw). Water activity measurements were calibrated relative to an external standard of magnesium nitrate as a saturated solution with a water activity (Aw) of 0.592. Recorded water activity values were converted to moisture content (% moisture) against a cannabis isotherm-adsorption curve.

(39) Analysis Specific Comments

(40) Moisture ContentAs both cannabinoid and terpene concentrations are reported relative to the mass of the sample, which will be impacted by moisture content, understanding of overall moisture content for the individual samples is important in understanding all analytical data. Measurement of moisture content for the samples, stored in various packaging under various conditions are shown in Graph 1 (FIG. 6) below:

(41) Graph 1 (FIG. 6)Over the course of these experiments, all samples reached approximately the same level of moisture content, with the sample held at 40 C. reaching the equilibrium moisture content the fastest. As the packaging material has been designed to breathe, this is not unexpected, permitting the sample at the higher temperature to dry more quickly than those held at ambient temperatures.

(42) Cannabinoid ContentAs samples were held under both ambient (room temperature) and elevated temperature (40 C.), it was anticipated that at the elevated temperature, the THCA, the acidic form of the cannabinoid, would be converted or decarboxylated to THC, the neutral form of the cannabinoid. This is highlighted for these samples by comparing, for each sample, the ratio of THCA/THC, as shown in Graph 2 (FIG. 7).

(43) For the sample held at 40 C., significant decarboxylation was observed over the first month. The sample stored in vacuum packaging at ambient conditions was fairly stable for the first two months, with more evidence of decarboxylation visible after the second month. For the sample stored in Ziploc bags under ambient conditions, an increase in the ratio of THCA/THC is observed. This can be accounted for by comparison of the total cannabinoid, shown in Graph 3 (FIG. 8), which shows for this sample a decrease in total THC. For this sample, the degradation of THC was more rapid than the degradation for THCA, resulting in the increase in the THCA/THC ratio. This is most likely a result of oxidative degradation of the cannabinoid in the Ziploc bag, which was reduced for samples packaged under vacuum conditions.

(44) During the decarboxylation process, there is a loss of a carboxylic acid group from the acidic form of the cannabinoid, such that the resulting neutral product weighs less than the original cannabinoid by a factor of 0.877. To account for this weight loss, the Total Cannabinoid concentrations are calculated by summation of all the acid concentrations, multiplied by this loss factor, then added to all the sum of all the neutral cannabinoids. This permits evaluation of products without the effects of conversion from one form of a cannabinoid to another. From the data shown in Graph 3 (FIG. 8), it can be seen that for several of the samples, there appears to be more total cannabinoid at the time of measurement, than what was present initially (represented by the horizontal line). This is, in part, a result of the loss of moisture, which would result in higher values than initially recorded. Even in consideration of the moisture loss, there is evidence of cannabinoid degradation for most packaging/storage conditions. It appears that there is a slightly more rapid degradation for samples in the Ziploc bags, as mentioned previously, most likely due to oxidative degradation. Included in the graph are additional results for samples stored under freezer (20 C.) or refrigerated (4 C.) conditions. Under each condition, the sample packaged under vacuum retained more total cannabinoid than sample packaged in Ziploc bags. As anticipated, the colder storage temperatures provide greater retention of the cannabinoids, relative to warmer temperatures.

(45) Terpene Content (FIG. 9Graph 4)Monitoring the terpene concentrations proved more challenging. Many of the terpene structures are very closely related, such that degradation of one terpene may result in the formation of another terpene. So like the cannabinoids, evaluation of total terpenes may be more indicative of overall performance under each condition. Like the cannabinoids, the reported values will also be impacted by changes in moisture, which resulted in values greater than the initial conditions for some samples. Under each storage condition, samples stored in vacuum packaging retained more overall terpene concentrations relative to samples stored in the Ziploc bags. This is not surprising, as terpene compounds are more prone to oxidative degradation than the cannabinoids. As was observed for the cannabinoids, samples stored at lower temperatures maintained higher concentrations of terpenes.

CONCLUSION

(46) From these evaluations, it appears that the vacuum packaging had slightly better performance in maintaining cannabinoid and terpene concentrations, relative to a standard Ziploc bag. But the differences did not, at lease during the first three months of this study, appear to be dramatic. There appears to be a general trend for all samples to degrade more with passing time, with a slightly higher rate of degradation for the less controlled Ziploc bag samples. The elevated temperature of 40 C. is typically used to evaluate product stability in an accelerated manner, with a 4 acceleration factor for product aging, for samples which would normally be stored under ambient conditions (room temperature). With that in mind, the results here indicate that for samples packaged under vacuum conditions, in the specialize packaging, the total cannabinoid values had good stability for the 3-months of the study, indicative of product stability for 12 months under normal storage conditions. When considering terpene stability, the concentrations were only stable over the first month, indicative of product stability for 4 months, with regard to the terpenes under normal storage conditions. For each time point considered, under each storage condition, the vacuum packaging performed better than the sample packaged under ambient conditions, in the Ziploc bags. This is most likely due to reduced oxidative degradation of the cannabinoids and terpenes for samples packaged under vacuum, relative to samples packaged with ambient air.

(47) This description and the accompanying drawings herein are exemplary and provided for purposes of describing and understanding the invention, and are not intended to limit the scope or spirit of the invention.