PACKAGING ADDITIVES AND METHODS

Abstract

Improved packaging system wherein a single absorber is sealed and attached to the product (e.g., food) container. The container may be a bag, trays, etc. The absorber would be attached by: a) placing an absorber on film while the film is being converted into a bag, or b) the bag customer could insert pod style absorber by sticking to an inner wall of bag. There could be two main styles of absorber pod: a) one that pod is premade and then either adhesive is used to attach to package or the pod is heat sealed to package, or b) individual pods are manufactured, and the user could install them inside the container in the same manners.

Claims

1. A consumer package, comprising: a flexible package forming an inner cavity for containing a perishable item and having a removable sealed opening to prevent an external atmosphere from reaching the inner cavity; a packaging additive pod with an active element therein positioned and secured on an inside wall of the package, the packaging additive pod having a gas-impermeable barrier separating the active element from the package inner cavity, the barrier having a portion that may be compromised, after opening the sealed opening, to expose the active element to the inner cavity.

2. The consumer package of claim 1, wherein the active element is an oxygen absorber.

3. The consumer package of claim 1, wherein the active element comprises a second component selected from the group consisting of desiccants, humectants, rust inhibitors and fragrances.

4. The consumer package of claim 1, wherein the active element is selected from the group consisting of desiccants, humectants, rust inhibitors and fragrances.

5. The consumer package of claim 1, wherein the wall of the package on the inside of which the packaging additive pod is positioned includes a transparent window, and the packaging additive pod is positioned so that the active element is visible through the window from outside the package.

6. The consumer package of claim 1, further including a film layer that forms the gas-impermeable barrier having outer edges secured to the inside wall of the package and forming a volume in which the active element is located.

7. The consumer package of claim 6, wherein the film layer is secured to the inside wall of the package with a peelable adhesive so at least a portion of the film layer may be peeled away manually to compromise the gas-impermeable barrier.

8. The consumer package of claim 7, wherein the active element is contained in a sachet which is also adhered to the inside wall of the package under the film layer.

9. The consumer package of claim 7, wherein the film layer has an edge region that is left unattached to the inside wall of the package that forms a pull tab for grasping and peeling away the film layer.

10. The consumer package of claim 6, wherein the film layer includes a strip contiguous with the film layer via weakened outer edges such that the strip can be partly or wholly separated from the film layer to compromise the gas-impermeable barrier.

11. The consumer package of claim 10, wherein the strip has a pull tab that is not adhered to the inside wall of the package that facilitates grasping and separating the strip from the film layer.

12. The consumer package of claim 6, wherein the film layer includes a line of weakness that can be ruptured to compromise the gas-impermeable barrier.

13. The consumer package of claim 12, wherein the line of weakness comprises a perforated line in the film layer.

14. The consumer package of claim 1, wherein the active element is held in place by a protective gas-permeable overlay adhered to the inside wall, the overlay being covered by a peelable layer of material that forms the gas-impermeable barrier so at least a portion of the peelable layer may be peeled away manually to compromise the gas-impermeable barrier.

15. The consumer package of claim 14, wherein the overlay is a mesh material.

16. The consumer package of claim 1, wherein the active element is directly attached to the inside wall and covered by a peelable layer of material that forms the gas-impermeable barrier so at least a portion of the peelable layer may be peeled away manually to compromise the gas-impermeable barrier.

17. The consumer package of claim 1, wherein the active element is held in a space between a barrier material underlayer and a peelable layer of material that forms the gas-impermeable barrier so at least a portion of the peelable material may be peeled away manually to compromise the gas-impermeable barrier, the underlayer being secured to the package inside wall.

18. The consumer package of claim 17, wherein the active element is held against the underlayer by a protective gas-permeable overlay adhered to the underlayer.

19. The consumer package of claim 1, wherein the active element comprises a sublayer adhered to the inside wall and having a gas-impermeable peelable layer that forms the gas-impermeable barrier adhered thereover.

20. The consumer package of claim 19, wherein the peelable layer has a tab that remains unattached to the inner wall and which can be grasped and pulled to peel all or a portion of the peelable layer away from the active element sublayer to compromise the gas-impermeable barrier.

21. The consumer package of claim 1, further including a vacuum port provided in a wall of the package enabling engagement of a vacuum pump to remove oxygen from the inner cavity.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Features and advantages of the present invention will become appreciated as the same become better understood with reference to the specification, claims, and appended drawings wherein:

[0015] FIGS. 1A-1C are front views of three different pods which may be used as packaging additives in accordance with the present invention;

[0016] FIG. 2 is an outer face view of a front wall of an exemplary packaging container in the form of a bag having one of the packaging additive pods from FIGS. 1A-1C fastened to an inner face behind a transparent window thereof;

[0017] FIGS. 3A and 3B show two steps in assembling a packaging additive pod of the present application to an inner face of a bag in accordance with the methods disclosed herein; and

[0018] FIGS. 4A and 4B are sectional views showing different ways to create the packaging additive pods of the present application;

[0019] FIGS. 5A and 5B are sectional views showing further ways to create the packaging additive pods of the present application;

[0020] FIGS. 6A-6C are sectional views showing an active element incorporated into a package film and covered with a peelable layer; and

[0021] FIGS. 7A and 7B illustrate two alternative packaging additive pods secured to an inner face of a bag.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] The present application provides solutions for assembling packaging additives into containers which avoids the problems of existing packaging additives. The solutions result in a premade package that comes with an attached packaging additive that can be activated by peeling, puncturing, or other such techniques to expose the active element to atmosphere, thus allowing element to begin functioning. A second option is a packaging additive that can be attached to an inner wall of a container that is still protected from atmosphere, wherein the packaging additive and the container could come from two separate locations.

[0023] FIGS. 1A-1C are front views of three different pods which may be used as packaging additives in accordance with the present invention. FIG. 1A illustrates an inner pod or sachet 20 having an oxygen absorber or deoxidizer as an active element. A circular bag or layer 22 either encompasses or covers the sachet 20 within the product container, as will be seen. The bag or layer 22 may have an outer border 24 with adhesive thereon, or that acts as a border for heat sealing or the like.

[0024] FIG. 1B shows both an inner pod or sachet 40 having an oxygen absorber or deoxidizer as an active element and a sachet 42 and carrying an oxygen indicator. A circular bag or layer 44 either encompasses or covers the sachets 40, 42 within the product container, as will be seen. The bag or layer 44 may have an outer border 46 with adhesive thereon, or that acts as a border for heat sealing or the like.

[0025] Finally, FIG. 1C shows an inner pod or sachet 60 having a dehumidifier as an active element. A circular bag or layer 62 either encompasses or covers the sachets 60 within the product container, as will be seen. The bag or layer 62 may have an outer border 64 with adhesive thereon, or that acts as a border for heat sealing or the like.

[0026] FIG. 2 is an outer face view of a front wall of an exemplary packaging container in the form of a bag 80 having one of the packaging additive pods from FIGS. 1A-1C fastened to an inner face behind a transparent outer window 82 thereof. The bag 80 is shown from a front side with the label indicating the product contents (e.g., beef jerky). This view may be just the front wall 84 of the bag 80, or may indicate the finished product with the rear wall heat sealed around the edges of the front wall and the product in the cavity therebetween. An optional vacuum port 85 is shown and will be described below.

[0027] The packaging additive pod is clearly visible through the transparent window 82 so that the pod may be clearly seen. This indicates to a food manufacturer that the pod is present, and once activated may also indicate the state of activation and also the presence of oxygen within the bag 80 if an oxygen indicator is provided. That is, some product packaging is done in a vacuum and then the container sealed so that there is no oxygen inside. An oxygen indicator may indicate tampering or otherwise that the container has been compromised so that oxygen is present.

[0028] FIGS. 3A and 3B schematically show two steps in assembling a packaging additive pod of the present application to the inner face of the bag 80 in accordance with the methods disclosed herein. First of all, just the front wall 84 of the bag is shown from an inner face, with the labeling shown reversed for clarity, though such may not be visible through the front wall. One of the sachets 20, 40, 60 described above with respect to FIGS. 1A-1C is shown in FIG. 3A being attached to the inner face of the front wall 84, and preferably within the transparent window 82. The sachet 20, 40, 60 may be attached via adhesive, thermal welding, or other such technique around the outer border to the transparent window 82. FIG. 3B then indicates a covering sheet or layer 86 attached over the sachet 20, 40, 60. The layer 86 represents a fluid- and/or gas-impermeable membrane that seals the sachet 20, 40, 60 within a pocket against the inner face of the front wall 84. (It should be noted that the membrane layer 86 is at least gas-impermeable. And may also be fluid-impermeable if used with food products with significant moisture content.)

[0029] When the rear wall (not shown) is attached to the front wall 84, such as by heat sealing around three edges, the sachet 20, 40, 60 is positioned in the inner cavity of the bag 80 thereby formed. Typically a top edge is left open so that the bag 80 can be filled with product such as beef jerky, and then the top edge is also sealed. This closes up the cavity of the bag, and seals the product as well as the sachet 20, 40, 60 inside. Because of the fluid- and/or gas-impermeable layer 86, the active element in the sachet 20, 40, 60 remains sealed from the external environment, even a vacuum environment within a sealed bag 80. Consequently, the active element within the sachet 20, 40, 60 is not activated.

[0030] Ultimately, the bag 80 may be sold in a retail establishment and opened up. The consumer can then remove the covering layer 86 to compromise the seal of the layer and activate the active element within the sachet 20, 40, 60. To facilitate this removal, an edge region 88 of the covering layer 86 may remain unattached to the inner face of the front wall 84. That is, for example, the covering layer 86 may be provided with an adhesive around its border but not in the edge region 88 to result in a loose flap which can be easily pulled away. Similarly, the covering layer 86 may be heat sealed to the inner face of the front wall 84 in a border region circumscribing the sachet 20, 40, 60 while the edge region 88 is left unattached.

[0031] FIGS. 4A and 4B are sectional views showing different ways to create the packaging additive pods of the present application.

[0032] In FIG. 4A, a pod 100 is constructed incorporating an inner wall of a bag or container A1. B1 indicates the active element or material. Protective overlay C1 allows the active element B1 to be exposed to atmosphere while holding the active element in place. For example, the overlay C1 could be a mesh material. The overlay C1 allows atmosphere to contact active element B1 within the container so that the active element can begin to function. Finally, layer D1 is a peelable barrier material that prevents the atmosphere within the container from contacting absorber until peeled, punctured, removed etc. When the impermeable layer D1 is removed, the seal over the active element B1 is compromised, while the overlay C1 keeps the active element B1 from falling, moving, shifting or otherwise becoming dislodged.

[0033] FIG. 4B shows a pod 102 similar to that in FIG. 4A, but without the protective overlay C1. The active element B2 may be directly attached to the inner wall A1 of bag or container A2, as shown. Layer D2 is peelable barrier material that prevents atmosphere from contacting the active element B2 until peeled, punctured, removed, etc., since the active element B2 is attached to the bag or container A2

[0034] FIGS. 5A and 5B are sectional views showing alternative ways to create the packaging additive pods of the present application.

[0035] FIG. 5A shows a pod 104 with a configuration similar to that in FIG. 4A, but with the addition of a barrier material underlayer A3 which is not part of the container inner wall. The inner face of the container wall is shown below and only used to support pod 104. The pod 104 could be shipped separately from the container and attached to the inner face of the container wall at any time while absorber is still protected from atmosphere. The style of FIG. 5A means that the pod is attached to the inside of container after the pod is assembled. Barrier layer A3 and layer D3 are fluid- and/or gas-impermeable and protect active element B3 from atmosphere until layer D3 is peeled, punctured, removed, etc. Overlay C3 allows the active element B3 to be exposed to atmosphere while holding the active element in place. For example, the overlay C3 could be a mesh material. Though a space is seen between the lower barrier material underlayer A3 and the container wall A1, the support pod 104 would, in use, be secured to the container wall. For instance, an adhesive between the two may be used.

[0036] Finally, FIG. 5B shows a pod 106 with the same as in FIG. 5A but with the layer C3 removed. The layer C3 is used to hold absorbent in place but is permeable and allows atmosphere to penetrate so absorbent can function. In FIG. 5B, on the other hand, the active element B4 is directly attached to barrier underlayer A4. Barrier underlayer A4 is then attached inside of container wall A1, as indicated, such as with adhesive or heat sealing.

[0037] Rather than add a free-floating packet/sachet in with the food, some manufacturers now add a layer of oxygen-absorbing film to the package itself. Multisorb Filtration Group of Buffalo, NY, supplies such films. The film is built into the package, so the customer is ignorant of the benefits unless notified. For instance, film may be impregnated with an oxygen-absorbing resin which is fully integrated into the package containing foods such as beef jerky, for example. It can be used in pouches, bags, lidding film, and flow wrap. However, these oxygen-absorbing films are exposed to the package contents from the moment the contents are sealed in the package, and once the customer opens the package the oxygen-absorbing capacity of the film is either removed or diminishes quickly. The present application contemplates delaying activation of an oxygen-absorbing film within a package until the customer opens the package and exposes the film.

[0038] FIGS. 6A-6C are sectional views showing a film package 120 incorporating an active element sublayer 122 sandwiched between a fluid- and/or gas-impermeable peelable layer 124 and a fluid- and gas-impermeable outer layer 126. The inside of the container (e.g., with the food contents) is up, and outside is down. The outer layer 126 may be a flexible film, or be a more rigid package wall to which the combined active element sublayer 122 and peelable layer 124 are adhered. The active element 122 may extend across the entire packaging, or may be segregated into just a portion of the sublayer, as indicated by the different cross-hatching.

[0039] The active element sublayer 122, which can be any of the variations discussed herein, remains enclosed between the two impermeable layers 124, 126 until the package 120 is opened by the consumer, thus preserving the efficacy of the active element sublayer 122. The customer is notified by labeling that there is an active element, such as an oxygen scavenger, within the package, and how to activate it. For instance, the peelable layer 124 may have a marked tab 128 that remains unattached and which can thus be grasped and pulled to peel the entire layer 124 or just a portion thereof, away from the active element sublayer 122. This compromises the seal of the layer 124 and exposes the active element sublayer 122 to the atmosphere within the container, and thus the active element begins to work. If the package is properly sealed after first use, the active element, say an oxygen scavenger, absorbs all the oxygen within the package and continues to do so upon repeated package openings since it is relatively fresh, not having been exposed to oxygen before. Although just two layers are shown, some oxygen-absorbing films may have up to 4 layers to which the gas-impermeable peelable layer 124 may be added.

[0040] FIGS. 7A and 7B are two alternative packaging additive pods secured to an inner face of a bag containing food or other perishable item. The figures are akin to that of FIG. 3B, showing the inside face of a bag having a visibility window and a sachets 20, 40, 60 described above with respect to FIGS. 1A-1C contained under a covering sheet or layer such as shown at 86 in FIG. 3B.

[0041] FIG. 7A shows a covering sheet or layer 140 with its outer edges secured via adhesive, welding, heat sealing or other means to the inside face of the bag, and the sachet 20, 40, 60 contained in a cavity therein. A central strip 142 is contiguous with the layer 140 via weakened outer edges. The edges may be perforated or otherwise weakened, but remain fluid- and/or gas-impermeable. For instance, the edges may be thinner than the surrounding portions of the layer 140. A pull tab 144 forms an extension of the strip 142 and extends away from the layer 140. The pull tab 144 is not adhered to the bag and therefor may be grasped to pull the strip 142 up and away from the rest of the layer 140. The pull tab 144 may alternatively be formed within the periphery of the layer 140, with the strip 142 not extending all the way to an edge of the layer 140. By grasping and pulling the tab 144 the strip 142 may be partially or completely removed, which compromises the seal of the layer 140 over the sachet 20, 40, 60. Due to the relative size of the strip 142, the majority of the layer 140 remains intact to contain the sachet 20, 40, 60 from becoming loose in the bag. This step is taken by the consumer after first opening the bag to expose the sachet 20, 40, 60 to the contents therein, thus enabling the sachet 20, 40, 60 to perform its preserving function.

[0042] FIG. 7B shows an alternative covering sheet or layer 150 again with its outer edges secured via adhesive, welding or other means to the inside face of the bag, and the sachet 20, 40, 60 contained in a cavity therein. A single line of weakness 152 such as a perforation or thinned area is formed, preferably across a middle section. The line of weakness 152 may extend across the layer 150 or along just a portion thereof. By rupturing the line of weakness 152 the sachet 20, 40, 60 is thus exposed to the contents of the bag. Again, the majority of the layer 150 remains intact to contain the sachet 20, 40, 60 from becoming loose in the bag. The line of weakness 152 may be ruptured by hand, such as by pulling it apart, or a tool such as a spoon may be used to form an opening therein.

[0043] Other ways to compromise the seal of the layer over the sachet 20, 40, 60 are contemplated. For instance, [Richard, please brain-storm alternatives and add them here.]

[0044] The present application thus discloses a product additive having an active element (informally, pods) protected from atmosphere. Various applications for the pods include: [0045] production could purchase containers with pods already attached. [0046] production could attach the pods to container and activate the active element during filling, or [0047] end user could activate after opening the modified atmosphere package at home to extend shelf life.

[0048] The present application focuses on bags but similar containers like trays would also work. The pods could also be attached by: [0049] placing a pod on film while the film is being converted into a bag; and/or [0050] the end user could insert a pod by sticking it to an inner wall of bag.

[0051] There could be two main styles of product additive pod: [0052] one that pod made using actual container wall as part of the protective barrier; and [0053] individual pods are manufactured, and a user could install inside the container.

[0054] Pods would consist of container side material, this could be the actual side of the package (the bag itself) next an absorber would be placed, a layer that would prevent the absorber from falling off but highly porous to allow oxygen to get to the absorber and finally a peelable outside layer that prevents the absorber from working. Outside layer can be pulled back either when the product is loaded or by the end user to extend product life after container is opened. Peelable layer should have a stronger seal on the opposite end, so material does not get lost in the package but stays part of the pod. Side material and peelable material would have a high oxygen transfer rate (OTR) to protect absorber from atmosphere until peeled exposing absorber to atmosphere.

[0055] A premade separate pod could be manufactured that consist of package side layer, absorber, absorber holding layer and peelable layer. Customers could then open container and apply pod to side of container themselves.

[0056] Multiple pods could be placed in the containers, one activated when product is filled, and the second pod activated when consumer has opened package and wants to reclose. Reclose can be zipped or sealed.

[0057] A zipper to expose the active element instead of a peelable film so either would work, though a peelable film would expose more surface area to absorber to allow absorber to work faster. The bottom line is that the active element must be protected from exposure to the atmosphere within the product container until its use is needed. Various ways to first contain or protect an active element and then expose it are contemplated. For example, the active element could be enclosed within a layer having a weakened section, such as a perforation, which can be easily compromised by a manufacturer or end consumer. Alternatively, a Ziploc type of removable seal could be used. Still further, the layer protecting the active element could be punctured using scissors or other such external instrument, with instructions thus provided. It should be understood that the term compromised will be used to encompass the various methods of severing or removing protective layers.

[0058] Colored sensors could also be placed on the pods that change colors when exposed to oxygen showing a pod has been activated. Sensor could actually be shown through a window of clear material to outside of package.

[0059] Modified atmosphere packages (MAP) are so-called because as much ambient atmosphere from the package is removed by vacuum and then a gas such as nitrogen is inserted to dilute atmosphere in a package. The application of a vacuum by itself can only reduce the oxygen level so far. Tests have shown that even with vacuuming and nitrogen flushing of a bag, for instance, the internal atmosphere only gets to about 1% residual oxygen. Even if the vacuum/gas insertion is repeated several times, it is difficult to get to 0% oxygen. Scavengers come in handy to remove most or all of the remaining oxygen in a MAP. Sometimes when items like meat or fish are packaged, a blend of gases are used to assist in preserving color, texture, etc., for a different type of MAP.

[0060] The package (bag/pouch/container) may also have a vacuum port 85 (see FIG. 2) for application of a vacuum to pull the inner package atmosphere down to a miniscule level of oxygen, and then the absorber/scavenger can finish removal to 0% percent oxygen. Small vacuum pumps that engage the port 85 are available, as well as automated systems with more robust vacuum pumps. The vacuum will remove most of the oxygen, thus allowing the use of less oxygen absorber material. Addition of an oxygen absorber/scavenger lowers the oxygen level down to 0%.

[0061] Coffee is a good project because many times coffee is packed right after roasting. Fresh roasted coffee outgases and when a bag has a one-way valve does a natural MAP. Just outgassing alone can get a package down around 4% oxygen. With the addition of a scavenger, we can get below 0.5% and sometimes zero; this required no vacuum/gas flush sealing.

[0062] While the invention has been described in its preferred embodiments, it is to be understood that the words which have been used are words of description and not of limitation. Therefore, changes may be made within the appended claims without departing from the true scope of the invention.