Foodstuff tray

Abstract

Plastic tray (1) for foodstuffs, comprising a bottom region (5), perimeter walls (6) extending upwards from the bottom region (5) and delimiting an internal volume (8) for receiving foodstuffs, and a perimeter flange (7) which extends horizontally outside said receiving internal volume (8), defines the access opening (20) of the tray (1) and has an abutment surface (9) against which a plastic sealing film (11) can be sealed, at least one removable transverse shelf (10) being provided in the tray (1) and dividing the internal volume (8) of the tray.

Description

“FOODSTUFF TRAY’’DESCRIPTIONField of Application

[0001] In its broadest sense, the present invention relates to food packaging, in particular to a tray for packaging perishable foodstuffs and, more specifically, sliced perishable foodstuffs, which are normally packaged in plastic trays sealed with plastic films.

[0002] The present invention finds its preferred, though not exclusive, application in a thermoformed tray for packaging sliced foodstuffs, particularly in a modified atmosphere (MAP), to which reference will be made below without thereby losing generality.

[0003] The present invention also relates to a method of filling foodstuff trays and packaging them in a modified and / or controlled atmosphere.Background Art

[0004] The use of containers made of plastics or other materials suitable for packaging foodstuffs, is currently quite widespread, especially for retail sales in supermarkets.

[0005] In common practice, plastic trays, such as thermoformed or injection-moulded trays, are used to package products, particularly foodstuffs.

[0006] A foodstuff tray typically has a substantially polygonal bottom region, with a plurality of side walls extending upward from a peripheral edge of the bottom region and with a perimeter flange. The peripheral flange generally extends horizontally outward from the side walls and is adapted to define a horizontal closure surface for the application of a heat-sealable foil or film.

[0007] A conventional food tray typically has a round, rectangular, or square shape and is typically heat-formed from a sheet of transparent plastic material. This plastic material generally consists of a main layer of polyethylene or equivalent materials, which forms the inner surface of the material in contact with the foodstuff, and a plurality of barrier layers superimposed on each other on a surface of the main layer facing the outside of the tray. These barrier layers are designed to reduce, or substantially eliminate, the permeability of the material to external agents (in particular light and oxygen), in order to improve foodstuff preservation. The bottom region of the tray is generally provided with raised areas or ribs, which have the dual purpose of improving the rigidity of the tray, reducing its bending when it is picked up manually, and giving the foodstuff, for example sliced cured meat, a “wavy” effect that increases the appeal of the final package.

[0008] Typically, these ribs run parallel to the longer side of the bottom region of the tray, so as to stiffen said bottom region longitudinally, i.e., in the direction along which the trayis most prone to bending.

[0009] The walls of the tray are also generally provided with reliefs, ribs, or knurling, which extend from the bottom region of the tray towards the upper flange along the aforementioned walls, in order to increase the mechanical rigidity of the tray while essentially using the same amount of raw material.

[0010] In order to reduce material consumption, and therefore the environmental impact of the trays and their cost, it is desirable to reduce the thickness of the material itself as much as possible. However, this requirement conflicts with the need to maintain or, possibly, improve the mechanical rigidity of the tray.

[0011] Another aspect to consider when manufacturing foodstuff trays is their ability to extend as much as possible the shelflife of the foodstuffs contained therein, i.e., the period during which the food retains its organoleptic, nutritional, and hygienic characteristics substantially unchanged and retains an appearance as identical as possible to that of the fresh product, in order to maximize the profitability of all entities involved in the distribution chain.

[0012] In order to increase the shelf life of products while ensuring good tray rigidity, the latter are equipped with an EVOH polymer (ethylene-vinyl alcohol) barrier film, a material known for its exceptional ability to reduce gas permeability, which has a high degree of resistance to atmospheric agents, preventing the penetration of oxygen and other contaminants into the food trays.

[0013] As is known, oxygen (02) causes food to deteriorate due to oxidation and creates ideal conditions for the growth of aerobic microorganisms. As a result, oxygen is frequently excluded from modified atmosphere packaging (MAP).

[0014] Beside the materials used to make the packaging, the environment in which foodstuffs are stored is also a critical factor in the preservation process. Not only is it important to maintain an adequate temperature, but the molecular and chemical content of the gases surrounding the foodstuffs is also significant.

[0015] Nowadays, indeed, in order to extend the shelf life of foodstuffs while preserving their organoleptic characteristics, flavour, and freshness, modified atmosphere packaging (MAP) is increasingly being used. This slows down chemical, physical, and microbiological processes, thus preventing rapid deterioration in product quality.

[0016] Modified atmosphere packaging (MAP) involves hermetically sealing trays containing foodstuffs and replacing the air inside them with certain gases known as packaging gases, which may be pure or mixed, depending on the foodstuff to be preserved.

[0017] To carry out modified atmosphere packaging (MAP), special machines are used consisting of a suction pump that creates a vacuum in a “bell jar” in which the product is placed, having been previously inserted into the still-open package.

[0018] After extracting the air contained inside the package by using a vacuum pump, a mixture of packaging gases is injected to occupy the volume initially occupied by the air. At the end of this procedure, the package is hermetically sealed using a heat-sealed plastic film.

[0019] Replacing the air inside the tray with a packaging gas creates a so-called “modified atmosphere,” which preserves the characteristics of the foodstuffs; for example, carbon dioxide dissolves in the water and fat of the foodstuffs, thus allowing lowering the pH.

[0020] A low pH allows for better food preservation as it inhibits bacterial activity and the growth of molds, thus creating an environment that is hostile to their proliferation.

[0021] Gases defined as packaging gases are listed and approved as food additives in Regulations EC 178, EC 1935, and EC 2023. Among the most commonly used gases are carbon dioxide (CO2), oxygen (02), and nitrogen (N2), as well as carbon monoxide (CO), argon (Ar), helium (He), and nitrous oxide (N2O), or appropriate mixtures thereof.

[0022] It is well known that there are essentially three packaging techniques for packaging foodstuffs in a modified atmosphere. The first technique involves the use of a plastic tray, on the bottom of which the foodstuff is placed. The tray is then sealed with a gas-permeable film and placed inside a gas-impermeable bag.

[0023] The air contained inside the bag is then replaced with a packaging gas mixture (usually nitrogen and carbon dioxide), possibly applying vacuum and then introducing the aforementioned packaging gas mixture.

[0024] The second technique, instead, involves the use of a plastic tray coated on the outside with a gas-impermeable film.

[0025] The foodstuff is placed on the bottom of the tray, which is then sealed with a gas-impermeable plastic film.

[0026] In this case too, before the tray is completely sealed, a modified atmosphere (MAP) is introduced inside it in the manner mentioned above.

[0027] The third technique involves the use of a plastic tray, made gas-impermeable by coupling a gas barrier film to the inner surface of the tray.

[0028] Before sealing said tray with a gas barrier film coating, the air contained in the package is replaced with a suitable gas mixture.

[0029] One problem encountered with the first two techniques mentioned above is the impossibility of completely removing oxygen from the internal atmosphere of the tray, as the closed structure of the plastic trays retains air, despite the application of vacuum, gradually releasing it into the space where the foodstuff is subsequently stored.

[0030] One disadvantage of the third technique mentioned above is the time required to evacuate the air from the tray, which is very long and therefore negatively affects production costs, without achieving low levels of residual oxygen inside the package.

[0031] Furthermore, the standard dimensions of food containers in general, as well as the dimensions of commercial plastic trays, are pre-established and bound by industry standards such as the Gastronorm (GN) standard to meet the dimensional requirements for compatibility with refrigerated display cases and large-scale retail display cases.

[0032] Furthermore, the intrinsic characteristics of certain foodstuffs dictate the type and shape of tray to be used for a given foodstuff.

[0033] As an example, consider the trays used for modified atmosphere packaging (MAP) of certain sliced foodstuffs, in particular sliced cured meats and sliced cheeses.

[0034] In general, cured meats are cut into thin slices, as the thinner the slice, the more the flavours of the cured meat are enhanced. Furthermore, thinly cut slices are particularly sensitive to contact with other slices, as contact promotes oxidation and souring thereof.

[0035] Sliced cured meats are also prone to being squashed, so it is preferable to package them in single layers to prevent the slices or layers of slices from squashing each other and negatively affecting their texture, fragrance, and typical aromas.

[0036] To avoid the above inconveniences, the trays for cold cuts are smaller in size and capacity, as the intrinsic characteristics of the foodstuff make it inadvisable to package sliced cured meats in multi-layer packages.

[0037] In view of the above, the trays for sliced cold cuts have a limited capacity for each tray.

[0038] Document TW201808741A describes a foodstuff tray comprising at least one foldable perforated divider capable of dividing the internal space of the container so as to create different sub-volumes for storage. It is clear that the solution proposed in the Taiwanese document is not ideal, as any impurities, leaks, or drainage from the food contained in a given sub-volume can spread through the holes in the dividers and compromise the food contained in the adjacent sub-volume. Furthermore, when foodstuffs are present across the entire surface of a perforated divider, all the holes are blocked by the foodstuff itself, making it impossible to connect the various sub-volumes and obtain a traysuitable for modified atmosphere packaging.

[0039] Document US2016005990A1 describes a collapsible food tray designed to accommodate collapsible dividers inside it.

[0040] However, it is clear that, being a foldable, resealable tray, it is not suitable for modified atmosphere packaging as it cannot guarantee an oxygen-tight seal, particularly at the joints.

[0041] Document US4003490A describes a container for yogurt and / or cheese whose internal volume is divided into two chambers connected by a divider that serves to define the two chambers and provide communication passages between them.

[0042] Although the two chambers communicate with each other by means of the configuration shown, it is not possible to establish direct fluidic communication between the inlet of the container and its bottom, and therefore it is not possible to carry out packaging in a controlled atmosphere with low oxygen content.

[0043] US document US5698250 describes a plastic foodstuff tray suitable for modified atmosphere packaging (MAP) containing chemicals known as “oxygen scavengers,” which neutralize residual oxygen inside the tray.

[0044] It is clear, however, that the solution proposed by said US document is not advantageous as it entails significant additional costs due to the use of these chemicals and also does not guarantee against contamination of the foodstuffs themselves.

[0045] Document WO9736504A1 describes a package suitable for packaging foodstuffs in a modified atmosphere (MAP) and composed of an internal container, represented by a plastic tray, suitable for holding the food and an external container, represented by a plastic bag, suitable for receiving the internal container and isolating it from the external environment.

[0046] However, the packaging described is inefficient as it is necessary to wash the internal and external containers independently before packaging.

[0047] Document IT202200012554A1 describes a tray for sliced foodstuffs that has low walls and therefore a reduced storage capacity.

[0048] In the light of the above-mentioned drawbacks, there is a need to provide the packaging sector with an improved tray for containing foodstuffs and similar products that can overcome the drawbacks encountered in the prior art.

[0049] A first object of the present invention is therefore to provide a tray -type container which is suitable for modified atmosphere packaging (MAP) and allows the foodstuff to be contained safely and stably inside it during transport and until the foodstuff is consumed bythe user, and at the same time allows the foodstuff to be easily extracted from inside the container, without altering the shape of the foodstuff, making the foodstuff suitable for being served in its original form.

[0050] Another object of the invention is to develop a container capable of allowing stacking both when empty and when filled.

[0051] A further object of the invention is to develop a container capable of achieving long shelf lives for the foodstuffs contained therein.

[0052] Another object of the present invention is to provide a tray for packaging foodstuffs which allows for efficient oxygen evacuation from the tray when modified atmosphere packaging (MAP) is performed and at the same time solves the problem of poor penetration of nitrogen and packaging gas mixtures in general into the tray during oxygen evacuation during modified atmosphere packaging (MAP).

[0053] Another object of the present invention is to provide a tray-type container for foodstuffs that is robust and compact, and at the same time capable of increasing the relative storage capacity of the single tray for the same dimensions without affecting the characteristics of the foodstuff contained within it, in particular for sliced cured meats.

[0054] A further object of the invention is to solve the problem of how to package foodstuffs, such as sliced cured meats, in such trays using an improved filling method.

[0055] Not least object of the invention is to provide a food tray that provides a solution to the aforementioned problems, to be produced using traditional plastic injection moulding methods and equipment, which is simple and economical and therefore suitable for industrial production at low costs.

[0056] To overcome the above-mentioned drawbacks of the known art, and to obtain these and further purposes and advantages, the Applicant has studied, tested and realised the present invention.Summary of the invention

[0057] The present invention is set forth and characterized in the independent claims, while the dependent claims set forth other preferred and non-essential features, or variations of the main solution idea.

[0058] The foodstuff tray according to the invention is used for the modified atmosphere packaging (MAP) of foodstuffs, in particular sliced foodstuffs, such as cheeses and cured meats, so as to ensure their longer shelflife and an aesthetically pleasing presentation of the foodstuff to the public.

[0059] The plastic tray for foodstuffs according to the invention comprises, in a mannerknown per se, a main body in which there are defined a bottom region, a plurality of perimeter walls extending upwards from the peripheral edge of the bottom region, and a perimeter flange defining an edge surrounding the tray access opening.

[0060] The tray according to the invention can have any geometric shape that has one or more perimeter walls extending upwards from the bottom region and ending with a perimeter flange.

[0061] Preferably, the surface subtended by the perimeter flange is greater than the surface area of the bottom region. Thus, the tray has, when in use, a shape that is substantially flared outwards and upwards. For example, the tray, when in use, can take the geometric shape of an inverted truncated pyramid.

[0062] When the tray lies on a horizontal surface, the bottom region has one or more reliefs extending upwards, i.e. towards the inside of the tray, and / or downwards, i.e. correspondingly towards the outside of the tray, which reliefs serve to stiffen the bottom region and provide support for the foodstuff that will be contained in the tray, also allowing air to pass between the foodstuff and the bottom region when the foodstuff is received inside the tray. These reliefs in the bottom region also preferably have an arched profile.

[0063] In a preferred embodiment of the invention, the bottom region is essentially quadrangular, and the tray comprises four perimeter walls extending vertically upwards from the bottom region. Preferably, the perimeter walls are joined to one another by inclined junction regions, which also comprise chamfered edges, for example 45° chamfered edges, inferiorly, i.e. at the bottom region.

[0064] The reliefs of the bottom region are preferably arch-shaped. Furthermore, preferably, the central reliefs of the bottom region have an "L"-shape, whereas the peripheral reliefs, which are located near the perimeter walls, define "C"-shaped recesses, opened towards said perimeter walls to form a perimeter channel located inside the perimeter of the bottom region and connecting said "C"-shaped perimeter recesses of the peripheral reliefs to one another.

[0065] The comer zones of the bottom region extend over the side walls of the bottom region up to a height that is approximately double that of the side walls.

[0066] The perimeter walls preferably have a substantially trapezoidal shape of a rectangular trapezoid with the base of the trapezoid having a shorter length at the side walls.

[0067] The perimeter walls of the tray according to the invention are joined to one another by rounded junction regions with a substantially semicircular profile.

[0068] The tray has a flared shape with a substantially quadrangular base.

[0069] In addition, advantageously, a plurality of vertical grooves preferably having a substantially trapezoidal cross-section extend on each perimeter wall.

[0070] Said vertical grooves are preferably provided along all the perimeter walls and preferably in an alternate succession obtained by a tilt in the plane and a 180° inversion of a vertical groove around its own axis relative to the adjacent vertical groove.

[0071] Each vertical groove defines a corresponding protrusion on the opposite face of the corresponding perimeter wall.

[0072] In addition, according to the invention, each protrusion facing the inside of the tray has at least one geometric discontinuity forming a corresponding step on which a substantially horizontal abutment plane is defined when the tray is in use, lying on a horizontal plane.

[0073] As will become more evident from the following description, according to the invention each abutment plane defines a corresponding support area for a removable partition shelf which can be housed in the tray.

[0074] Preferably the junction regions joining the perimeter walls of the tray also have at least a corresponding geometric discontinuity, analogous to the one of the vertical grooves, thereby creating a corresponding step defining an abutment plane comprising a support area for the partition shelf.

[0075] Advantageously, the discontinuities of the vertical grooves and the discontinuities of the junction regions are aligned to each other relative to a horizontal plane that runs transversely across the tray, so as to define altogether a discontinuous perimeter abutment for said removable shelf.

[0076] According to the invention, the step-like discontinuities are located in such a way as to ideally define a zone that separates the overall storage volume of the tray into smaller sub-volumes of smaller size and preferably different from one another.

[0077] In addition, still advantageously, said alternate succession of vertical grooves provides corresponding stiffening along the perimeter walls, which stiffening gives greater strength to the tray with the same thickness of the plastic walls.

[0078] The alternate succession of vertical grooves along the inner face of the perimeter wall also results in an alternation of corresponding recesses and reliefs along the outer face of the wall of the foodstuff tray.

[0079] The succession of recesses and reliefs provided on the inner face of the perimeter wall of the foodstuff tray is such as to define a plurality of upward channels extending vertically with their concavity facing the inside of the perimeter wall from the edge of theperimeter flange surrounding the access opening of the tray to the bottom region of the tray.

[0080] Advantageously, said upward channels are such as to fluidically communicate the upper part of the foodstuff' tray with the lower part of the tray when said parts are divided by a removable shelf and the tray is in its condition of use, arranged with its own base on a horizontal support plane, as will be evident from the following description.

[0081] The perimeter walls of the tray may further comprise a smooth junction surface portion for junction to the perimeter flange surrounding, in whole or part, the tray. This smooth junction surface portion joining the perimeter walls of the tray to the perimeter flange may represent a variable vertical extension depending on the design of the tray.

[0082] Furthermore, according to another embodiment of the invention, the perimeter walls may not have a smooth junction surface portion and may be connected directly to the perimeter flange.

[0083] The horizontal edge defined by the perimeter flange faces the outside of the tray and is also preferably turned downwards, thus forming a U-shaped section overall.

[0084] The upper plan face of the edge of the perimeter flange of the tray is suitable to define a corresponding adhesion surface for sealing the tray by means of a sealing element consisting, for example, of an adhesive and / or heat-sealable foil or film.

[0085] Advantageously, on the inner surface of the edge of the perimeter flange, at the comers thereof, there are formed concave recesses facing the inside of the tray.

[0086] Preferably, said recesses extend over the whole thickness of the inner surface of the edge of the perimeter flange of the tray.

[0087] This particular design of the inner surface of the perimeter flange forms insertion portions that allow the trays to be stacked inside one another, holding them firmly together.

[0088] The length, width and depth dimensions of the tray allow one tray to be inserted inside another, ensuring mutual stability between trays and allowing them to be stacked together, thus taking up less storage space.

[0089] Still according to the invention, the combination of at least one geometric discontinuity in each vertical groove and at least one corresponding geometric discontinuity in each semi-circular joint is suitable to define a discontinuous supporting surface for a corresponding removable shelf, plate or partition, capable of dividing the tray into separate compartments.

[0090] The removable shelf has a shape suitable to be received geometrically inside the foodstuff tray, in abutment against the surface of the step defined by the geometrical discontinuity of the grooves and joints.

[0091] Said shelf is preferably rigid or semi-rigid and has a plurality of recesses and reliefs designed to provide greater structural rigidity in order to provide stable support for the material that will be placed on the surface of the shelf.

[0092] Advantageously, the shelf further has a U-shaped perimeter edge, raised above the surface of the shelf and stiffening the peripheral surface of the shelf intended to rest on the discontinuous perimeter step of the tray. In addition, the perimeter edge of the shelf preferably has an inner contour wall forming a delimiting frame for the foodstuff contained on the shelf.

[0093] Said perimeter edge of the U-shaped shelf has a structure consisting of an alternation of concave recesses and convex protrusions that are shaped to come into mutual contact and mate with the vertical reliefs and recesses provided on the inner walls and with the corresponding upward channels of the foodstuff tray.

[0094] Advantageously, the concave recesses of the outer perimeter of the shelf are suitable to interfere with and press on the corresponding discontinuous surface of each relief provided on the walls of the tray and facing the inside of the tray.

[0095] Still advantageously, the convex reliefs of the outer perimeter of the shelf, which preferably have a polygon-like or semicircular shape, are shaped to cooperate with the upward channels of the tray so as to allow maintaining a fluidic communication between the volumes defined below and above the shelf and separated by the shelf.

[0096] According to another particular embodiment of the invention, if there are more than one geometric discontinuity in height and therefore more than one discontinuous perimeter step is formed, it will be possible to accommodate a corresponding number of removable shelves in the tray.

[0097] The interposition of one or more removable shelves inside the tray allows for compartmentalization into a plurality of sub-volumes defined respectively by the volume between the bottom region and a first removable shelf, by the volume between two removable shelves arranged inside the tray, and by the volume between a removable shelf and the tray-closing film-like foil arranged on the upper surface of the edge of the perimeter flange of the tray.

[0098] Each shelf inside the tray acts as a separator for the individual volumes inside the tray and as a mechanical support for the foodstuffs contained inside the tray.

[0099] The internal volume of the tray can therefore be advantageously chosen based on the type of foodstuff and the size of the foodstuff itself, allowing even different foodstuffs to be stored inside the tray.

[0100] Advantageously, for foodstuffs that are susceptible to squashing and contact between slices, such as sliced cured meats and sliced cheeses, it is possible, according to the invention, to place a plastic sheet between the individual layers of sliced foodstuffs, which plastic sheet has the function of preventing contact between the various layers of foodstuff, allowing the tray to be filled with a greater quantity of foodstuff.

[0101] Still advantageously, the compartmentalization of the storage volume by means of removable plastic shelves according to the invention allows for an increase in the intrinsic capacity of the tray, allowing for the storage of those particular foodstuffs that are susceptible to superficial crushing.

[0102] The improved tray according to the invention and the shelf can be manufactured in a rigid or semi-rigid, gas-impermeable plastic material normally used for this type of application, sufficiently elastic and deformable, and can be made by hot moulding (thermoforming) or injection.

[0103] The materials used are advantageously recyclable and suitable for pursuing an eco-sustainability policy.

[0104] Still advantageously, the materials used are easily made using moulds, and customizable, meaning they can be easily shaped and die-cut to obtain even unusual shapes.

[0105] The improved tray and the shelf according to the invention will preferably be made of a transparent plastic material.

[0106] The plastic sheets optionally interposed between the slices preferably have excellent opacity and gloss properties and are preferably made as polypropylene (PP) sheets, even more preferably as white cavitated polypropylene sheets with biaxial orientation.

[0107] Still advantageously, the improved tray according to the invention can be manufactured according to the most common standards for trays in the food industry, preferably according to the Gastronorm standard.

[0108] The tray according to the invention as described is suitable for packaging food foodstuffs in a modified atmosphere (MAP).

[0109] Advantageously, the access opening of the tray is compatible with all packaging machines used in the food industry, such as air evacuation pumps, vacuum machines, bell jar evacuation machines, thermoforming machines, flow pack machines, and chamber packaging machines.

[0110] Modified atmosphere packaging (MAP) requires the evacuation of air from inside the tray and its replacement with a gas mixture containing a residual amount of atmospheric oxygen.

[0111] The air is generally removed using a pump, thus creating a vacuum inside the packaging, and then the desired gas mixture is blown in.

[0112] However, this gas exchange process is time-consuming and problematic, and difficult to achieve reliably.

[0113] Ideally, for low-oxygen MAP systems, the residual amount of atmospheric oxygen should not exceed an amount between 100 and 300 ppm (parts per million), with the rest of the gas mixture including nitrogen and carbon dioxide and / or other inert or oxygen-free gases.

[0114] Currently, with standard tray, in the best-case scenario it is possible to achieve a residual oxygen percentage of 2000 ppm after evacuating the air inside the tray.

[0115] Thanks to its special structural design, the improved foodstuff tray according to the invention, when used in the modified atmosphere packaging (MAP) process, allows the air inside the package to be replaced with a gas mixture in a short time.

[0116] In particular, the upward channels arranged on the perimeter walls of the tray, which channels directly connect the individual compartments of the tray to the access opening and thus with the air-evacuating machine, reduce the time required to evacuate air from the tray and improve overall evacuation thereof.

[0117] The evacuation of the air contained within the tray according to the invention allows residual atmospheric oxygen percentages within the tray to be obtained in the order of 200 ppm.

[0118] Another aspect to consider is the dispensing of gas mixtures into the tray after air evacuation, particularly mixtures containing a high percentage of nitrogen (N).

[0119] Still advantageously, the special structural design of the tray according to the invention with the upward channels along the perimeter walls allows nitrogen-based mixtures to be effectively distributed within the tray, thus overcoming the problem of poor nitrogen (N) penetration inside foodstuff trays.

[0120] Advantageously, the present invention also concerns a method for filling the tray with sliced foodstuffs, in particular sliced cold cuts and cheeses, and the packaging under a modified atmosphere (MAP) of the improved foodstuff tray.

[0121] The preferred method of filling the improved tray according to the invention mainly comprises:a first step in which stacks of foodstuff trays and stacks of shelves are removed from their packages and moved close to the modified atmosphere packaging area; optionally, when different shelves, for example different in size, need to be placed inside the tray,several stacks of shelves are moved close to the packaging area;a second step in which a single tray is removed from the stack of trays and brought into the filling position;a third step in which a first quantity of foodstuff, for example a first layer of slices of a sliced foodstuff, is arranged on the bottom region of the tray; at this step, a sliced foodstuff can be placed inside the tray with the slices in contact with one another (“wavy slices”) or with a plastic sheet inserted between them (“laid-flat slices with interposed sheet(s)”);a fourth step in which a plastic sheet is arranged onto the surface of the foodstuff layer provided in the previous step; said third and fourth steps may advantageously be repeated several times until the corresponding internal volume of the tray is filled;a fifth step of picking a plastic shelf and inserting the same into the tray in contact with the discontinuous shelf-supporting surface; said third and fourth steps can be cyclically repeated until completion of the filling of the corresponding tray volume.a sixth step in which the tray full of foodstuff is placed onto a multifunctional machine for MAP sealing; said sixth step comprises sub-steps consisting in:evacuating the air from the inside of the tray by means of a vacuum pump; blowing a specific mixture of gases into the tray;applying a plastic foil or film on the adhesion surface for sealing which is located on the upper edge of the perimeter flange;heat-sealing and / or gluing the plastic foil or film on the adhesion surface of the perimeter flange.

[0122] According to the present invention, therefore, a foodstuff tray, in particular a tray for sliced foodstuffs, comprising a bottom region and side walls, wherein inside the tray there is provided at least a supporting shelf for the foodstuff contained in the tray. Still according to the invention, the shelves are removably arranged in said tray and supported by discontinuous supporting surfaces. In addition, still according to the invention, channels are provided in the tray which fluidically communicate the upper part and the lower part of the tray and, in particular, the sub-volumes defined by the at least one supporting shelf.

[0123] Thanks to this improved tray design, the capacity of the tray, particularly for sliced cured meats, is greater than that of traditional trays.

[0124] According to the invention, this results in a better quality of the consumable foodstuffs stored in the tray, preserving their intrinsic qualities and extending the shelf life of the foodstuffs packaged inside the tray.

[0125] Advantageously, this type of tray can be used and presented in freezers or refrigerated display cases, without any deterioration in the nutritional qualities of the food and in which the shelflife of the packaged foodstuffs can be extended.

[0126] Furthermore, the tray according to the invention can be marketed through suitably equipped vending machines.

[0127] Further advantageously, by reducing the amount of residual oxygen inside the tray, the use of auxiliary preservatives is not necessary to extend the shelflife.

[0128] Furthermore, the particular structure of the tray according to the invention reduces the use of material to make it and at the same time gives it a pleasant appearance, making the tray more appealing.

[0129] By doing so, the trays according to the invention help reduce food waste and environmental impact.Brief Description of Drawings

[0130] The advantages of the invention will become more evident in the following description, in which some preferred embodiments of the invention are described.

[0131] The invention will now be described in detail with reference to the attached figures relating to some preferred embodiments, provided purely by way of non-limiting example and in which:

[0132] Fig.l is a perspective view from above of a first embodiment of a tray according to the present invention, provided with a shelf;

[0133] Fig.2 in an exploded perspective view from above of the tray of Fig.l;

[0134] Fig.3 is a side view of the tray of the tray of Fig.l;

[0135] Fig.4 is a plan view from above of the inside of the tray of Fig.1 without the shelf;

[0136] Fig.5 is a plan view from above of the inside of the tray of Fig.1 with the shelf;

[0137] Fig.6 is a plan view from below of the tray of Fig.l;

[0138] Fig.7 is a perspective view from above of a second embodiment of the tray according to the present invention, provided with two shelves;

[0139] Fig.8 is an exploded perspective view from above of the tray of Fig.7;

[0140] Fig.9 is a side view of the tray of Fig.7;

[0141] Fig.10 is a perspective view of a stack of trays and shelves;

[0142] Fig.11 is a side view of the tray of Fig.l in its operational configuration with sliced cold cuts placed inside it.Description of a preferred embodiment

[0143] With reference to the annexed figures, the foodstuff tray according to the inventionhas been indicated as a whole with reference numeral 1.

[0144] Referring to Figures 1-6, the tray 1 has a quadrangular shape with a substantially square base, and comprises a bottom region 5, four perimeter walls 6 extending upwards from said bottom region 5 and delimiting a foodstuff storage compartment 8. The perimeter walls 6 end with a perimeter flange 7 which extends horizontally outside said foodstuff storage compartment 8 and defines, with its edge, an upper abutment surface 9. Depending on the application, the tray 1 may also have a different shape, for example with a polygonal or circular base.

[0145] According to this preferred embodiment, the bottom region 5 of the improved foodstuff tray 1 comprises four perimeter walls 6 extending upwards from the surface of the bottom region 5 and are joined to one another by rounded junction regions 4 having a substantially semicircular profile. The junction regions 4 are inclined and further comprise, inferiorly, i.e., at the bottom region 5, chamfered corners 2 with a chamfer of about 45°.

[0146] The bottom region 5 of the tray 1 comprises a plurality of reliefs facing the inside of the tray. The reliefs of the bottom region comprise some L-shaped internal reliefs 12 and some C-shaped reliefs 13. The C-shaped reliefs are open towards the perimeter walls 6 and form therewith a perimeter channel 14 running along the perimeter of the bottom region 5 of the tray 1.

[0147] The reliefs 12 and 13 of the bottom region 5 help to make the bottom region more rigid and also allows forming a raised portion for the foodstuff lying on the bottom region 5.

[0148] The corner areas 2 joining inferiorly the perimeter 6 and the curved junction regions 4 extend to a height that is approximately equal to the depth of the perimeter channel 14, helping to stiffen the perimeter edge of the bottom region 5.

[0149] In the illustrated embodiment, the perimeter walls 6 of the foodstuff tray 1 extend upwards from the bottom region 5 and are inclined outwards relative thereto, gradually increasing their width starting from the bottom region 5.

[0150] The perimeter walls 6 comprise an alternate succession of vertical reliefs and recesses obtained by a tilt in the plane and a 180° inversion of vertical grooves or protrusions 15 relative to the adjacent vertical groove or protrusion. The succession of reliefs and recesses is suitable to define a structure having alternating concavities and respective convexities, towards the inside and the outside of the perimeter wall.

[0151] As shown in the detail of Fig.2, the reliefs protruding inward of the tray have a geometric discontinuity in height with a reduction in the cross-section and a reduction in thedimension of the profile.

[0152] The two portions thus obtained of the vertical reliefs are joined to each other by a junction region defining a step-like surface 16, which has a transverse abutment plane parallel to the bottom region 5 of the tray 1.

[0153] Similarly to the vertical reliefs, the semi-circular junction regions 4 of the perimeter walls 6 of the tray extend in height in a geometrically discontinuous manner, essentially similar to that of the vertical reliefs. The geometric discontinuity of the semi-circular junction regions 4 define a similar step-like surface 17 which also forms an abutment plane.

[0154] The set of abutment planes defined by the geometric discontinuities with step-like profile 16 of the vertical reliefs defined by the external grooves 15 and the set of abutment planes defined by the geometric discontinuities with step-like profile 17 of the semi-circular joining portions 4 define a corresponding discontinuous supporting surface for a corresponding removable shelf 10 suitable to be removably inserted in the tray 1.

[0155] On the inner surface of each lateral wall 6 facing the inside of the tray 1, the succession of recesses resulting from the alternate arrangement of vertical protrusions and recesses defines a plurality of upward channels 18 with their concavity facing the inside of the tray, which upward channels extend from the edge of the perimeter flange 7 of the tray 1 to the perimeter channel 14 of the bottom region 5 of the tray 1.

[0156] The upward channels 18 are designed to fluidically connect the tray access opening 20, substantially delimited by the inner surface of the perimeter flange 7, with the perimeter channel 14 of the bottom region 5 of the tray 1.

[0157] The perimeter flange 7 is used, in the process of packaging foodstuff's inside the tray 1, for attaching, for example by heat-welding or gluing, a sealing foil 11 (Fig.11) suitable to act as a lid for said tray 1, to the abutment surface 9 of the tray.

[0158] On the inner surface 27 of the perimeter flange 7, at the corners thereof, concave recesses 19 are formed, facing the inside of the tray and extending towards the outside of the tray 1 over the entire thickness of the perimeter flange 7. Advantageously, these recesses 19 have a supporting function to stack a set of trays according to the invention into one another. In the illustrated embodiment, there are four recesses 19 provided on the inner surface 27 of the perimeter flange 7.

[0159] Fig. 2 shows a removable shelf 10, shown separated from the tray 1, for supporting foodstuff's, said shelf being adapted to be accommodated inside a tray 1 according to the invention. Said removable shelf 10 has a substantially flat shape and is suitable to be placed inside the tray 1 on the discontinuous supporting surface defined by the plane containingthe set of abutment planes of the step-like discontinuities 16 of the recesses defined by the external grooves 15 and the set of the abutment planes of the step-like discontinuities 17 of the semi-circular junction regions 4. The removable shelf 10 further has a U-shaped perimeter edge 21 raised relative to the surface of the shelf surface 22, said perimeter edge having the purpose of stiffening the surface intended for supporting the removable shelf 10 and for resting on the discontinuous surface 16,17 supporting the tray.

[0160] The removable shelf 10 further has L-shaped central recesses 23 extending downward from the shelf surface 22 and suitable to give greater structural rigidity to the removable shelf 10.

[0161] The outer surface of the perimeter edge 21 of the removable shelf 10 has a structure formed by an alternation of concave recesses 26 and convex protrusions 25, shaped to come into mutual contact and mate with each other with the vertical reliefs and recesses provided on the inner walls and with the corresponding upward channels of the foodstuff tray. The concave protrusions 25 of the outer perimeter edge 21 of the removable shelf 10 have the function of resting on the discontinuous surface supporting the tray 1. The polygonal-shaped convex recesses 26 are shaped to be located at the upward channels 18 of the tray 1 , allowing fluidic communication between the separate storage volumes VI and V2 obtained by inserting the removable shelf 10 into the tray 1.

[0162] Advantageously, according to a further aspect of the invention, the tray 1 can be arranged to contain a variable number of removable shelves 10, so that it is possible to compartmentalize the internal storage volume of the tray depending on the type of foodstuff to be packaged.

[0163] Referring particularly to Figures 7-9, these illustrate a second preferred embodiment relating to a tray 100 according to the invention shaped to accommodate therein a first partition shelf 110 and a second partition shelf 111.

[0164] The removable shelves 110 and 111 will have different geometric dimensions, because they will have to engage with supporting surfaces 280 and 281 which, being arranged at different heights within the tray, will have different dimensions, as the perimeter walls of the tray are inclined to give the shape substantially of an inverted truncated pyramid to the tray.

[0165] Accordingly, it is necessary to provide two discontinuous supporting surfaces 280 and 281 for the removable shelves 110 and 111.

[0166] The first supporting surface 280 will be defined by the plane containing the set of abutment planes of the step-like geometric discontinuities 160 of the vertical reliefs definedby corresponding external grooves 150 and the set of abutment planes of the step-like geometric discontinuities 170 of the semi-circular junction regions 40.

[0167] The second support surface 281 will be defined by the plane containing the set of the terminal surfaces 310 of the reliefs defined by the external vertical grooves 150 and the set of the abutment planes of the geometric discontinuities with step-like profile 320 of the semi-circular junction regions 40.

[0168] In this preferred embodiment of the invention illustrated, the internal volume 80 for food storage inside the tray 100 is advantageously divided into three separate storage subvolumes V10, V20 and V30.

[0169] Apart from the different characteristics compared to the tray 1 according to the first embodiment, the tray 100 of the second embodiment essentially has all the other characteristics described in the first embodiment and therefore they will not be repeated here.

[0170] Referring to Figures 10 and 11, these illustrate a method of filling, particularly with sliced cold cuts or cheese, the foodstuff tray according to the invention.

[0171] Figure 10 shows a stack of trays 50 according to the invention stacked in one another and a stack of shelves 51 arranged one on top of another near a packaging station for foodstuff's, in particular for sliced cured meats.

[0172] The shelf 10 inserted inside the tray according to the invention divides the internal storage volume 8 into two separate storage volumes VI and V2.

[0173] Figure 11 shows a transparent tray 1 according to the invention filled with slices of cold cuts or cheese 33 arranged in layers inside the tray.

[0174] Starting from below, a first layer of slices 33 is arranged onto the bottom region 5 of the tray.

[0175] A first plastic sheet 43 is arranged onto the first layer of slices 33, with the function of preventing direct contact between a first layer of slices 33 and the second layer of slices 34

[0176] A second layer of slices 34 is placed onto the first plastic sheet 43.

[0177] A second plastic sheet and a second layer of slices of cold cuts are then placed on top, continuing in sequence to alternate a layer of slices and a plastic sheet to separate two adjacent layers.

[0178] Once the storage volume VI is full, the removable shelf 10 is placed onto the supporting surface 16, 17.

[0179] The layered filling sequence previously used for storage volume VI is now repeatedfor storage volume V2.

[0180] After filling the improved tray 1 with alternating layers of slices and plastic sheets, the tray is placed onto a multifunction machine for MAP sealing.

[0181] Specifically, the multifunction machine first evacuates the air inside the package, creating a vacuum, and, thanks to the structure of the tray 1 according to the invention, particularly thanks to the provision of the upward channels 18 provided on the inner surfaces of the perimeter walls 6, can reduce the amount of residual oxygen inside the tray to less than 200 ppm.

[0182] A specific mixture of gases is then blown into the tray to ensure the sliced foodstuff is stored correctly.

[0183] Finally, the foil consisting of a plastic film 11 is arranged onto the adhesion surface 9 of the edge of the perimeter flange 7. The foil is heat-welded to isolate the inside of the tray containing the foodstuff to be stored under modified atmosphere from the outer environment.

[0184] An examination of the characteristics of the trays 1 and 100 manufactured according to the invention clearly shows the advantages they offer.

[0185] Thanks to this configuration, the intrinsic capacity of the tray 1 is increased.

[0186] It will also be possible to create and guarantee different VI and V2 storage volumes to meet packaging and storage criteria, particularly in the case of sliced foodstuffs 33. This type of packaging, which is extremely simple to produce and comes in a wide variety of shapes, offers numerous advantages. In particular, it allows the slices to be separated to ensure better preservation, while at the same time allowing the consumer to see the foodstuff immediately thanks to the transparency of the tray.

[0187] Furthermore, this type of packaging using the tray according to the invention advantageously offers multiple storage options depending on the type and different nature of the foodstuffs to be consumed.

[0188] The invention as described and illustrated is susceptible to numerous variations and modifications, all falling within the inventive principle characterizing it. Furthermore, all details can be replaced by other technically equivalent elements. In practice, any materials as well as dimensions can be used, depending on requirements.

[0189] Of course, construction details and embodiments may vary widely from those described and illustrated in this document, without departing from the scope of the present invention as defined in the following claims.

Claims

CLAIMS1. Plastic tray (1) for foodstuffs, comprising a bottom region (5), perimeter walls (6) extending upwards from the bottom region (5) and delimiting an internal volume (8) for storing foodstuffs, and a perimeter flange (7) which extends horizontally outside said internal storage volume (8), defines the access opening (20) of the tray (1) and has an abutment surface (9) against which a plastic sealing film (11) can be sealed, said plastic tray comprising at least one removable transverse shelf (10) dividing the internal volume (8) of the tray (1), characterized in that the perimeter walls (6) comprise a plurality of upward channels (18) extending vertically with the concavity facing the inside of the perimeter wall (6) from the edge of the perimeter flange (7) surrounding the access opening (20) of the tray (1) to the bottom region (5) of the tray (1), and wherein said upward channels (18) are such as to fluidically communicate the upper part of the foodstuff tray (1) with the lower part of said tray (1) when said parts are divided by a removable shelf (10) and the tray (1) is in its condition of use, arranged with its own base lying on a horizontal support plane.

2. Tray (1) according to claim 1, wherein the perimeter walls (6) of the tray (1) comprise a step (16) defining a corresponding abutment surface for supporting said removable shelf (10).

3. Tray (1) according to claim 2, wherein the perimeter walls (6) comprise protrusions facing the inside of the tray (1) and having at least one geometric discontinuity forming said step (16).

4. Tray (1) according to claim 3, wherein the perimeter walls (6) comprise an alternate succession of vertical grooves (15) that is obtained by a tilt in the plane and a 180° inversion of a vertical groove (15) around its own axis relative to the adjacent vertical groove (15), said vertical grooves (15) defining a corresponding protrusion on the opposite face of the corresponding perimeter wall (6).

5. Tray (1) according to claim 4, wherein each protrusion facing the inside of the tray (1) has at least one geometric discontinuity forming a corresponding step on which a substantially horizontal abutment plane is defined when the tray (1) is in use, lying on a horizontal plane.

6. Tray (1) according to any one of the preceding claims, wherein the perimeter walls (6) are joined to one another by junction regions (4) comprising chamfered edges (2) inferiorly, i.e. at the bottom region (5).

7. Tray (1) according to claim 6, wherein the junction regions (4) connecting the perimeter walls (6) of the tray (1) have at least one corresponding geometric discontinuityforming a corresponding step (17) that defines an abutment plane comprising a support region for the removable shelf (10).

8. Tray (1) according to claim 5 and 7, wherein the discontinuities of the vertical grooves (15) and the discontinuities of the junction regions (4) are aligned to each other relative to a horizontal plane running transversely across the tray, so as to define altogether a discontinuous perimeter abutment for said removable shelf (10).

9. Tray (1) according to any one of the preceding claims, wherein the surface subtended by the perimeter flange is greater than the surface area of the bottom region, so that the tray has, when in use, a shape that is substantially flared outwards and upwards.

10. Tray (1) according to any one of the preceding claims, wherein the tray, when in use, takes the geometric shape of an inverted truncated pyramid.

11. Tray (1) according to any one of the preceding claims, wherein the tray (1) is made of a semi-rigid plastic material.

12. Tray (1) according to any one of the preceding claims, wherein the removable shelf (10) is made of a semi-rigid plastic material.

13. Tray (1) according to any one of the preceding claims, wherein the tray (1) and the removable shelf (10) are both made of an elastic, deformable, semi-rigid material impermeable to the gases normally used for foodstuff packaging.

14. Method of filling a tray (1) made according to any one of the preceding claims, comprising the steps of:bringing a tray (1) and at least one removable shelf (10) near a Modified Atmosphere Packaging (MAP) zone;bringing the tray (1) to its filling position;arranging a first layer of foodstuff onto the bottom region (5) of the tray (1); inserting said at least one removable shelf (10) into the tray (1) and bringing said removable shelf (10) into contact with a supporting surface defined along the perimeter walls (6) of the tray (1);carrying out the process of sealing the tray (1) under MAP conditions; removing the tray (1).

15. Method according to claim 14, wherein the process of sealing the tray under MAP conditions is carried out by evacuating the air contained inside the tray thanks to the tray structure and the upward channels (18) provided on the inner surfaces of the perimeter walls (6), and is capable of reducing the amount of residual oxygen contained within the tray to values below 200 ppm.

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