Tray, packaging system and process for packaging a product

Abstract

The present disclosure relates to a tray comprising: a base including a surface for supporting a product; a plurality of fluid retention recesses formed in the base; and one or more flaps movable between a first configuration in which the one or more flaps extend outward from the base and a second configuration in which cover the one or more fluid retention recesses. The present disclosure also relates to a process for manufacturing the tray, to a packaging system comprising the tray, and to a process for packing a product in the packaging system.

Description

TRAY, PACKAGING SYSTEM AND PROCESS FOR PACKAGING A PRODUCT

[0001] The present disclosure relates to trays suitable for use in the packaging, storage, transportation and / or display of a product, such as a fresh food product, to packaging systems comprising said tray, and to processes for making said tray and packaging.BACKGROUND OF THE INVENTION

[0002] Food chains and markets have rapidly been expanded and connected due to the globalisation and economic growth. These showed the key roles of food packaging in containing, preserving, and delivering food products within the global food chains. Therefore, various packaging solutions have been developed to drive the food packaging from its passive to active role. This involves addressing the challenges of food packaging in prolonging shelf life, maintaining freshness, quality, and safety of the packaged food.

[0003] Packaging of liquid-exuding foods such as fresh meats is the most crucial among food products due to their perishability. Meat, poultry and fish naturally exude juice (exudate) during storage resulting in limited shelf life. This exudate facilitates deterioration of meat / fish quality and safety due to high water activity, hence accelerated growth of spoilage and pathogenic microorganisms. Further, the accumulated exudate may leak from the packaging trays and it is perceived as unsanitary liquid by customers. Therefore, different packaging solutions have been developed to isolate the free exudate accumulated in meat and other food packaging.

[0004] Plastic trays with absorbent pads placed on their floor are widely used as a soak-away for the exudate released from fresh meat, poultry, and fish. The meat exudate is absorbed and immobilised in the absorbent pad structure to maintain low water activity and inhibit microbial growth. However, certain materials still lead to substantial microbial growth that causes contamination and can also break up and delaminate when theabsorbent layers are saturated with liquid resulting in contamination of contained meat. Further, absorbent pads with absorptive layers of tissue, paper or pulp have a limited capacity of liquid absorption and retention, or conversely when using super absorptive materials can lead to exudate draw from the produce adversely affecting produce quality and / or lead to accelerated spoiling. The absorbed drip can also be released back to the meat product, especially when the compressible pad undergoes pressure from the meat weight or packaging handling by customers.

[0005] Further, open-cell foam trays have also been used to absorb the meat exudate inside their porous structure. The polymeric foam can be used to form a single absorbent tray or absorbent pad inside a packaging tray. However, liquid absorbency of the open cells can be limited under stresses originated from product overloading. Further, liquid collected within the foam structure can lead to end of life recycling issues with that product.

[0006] Double-walled absorbent trays have also been devised with a cavity to trap the meat and food exudates. However, this technique fails to retain the liquid when the tray is tilted and the liquid can leak out. Although double walled trays have been developed to trap a sandwiched pad in the cavity between the walls, these pads have limited absorption capacity and the liquid can still escape from their edges. Further, this type of absorbent tray has higher cost of manufacture, transport and storage, higher material cost, and are less recyclable.

[0007] All of the above solutions include additional materials within the packaging which has extended to the increasing concern about eco-friendly food packaging as more pressure is exerted to reduce the use of non- recyclable packaging materials, especially for polymeric materials such as those widely used in food packaging. The polymeric packaging waste was estimated about 20 million metric tons within EU in 2015.

[0008] WO 2022 / 053547 Al describes a tray or substrate comprising a plurality of fluid retention recesses, which due to their nature provide for improved fluid retention bycapillary action. In this manner, capillary action is retained even when using larger capillary recesses, or wells, thus increasing overall volumes of fluid that can be retained. This therefore provides for an improvement over conventional capillary recess trays / pads, and preferable recyclable alternative to other absorptive pads.

[0009] However, the inventors observed that, when a softer product (such as fish slices, salmon slices) is placed directly onto the fluid retention recesses, the opening of the recesses can become hindered by the product such that the fluid retention capacity of the tray may become compromised. As a result, the shelf life of the product is decreased. Furthermore, the recess pattern may, in time, become embossed into the product thereby resulting in a less appealing product appearance, or the product may become partially trapped in the recessed.

[0010] It is an object of this invention to mitigate problems such as those described above and to provide an improved alternative to existing products. In particular, there is a need for a tray and packaging system for use in the packaging, storage, transportation and / or display of a fresh food product, such as a fresh product which may produce an exudate. It is an object of the present invention to improve the fluid retention capacity of known trays, without complicating the manufacturing process, without increasing costs and without compromising sustainability.STATEMENT OF INVENTION

[0011] According to a first aspect of the disclosure, there is provided a tray comprising: a base including a surface for supporting a product; a plurality of fluid retention recesses formed in the base; and one or more flaps movable between a first configuration in which the flap extends outward from the base and a second configuration in which the one or more flaps lie against the base.

[0012] In embodiments, a flap extends from an edge of the base and is pivotable about said edge. In embodiments, the flap is pivotable at an angle of from 0° to 360° relative to the base. In embodiments, a flap in the first configuration extends outward from the base and substantially in the plane of the base, that is, at an angle of around 180° relative to the base.

[0013] In the second configuration, the flap is positioned above the fluid retention recesses, that is, the flap is positioned at an angle of about 0° relative to the base. In embodiment, the tray is configured to receive a product on the supporting surface, which includes the flap(s) in their second configuration.

[0014] In embodiment, each flap comprises a first surface which, in the second configuration, forms part of the supporting surface of the base (that is, the first surface may face away from the base) and a second surface which, in the second configuration, faces the base and / or the fluid retention recesses.

[0015] In embodiments, the one or more flaps extend from an edge of the base. That is, one edge may comprise one or more flaps extending therefrom. In preferred embodiments, an edge comprises a single flap extending therefrom. That is, the tray may comprise a first edge with a first flat extending therefrom, and a second edge with a flap extending therefrom. In embodiments, the base is substantially square or rectangular and comprises two sets of opposing edges. In embodiments, the tray comprises two flaps, each flap extending from one of two opposing edges.

[0016] In embodiments, the one or more flaps are pivotable about the edge of the tray from which it / they extend. In embodiments, the one or more flaps may be connected to the edge of the tray by a line of weakness formed, for example by a relatively thinner strip of material or by a plurality of perforations.

[0017] In embodiments, the one or more flaps are detachable from the base. In embodiments, the tray comprises a detachment line between the one or more flaps and the base. In embodiments, the detachment line comprises a plurality of perforations.

[0018] In embodiments, the one or more flaps are configured such that, when a flap is in its second configuration, the flap is positioned above or covers a group of fluid retention recesses. In embodiments, the dimensions of a flap are the same as, or preferably greater than, the dimensions of the group of fluid retention recesses it is intended to cover. In this context, the dimensions means the length and the width. In embodiments, the outer contour of the flap is substantially the same as that of the group of fluid retention recesses it is intended to cover. In embodiments, the flaps are substantially rectangular or substantially square.

[0019] In embodiments, the flaps one or more comprise rounded corners.

[0020] In embodiments, the one or more flaps are integrally formed with the base. In embodiments, the tray has a one-component design. That is, all components of the tray are integrally formed. In embodiments, the tray is a thermoformed tray.

[0021] In embodiments, the fluid retention recesses are formed in a fluid retention area of the base, said fluid retention area being relieved relative to the supporting surface.

[0022] In embodiments, the one or more flaps are configured such that, when a flap is in the second configuration, the flap is positioned above or covers a fluid retention area. In embodiments, the dimensions of a flap are the same as, or preferably greater than, the dimensions of the fluid retention area it is intended to cover. In this context, the dimensions means the length and the width. In embodiments, the outer contour of a flap is substantially the same as that of the fluid retention area it is intended to cover.

[0023] In embodiments, each fluid retention recess comprises a raised rim surrounding the mouth of the fluid retention recess.

[0024] In embodiments, a fluid retention recess comprises a base and one or more walls extending from said base and forming a mouth. In embodiments, the mouth is levelled with the surface in which the fluid retention recess is formed. In embodiments, the raised rim extends above the surface in which the fluid retention recess is formed, and above the mouth of the fluid retention recess.

[0025] In embodiments, the mouth of the fluid retention recesses has a width or diameter of 1.0 mm to 15 mm.

[0026] In embodiments, the fluid retention recesses have a depth of 1.0 mm to 10.0 mm relative to the supporting surface.

[0027] In embodiments, the height of the raised rim is from 0.10 mm to 5.0 mm relative to the supporting surface. In embodiments, all the raised rims have substantially the same height.

[0028] In embodiments, the raised rim has a width of from 0.10 mm to 1.90 mm.

[0029] In embodiments, the fluid retention recesses are formed in a relieved retention area (i.e., a retention area relieved from the supporting surface), and are configured such that the apexes of the raised rims are relieved relative to the supporting surface.

[0030] In embodiments, the supporting surface comprises one or more grooves in fluid communication with the fluid retention recesses. In embodiments, the one or more grooves are configured to receive, retain and / or guide fluid towards the fluid retention recesses. In embodiments, the supporting surface comprises one or more grooves in fluid communication with the fluid retention recesses and / or with the fluid retention area.

[0031] In embodiments, the tray comprises one or more features configured to position the product in the tray. For example, the tray comprises one or more product positioningribs. In embodiments, the one or more positioning ribs are located on or formed in the supporting surface of the base and / or on the one or more flaps.

[0032] In embodiments, the one or more positioning ribs are formed in the supporting surface of the base, substantially parallel to an edge of the base. In embodiments, the one or more positioning ribs are positioned along or adjacent to an edge of the base. In embodiments, the one or more positioning ribs are formed on the upper, in use, surface of the supporting surface.

[0033] In embodiments, the one or more positioning ribs are formed in the one or more flaps, substantially parallel to an edge of the base. In embodiments, the one or more positioning ribs are positioned along or adjacent the edge from which the one or more flaps extend. In embodiments, the one or more positioning ribs are formed on the upper, in use, surface of the one or more flaps, when the one or more flaps are in the second configuration. That is, the one or more positioning ribs may be formed in the first surface of the flap which, in the second configuration, faces away from the supporting surface.

[0034] In embodiments, the one or more positioning ribs comprise an elongated portion which extends substantially parallel to the edge of tray. In embodiments, the one or more positioning ribs comprise one or two curved end portions adjacent corners of the base.

[0035] In embodiments, the tray comprises a first positioning rib substantially parallel to a first edge of the base and a second positioning rib substantially parallel to a second edge of the base. The first and second edges may be opposing edges, such that the first and second positioning ribs may be located on either side of the supporting surface.

[0036] In embodiments, the tray may further comprise a third positioning rib and a fourth positioning rib parallel to a third edge of the base and a fourth edge of the base, respectively. The third and fourth edges may be opposing edges, so that each edge has a corresponding parallel positioning rib and the positioning ribs surround, partially or completely the supporting surface.

[0037] In embodiments, the upper portion (or apex portion) of the one or more positioning ribs is curved.

[0038] In embodiments, the height of the one or more positioning ribs is 6.0 mm or less. In embodiments, the height of the one or more positioning ribs is 2.0 mm or more. In embodiments, the height of the one or more positioning ribs is from 2.00 mm to 6.00 mm, preferably from 3.00 mm to 4.00 mm, around 3.5 mm. In embodiments, all the positioning ribs have substantially the same height.

[0039] In embodiments, the width of the one or more positioning ribs is 2.0 mm to 10.0 mm, 4.0 mm to 8.0 mm, or 5.0 mm to 7.0 mm, most preferably around 6.0 mm. In embodiments, all the positioning ribs have substantially the same width.

[0040] In embodiments, the supporting surface comprises a central supporting area devoid of fluid retention recesses.

[0041] In embodiments, the one or more fluid retention recesses are positioned so as to be covered by the one or more flaps, when the one or more flaps are in the second configuration. In embodiments, the fluid retention recesses are located outside and / or around the central supporting area. For example, the fluid retention recesses may be located on opposing sides of the central supporting area, adjacent opposing edges of the base. The fluid retention recesses may be located along two opposing sides of the central supporting area, or along each side of the central supporting area, when the central supporting area is substantially square or rectangular.

[0042] In embodiments, the central supporting area is concave or comprises a concave section. In embodiments, the central supporting area comprises a substantially flat bottom surface. In embodiments, the bottom surface of the central supporting area is substantially rectangular or substantially square.

[0043] In embodiments, the product is supported by the supporting surface. In embodiments, the supporting surface may comprise a central supporting area and the upper, in use, surface (first surface) of the one or more flaps in the second configuration. In embodiments, the tray is configured such that, in use, the product does not directly contact the fluid retention recesses.

[0044] In embodiments, the tray comprises or consists of one or more plastics materials. In embodiments, the tray is formed from a mono-layer sheet or a multi-layer sheet of plastics material. In embodiments, the tray comprises or consists of one or more recyclable plastics materials.

[0045] In embodiments, the tray comprises or consists of one or more materials selected from polyethylene terephthalate (PET), more particularly amorphous polyethylene terephthalate (APET); polypropylene (PP); polyethylene (PE), for example, high-density polyethylene (HDPE) and low-density polyethylene (LDPE); polystyrene (PS), more particularly expanded polystyrene (EPS). Preferably, the tray comprises or consists of one or more materials selected from amorphous polyethylene terephthalate (APET), polypropylene (PP), high-density polyethylene (HDPE) and low-density polyethylene (LDPE), and expanded polystyrene (EPS). More preferably, the tray comprises or consists of amorphous PET.

[0046] In embodiments, the tray comprises or consists of one or more recycled plastics materials. In embodiments, the recycled plastics materials comprise manufacturing waste (that is, waste originating from the tray manufacturing process) and / or post-consumer waste. In embodiments, the manufacturing waste may comprise one or more of extrusion waste (from the extrusion of one or more plastics materials into a sheet), skeletal waste (from the step of separating or cutting trays from a thermoformed sheet comprising several trays), and trimming waste (from the step of trimming individual trays).

[0047] In embodiments, the tray, in the first configuration, is stackable onto or nestable into a second tray, in the first configuration. In embodiments, the tray is stackable onto or nestable into a second identical tray or a tray of the same type or with the same configuration.

[0048] In embodiments, the tray is devoid of denesting features, such as denesting recesses.

[0049] According to another aspect of the present disclosure, there is provided a tray system comprising two or more trays as described herein. In embodiments, the distance between two stacked or nested trays is between 0.25 mm and 6.0 mm, preferably between 0.50 mm and 2 mm or between 0.50 mm and 1 mm, most preferably around 0.75 mm.

[0050] According to another aspect of the present disclosure, there is provided a process for manufacturing a tray according to the present disclosure, comprising the step of thermoforming one or more trays from a sheet of plastics material(s).

[0051] In embodiments, the step of thermoforming comprises thermoforming a plurality of trays from a sheet of plastics material.

[0052] In embodiments, the process comprises one or more steps selected from:a. Extruding or co-extruding a sheet from one or more plastics materials;b. Thermoforming the sheet into one or more trays;c. Separating the trays from each other, for example by cutting;d. Trimming the trays;e. Stacking the trays on top of each other;f. Feeding the manufacturing waste back into the manufacturing process.

[0053] According to another aspect of the present disclosure, there is provided a packaging system comprising a tray according to the present disclosure and a top film configured to cover a product placed on the supporting surface of the tray.

[0054] In embodiments, the top film comprises or consists of a monolayer or a multilayer film. In embodiments, the top film comprises one or more layers or materials selected from polyethylene terephthalate (PET); polyethylene (PE), such as machine-direction oriented polyethylene (MDO-PE) or biaxially oriented polyethylene (BO-PE); polyamide (PA), such as bi-oriented polyamide (PA). In embodiments, the top film comprisesone or more additional layers selected from barrier layers, adhesive layers, sealing layers, antimicrobial layers, printing layers and the like.

[0055] In embodiments, the packaging system comprises a bottom support configured to be placed under the tray.

[0056] In embodiments, the packaging system is hermetically sealed. In embodiments, the top film 10 and the bottom support 11 are hermetically sealed with each other.

[0057] In embodiments, the packaging system is a flexible packaging system, a vacuum packaging, or a vacuum skin packaging system.

[0058] According to another aspect of the present disclosure, there is provided a process for packing a product in a packaging system according to the present disclosure comprising the step of covering a product and the supporting surface with a top film.

[0059] In embodiments, the process comprises the step of placing a product onto the supporting surface of the tray.

[0060] In embodiments, the product is a fish product, a meat product and / or a protein product. In embodiments, the product comprises slices or cuts of fish or meat.

[0061] In embodiments, the process comprises the step of modifying or controlling the atmosphere between the tray and the top film.ACCOMPANYING FIGURES

[0062] The details of one or more implementations are set forth, by way of example only, in the accompanying drawings and the description below. Other features, aspects, and advantages of the disclosure will become apparent from the description, the drawings, and the claims, in which:

[0063] Figure 1 is a schematic (top perspective view) representation of a tray according to the present invention;

[0064] Figure 2 is a schematic (bottom perspective view) representation of the tray of Figure 1;

[0065] Figure 3 is a schematic (top view) representation of the tray of Figure 1;

[0066] Figure 4 is a schematic (front view) representation of the tray of Figure 1;

[0067] Figure 5 is a schematic (side view) representation of the tray of Figure 1;

[0068] Figure 6 is a schematic representation of the tray of Figure 1 in which the flaps are partially folded;

[0069] Figure 7 is a schematic representation of the tray of Figure 1, in which the flaps are partially folded;

[0070] Figure 8 is a schematic representation of the tray of Figure 1, in which the flaps are folded;

[0071] Figure 9 is a schematic representation of a product packaged in a packaging system according to the present disclosure.

[0072] The embodiments described herein are provided as exemplary and non-limiting embodiments of the present invention.DETAILED DESCRIPTION

[0073] With reference to Figure 1, there is illustrated a tray 1 comprising a base 2 including a surface 3 for supporting a product; a plurality of fluid retention recesses 4 formed in the base 2; and one or more flaps 5 movable between a first configuration in which the one or more flaps 5 extend outward from the base 2 and a second configuration in which the one or more flaps cover the one or more fluid retention recesses 4.

[0074] Within the context of the present disclosure, the term "fluid" includes exudate from the product(s).

[0075] Directional terms as used herein— for example up, down, right, left, front, back, top, bottom, above, under, upper, lower —are made only with reference to the accompanying figures as drawn and are not intended to imply absolute orientation.

[0076] Advantageously, the tray 1 is integrally formed. That is, the tray may have a one-component design in which all components of the tray 1 integrally formed. This is achievable for example by providing a thermoformed tray 1 in which all the components are formed from a sheet of plastics materials. No subsequent coupling, welding, gluing, attachment steps are required which could complicate the manufacturing process, increase the manufacturing costs, increase the risk of contamination, compromise the structural integrity of the tray and / or undermine the sustainability of the tray.

[0077] As will be explained in further detail below, the tray 1 may be thermoformed in the first configuration. This facilitates the high volume production of the trays, for example by a thermoforming process. The trays 1 in the first configuration may be easily stacked onto each other and freely separated. In the second configuration, the product supportingsurface 3 of the tray 1 is increased, without compromising the total fluid retention capacity of the tray 1. In fact, the tray 1 exhibits an improved total fluid retention capacity since the fluid retention recesses 4 are unhindered by the product.

[0078] The tray 1 comprises a substantially square base 2. The shape of the base is not limited and the base 2 may have a different contour, although it is noted that substantially square and substantially rectangular are preferred for ease of packing and covering products such as meat or fish slices, for storing, displaying, and generally handling the packaging.

[0079] The tray 1 is preferably a thermoformed tray. The tray 1 may be thermoformed from an extruded sheet comprising one or more layers of plastics materials. The tray 1 may comprise or consist of one or more plastics materials. In embodiments, the tray 1 comprises or consists of one or more materials selected from polyethylene terephthalate (PET), more particularly amorphous polyethylene terephthalate (APET); polypropylene (PP); polyethylene (PE), for example, high-density polyethylene (HDPE) and low-density polyethylene (LDPE); polystyrene (PS), more particularly expanded polystyrene (EPS).

[0080] Advantageously, the tray 1 comprises or consists of one or more materials selected from amorphous polyethylene terephthalate (APET), polypropylene (PP), high-density polyethylene (HDPE) and low-density polyethylene (LDPE), and expanded polystyrene (EPS) - since these plastics materials are readily recyclable and may be fed into a recycling stream.

[0081] The tray 1 may comprise or consist of one or more recycled plastics materials. In embodiments, the recycled plastics materials comprise manufacturing waste (that is, waste originating from the tray manufacturing process) and / or post-consumer waste. For example, the manufacturing waste may comprise one or more of extrusion waste (from the extrusion of one or more plastics materials into a sheet), skeletal waste (from the step of separating or cutting trays from a thermoformed sheet comprising several trays), andtrimming waste (from the step of trimming individual trays). Recycled plastics materials are typically in the form of flakes resulting from the shredding of waste, whereas virgin plastics materials are typically supplied in the form of pellets.

[0082] In a preferred embodiment, the tray 1 comprises or consists of amorphous polyethylene terephthalate (APET). APET is readily recyclable and the use of APET provides a high clarity product that enables the customer to view the contents of the packaging. When the tray 1 consists of APET, no step is required to separate tray materials into recyclable APET and non-recyclable materials, or to feed the separated materials into different recycling streams.

[0083] The tray 1 comprises a plurality of fluid retention recesses 4. The fluid retention recesses 4 may have a base and one or more walls extending from the base of the recess and forming a mouth. In embodiments, the mouth is levelled with the surface in which the recess is formed. In embodiments, the mouth of the fluid retention recess 4 has a maximum width or diameter of 1.0 mm to 15 mm, the maximum width or diameter being measured in the level of the surface in which the fluid retention recess 4 is formed.

[0084] In embodiments, the fluid retention recesses 4 have a depth of 1.0 mm to 10.0 mm relative to the supporting surface 3.

[0085] In embodiments, each fluid retention recess 4 comprises a raised rim 6 (such as a peripheral rib) surrounding the mouth of the fluid retention recess 4. In embodiments, the raised rim 6 extends above the surface in which the fluid retention recess 4 is formed, and thus above the mouth of the fluid retention recess 4. Preferably, the height of the raised rim 6 is from 0.10 mm to 5.0 mm relative to the supporting surface. In embodiments, all the raised rims 6 have substantially the same height. In embodiments, the raised rim has a width of from 0.10 mm to 1.90 mm.

[0086] Capillary action is the ability of a liquid to flow or retract in narrow spaces without the assistance of, or even in opposition to, external forces like gravity. In the present context, the fluid retention recesses 4 retain liquid by capillary action through generating a liquid bridge under the effect of liquid surface tension. This liquid barrier prevents the liquid drainage from the fluid retention recesses 4. Unexpectedly, considered in the context of dimensions of the fluid retention recesses 4 to permit capillary action, the provision of a raised rim on the fluid retention recesses 4 vastly improves liquid retention capacity of the fluid retention recesses 4 considerably, even when tipped, in comparison with corresponding fluid retention recesses 4 without rim.

[0087] Without wishing to be bound by theory, the raised well rim increases the opening angle of the wells relative to the substrate surface, which improves their valving pressure barrier acting on the well openings. This allows a liquid meniscus to form a more stable liquid bridge to prevent the liquid drainage from the well. This configuration showed considerably improved fluid retention throughout testing compared to those wells without rim. The fluid retention recesses 4 are characterised by having a common hole cross-sectional size or diameter and notably the provision of a raised rim 6, which increases the well opening angle to enhance well capillary action (and so retention capacity).

[0088] In the tray 1 depicted in the accompanying figures, the fluid retention recesses 4 are formed in one or more fluid retention areas 7 located on either sides of a central supporting surface 3a. Where the fluid retention recesses 4 comprise a raised rim 6, the fluid retention recesses 4, the raised rims 6 and the fluid retention areas 7 may be configured such that the apexes of the raised rims 6 are levelled with or relieved relative to the supporting surface 3. In this configuration, the flaps 5, in their second configuration, may lie against the base 2 or its central supporting surface 3a.

[0089] In embodiments, the one or more fluid retention areas 7 are relieved relative to the supporting surface 7. For example, the surface of the fluid retention areas 7 may be 0.5mm to 3.0 mm lower than the supporting surface 3, preferably 0.75 mm to 2.0 mm or 1.0 mm to 1.5 mm, most preferably around 1.25 mm.

[0090] The supporting surface 3 or the central supporting surface 3a may comprise a concave portion 3b configured to receive and / or position the product within the packaging. Where the supporting surface 3 comprises a plurality of levels or is concave, the fluid retention area(s) 7 may be relieved relative the uppermost surface of the supporting surface 3. Thus, when the flaps 5 are in the second configuration, fluid can readily flow into and be retained in the fluid retention recesses 4.

[0091] The shape of the central supporting surface 3a is not particularly limited. The contour of the central supporting surface 3a may be substantially square, rectangular, circular or oval. In the depicted embodiments, the concave portion 3b comprises a product positioning surface which is relieved relative to the uppermost surface 3c of the supporting surface 3 and which coupled to the uppermost surface 3c of the supporting surface 3 by sloped walls.

[0092] The central supporting surface 3a is preferably devoid of fluid retention recesses 4. Thus, when a product is resting on the central supporting surface 3a, fluid retention is not impaired.

[0093] The base 2 may comprise one or more grooves 12 configured to receive, retain and / or convey fluid, such as the exudate. The one or more grooves 12 may form a fluid path to convey the exudate. In embodiments, the one or more grooves 12 are configured to convey fluid between the central supporting area 3a and the fluid retention recesses 4, or between the central supporting area 3a and the one or more fluid retention areas 7 comprising the one or more fluid retention recesses 4. The grooves 12 alone provide additional fluid retention capacity. In combination with the fluid retention recesses 4, the exudate is conveyed out of the central supporting surface 3a and away from the product by capillary action from the fluid retention recess(es) 4 and / or fluid retention area(s) 7.

[0094] According to the present disclosure, the tray 1 comprised one or more flaps 5 movable between a first configuration in which the one or more flaps 5 extend outward from the base 2 and a second configuration in which the one or more flaps 5 cover the one or more fluid retention recesses 4.

[0095] Figures 1 to 5 depict a tray 1 in which the flaps 5 are in the first configuration, for example at an angle of around 180° relative to the base 2. Figure 6 depicts the flaps 5 at an angle of around 135° relative to the base 2. Figure 7 depicts the flaps 5 at an angle of around 135° relative to the base 2. Figure 8 depicts the flaps 5 in the second configuration. In the second configuration, the flaps 5 may be at an angle of around 0° relative to the base 2 or to the supporting surface 3 or to the uppermost surface 3c of the supporting surface 3. In the second configuration, the flaps 5 may lie substantially against the base 2 or against the supporting surface 3 or against the uppermost surface 3c of the supporting surface 3. In the second configuration, the first surface 5a of the flap 5 faces away from the base 2, and the second surface 5b of the flap 5 faces the base 2.

[0096] In the first configuration, the flaps 5 and the base 2 may be substantially coplanar. The tray 1 may be thermoformed in the first configuration. The first configuration is particularly adapted for the manufacture of tray 1 by thermoforming, more particularly for thermoforming the components of the tray 1 as a single item. Particularly advantageously, the one or more flaps 5 are integrally formed with the base 2.

[0097] In the first configuration, tray 1 may be easily stacked onto or nested into each other to form a stack of trays. In embodiments, the distance between two stacked or nested trays is between 0.25 mm and 6.0 mm, preferably between 0.50 mm and 2 mm or between 0.50 mm and 1 mm, most preferably around 0.75 mm. Owing to its low profile, the trays 1 may be devoid of conventional denesting features, such as denesting recesses positioned at alternate positions, and still be stacked onto each other and freely separated from each other.

[0098] A flap 5 may extend from an edge 8 of the base 2 and preferably, a flap 5 is configured to pivot about the edge 8 from which it extends. For example, a line of weakness in the form of a thinner strip of material and / or a plurality of perforations may be formed along the edge 8. The one or more flaps 5 may comprise a first surface 5a and a second surface 5b. The one or more flaps 5 may pivot relative to the base 2 at an angle of from 0° (or slightly above, so that the second surface 5b of the one or more flaps 5 lie against the upperside base 2) to 360° (or slightly below, so that the first surface 5a of the one or more flaps 5 lie against the underside of the base 2).

[0099] In the second configuration, the one or more flaps 5 cover the one or more fluid retention recesses 4 so that, when a product is placed on the tray 1, the product is supported by the supporting surface and the top surface of the folded flap.

[0100] In the second configuration, the supporting surface 3 may advantageously comprise the central supporting surface 8 and the first surface 5a of the folded flaps 5. In this configuration, the area of the supporting surface 3 is increased. In addition, the product does not directly contact (and therefore hinder) the fluid retention recesses 4. The overall fluid retention capacity of the tray 1 is optimised.

[0101] When the one or more fluid retention recesses 4 for a grouped array of fluid retention recesses 4, a flap 5 may be configured to cover said grouped array. The outer contour of the flap 5 may be substantially the same as that of the group of fluid retention recesses 4 it is intended to cover. In embodiments, the flaps 5 are substantially rectangular or substantially square but other shapes are envisaged. The dimensions of the flap 5 may be the same or greater than those of the grouped array. The dimensions means the length and the width in the case of a substantially square or rectangular flap 5.

[0102] When the one or more fluid retention recesses 4 are formed in a fluid retention area 7, a flap 5 may be configured to cover said fluid retention area 7. The outer contour of theflap 5 may be substantially the same as that of the fluid retention area 7 it is intended to cover. In embodiments, the flaps 5 are substantially rectangular or substantially square but other shapes are envisaged. The dimensions of the flap 5 may be the same or greater than those of the fluid retention area 7.

[0103] The flaps 5 preferably have rounded or curved corners to minimise the risk of scratching or otherwise damaging the product.

[0104] The position, shape and number of flaps 5 is preferably selected such that every fluid retention recess 4 is covered when the flaps 5 are in the second configuration. Therefore, preferably the tray 1 comprises an equal number of flaps 5 and of fluid retention areas 7 (or groups of fluid retention recesses, or arrays of fluid retention recesses). In a preferred embodiment, the tray 1 comprises two flaps 5 each extending from opposing edges 8 of the base 2; and each flap 5 is intended to cover a fluid retention area 8. However, different configurations are envisaged. For example, the tray 1 may comprises four flaps 5 extending from each of the four edges 8 of the base 2 (i.e., one flap 5 per edge 8); the tray 1 may comprise more than one flap 5 per edge 8.

[0105] In embodiments, the one or more flaps are detachable from the base. For example, the tray 1 may comprise a detachment line (such as a line of weakness formed by a thinner strip of material or a plurality of perforations) along the edge 8 between a flap 5 and the base 2.

[0106] In embodiments, the tray 1 comprises one or more features configured to position the product in the tray 1. For example, the product may be positioned by means of a concave portion 3b of the central supporting surface 3a, as described hereinabove. The tray 1 may additionally or alternatively comprise one or more positioning ribs 9. The one or more positioning ribs 9 may be located on the base 2 and / or on the one or more flaps 5.

[0107] One or more positioning ribs 9a may be located on the upper, in use, surface of the base 2. The one or more positioning ribs 9a may be formed along or adjacent an edge 8 of the base 2. Preferably, the positioning ribs 9a are formed along or adjacent an edge 8 of the base 2 devoid of flap(s) 5.

[0108] One or more positioning ribs 9b may be located on the first surface of one or more flaps 5 -that is, the upper, in use, surface of the folded flaps 5. The one or more positioning ribs 9b may be formed along or adjacent the edge 8 of the base 2 from which the one or more flaps 5 extend.

[0109] With this context, "along the edge" means that the positioning rib is in physical contact with the edge, "adjacent the edge" means that the positioning rib is not in physical contact with the edge, and may be separated from the edge by a strip 13 of material. This strip 13 or a strip of material may extend partly or completely along the periphery of the base 2, and may be useful in the handling, for example, the machine handling, of the tray 1 during the thermoforming, packing and / or sealing process.

[0110] The one or more positioning ribs 9 may comprise an elongated portion which extends substantially parallel to an / the edge 8 of base 2. The tray 1 may comprise a first positioning rib 9 substantially parallel to a first edge of the base 2 and a second positioning rib 9 substantially parallel to a second edge 8 of the base. The first and second edges 8 may be opposing edges, such that the first and second positioning ribs 9 may be located on opposing side of the base 2. In embodiments, the tray 1 may further comprise a third positioning rib and a fourth positioning rib parallel to a third edge of the base and a fourth edge of the base, respectively. The third and fourth edges may be opposing edges, so that each edge has a corresponding parallel positioning rib and the positioning ribs surround, partially or completely the supporting surface.

[0111] The one or more positioning ribs 9 comprise one or two curved end portions. In embodiments, the curved end portions are located in a corner portion of the base 2.

[0112] The one or more positioning ribs 9 may be positioned such that, together, in the second configuration, they partly or completely surround the supporting surface 3. This configuration is illustrated for example in Figure 8, in which the positioning ribs 9a of the flaps 5 in the second configuration are aligned with the positioning ribs 9b of the base 2 to form a peripheral rib defining and surrounding the supporting surface 3. Also as illustrated in Figure 8, the supporting surface 3 may be formed of the central supporting surface 8 and the first surface 5a of the folded flaps 5. The product may therefore be secured into position within the packaging system.

[0113] In embodiments, the upper portion of the one or more positioning ribs 9 is curved or rounded so as not to damage the product and / or the cover wrap.

[0114] Preferably, all the positioning ribs have substantially the same height. The height of the one or more positioning ribs 9 may be from 2.0 mm to 6.0 mm. When the one or more positioning ribs 9 have a height of at least 2.0 mm, the product may be adequately secured into position within the packaging system. When the one or more positioning ribs 9 have a height of 6.0 mm or less, the trays 1 can be easily stacked and freely separated from each other. In addition, in a thermoformed tray, a lower height may be preferred to provide for a thicker and stronger positioning ribs and to decrease stacking height and storage space.

[0115] In embodiments, the width of the one or more positioning ribs is 2.0 mm to 10.0 mm, 4.0 mm to 8.0 mm, or 5.0 mm to 7.0 mm, most preferably around 6.0 mm. In embodiments, all the positioning ribs have substantially the same width. The positioning ribs also serve to strengthen the structural rigidity of the tray.

[0116] A packaging system 100 according to the present disclosure comprises a tray 1 as described herein and a top film 10 configured to cover a product placed on the supporting surface of the tray. As illustrated in Figure 9, the packaging system 100 may furthercomprise a bottom support 11, wherein the top film 10 and the bottom support 11 are configured to fully surround the tray 1 and the product.

[0117] The top film 10 may comprise or consist of a monolayer or a multilayer film. In embodiments, the top film comprises one or more layers or materials selected from polyethylene terephthalate (PET); polyethylene (PE), such as machine-direction oriented polyethylene (MDO-PE) or biaxially oriented polyethylene (BO-PE); polyamide (PA), such as bi-oriented polyamide (PA). In embodiments, the top film comprisesone or more additional layers selected from barrier layers, adhesive layers, sealing layers, antimicrobial layers, printing layers and the like. The top film 10 may be adhered to the tray 1 or to the bottom support 11.

[0118] The bottom support 11 may be made of the same as or different materials from those used for the top film. The bottom support 11 may comprise or consist of a carboard support (such as a laminated cardboard support) and / or a plastics support (such as a plastics card support).

[0119] Preferably, the packaging system 100 is hermetically sealed. In embodiments, the atmosphere contained within the packaging system 100 may be modified and / or controlled to increase the shelf life of the product. Modified atmosphere packaging (MAP) may contain increased levels of oxygen or other gases. For example, to package red meat, the modified atmosphere may contain increased levels of oxygen, such as from 25% to 90% of oxygen, preferably 80% oxygen. Alternatively, MAP may contain increased levels of carbon dioxide, as used to package poultry. These are examples only; there are a wide range of commercially available gas mixtures used across a wide range of foods and non-foods. There are also significant commercial volumes of controlled atmosphere packages where the gas mixture inside a sealed pack is initially air, but where the product consumes and also generates gases such that the atmosphere becomes modified by means of carefully designed and targeted film material and container material choices. This is known as controlled atmosphere packaging (CAP).

[0120] The packaging system may be a flexible packaging system, a vacuum packaging, or a vacuum skin packaging system. The packaging system is preferably a vacuum packaging (for vacuum packed products).

[0121] An exemplary process for manufacturing a tray according to the present disclosure will now be described.

[0122] Plastics materials (preferably a recyclable material, most preferably polyethylene terephthalate) in the form of flakes and / or pellets are fed into an extruder to produce a sheet of plastics material. In the case of a multilayer sheet, two or more plastics materials are co-extruded.

[0123] The sheet is thermoformed such that one or more trays 1 (typically a plurality) are formed in the sheet. A thermoforming mould may be provided which produces a plurality of tray 1 in the first configuration.

[0124] The trays 1 are separated from each other, for example using a cutting tool, and subsequently trimmed. The trays 1 may be stacked on top of each other for subsequent handling (e.g., storage, transport, packing and sealing).

[0125] Any manufacturing waste may be fed back into the manufacturing process. Intermediary recycling steps may be required, for example washing, shredding and / or mixing with virgin plastics materials to decrease the recycled to virgin material ratio.

[0126] The trays 1 from a stack of trays are fed into a packing line. The flaps 5 are folded into the second configuration so as to provide a supporting surface 3. In the second configuration, the product is not in direct contact with the fluid retention recesses 4 and cannot hinder the mouths of the fluid retention recesses 4, such that exudate can be conveyed into the fluid retention recesses.

[0127] The product may now be deposited onto the supporting surface 3 of the tray 1. The product may be a fish product, a meat product, a poultry product, or a protein product. The product is preferably in the form of slices or cuts.

[0128] A top film 10 is positioned above the tray 1 and product, and a bottom support 11 is positioned under the tray 1. The top film 10 and the bottom support 11 are hermetically sealed with each other. Sealing may be achieved by application of pressure and / or heat, by application of an adhesive on the top film 10 and / or on the bottom support 11 (preferably only on the area(s) to be sealed), by adding a sealing layer to the top film 10 and / or to the bottom support 11, and the like.

[0129] The atmosphere within the packaging system 100 may be modified or controlled (MAP or CAP applications).

[0130] Any exudate from the product may be received by and collected in the grooves 12, and conveyed towards the fluid retention areas 7 and into the fluid retention recesses 4. Thus, the product shelf life is increased.

[0131] Thus, the present disclosure provides a tray for use in the packaging, storage, transportation and / or display of a product, such as a fresh food product which produces an exudate. The exudate may be drained through grooves and collected into and retained by high fluid retention capacity recesses. The overall fluid retention capacity of the tray is improved by providing flaps which prevent the product from hindering the fluid retention recesses, without decreasing the area of the product supporting surface. The first configuration is advantageous in that the tray may be produced easily for example by a thermoforming process and in large volumes.REFERENCE NUMERALS1 Tray2 Base of the tray3 Surface for supporting a product, or supporting surface 3a Central supporting surface3b Concave portion3c Uppermost surface of the supporting surface4 Fluid retention recess5 Flap5a First surface5b Second surface6 Raised rim7 Fluid retention area8 Edge of the base9 Product positioning rib9a Positioning rib on the base9b Positioning rib on a flap10 Top film11 Bottom support12 Groove13 Strip100 Packaging system

Claims

CLAIMS1. A tray comprising:a base including a surface for supporting a product;a plurality of fluid retention recesses formed in the base; andone or more flaps movable between a first configuration in which the one or more flaps extend outward from the base and a second configuration in which the one or more flaps cover the one or more fluid retention recesses.

2. The tray according to claim 1, wherein the one or more flaps extend from an edge of the base.

3. The tray according to claim 1 or 2, wherein the one or more flaps are pivotable about the edge of the tray from which they extend.

4. The tray according to any one of the preceding claims, wherein the one or more flaps are detachable from the base.

5. The tray according to any one of the preceding claims, wherein the one or more flaps are integrally formed with the base.

6. The tray according to any one of the preceding claims, wherein the fluid retention recesses are formed in a fluid retention area, said fluid retention area being relieved relative to the supporting surface.

7. The tray according to any one of the preceding claims, wherein each fluid retention recess comprises a raised rim surrounding the mouth of the recess.

8. The tray according to any one of the preceding claims, wherein the supporting surface comprises one or more grooves in fluid communication with the fluid retention recesses.

9. The tray according to any one of the preceding claims, wherein the tray comprises one or more positioning ribs.

10. The tray according to claim 9, wherein the one or more positioning ribs are located on the supporting surface of the base and / or on the one or more flaps.

11. The tray according to claim 9 or 10, wherein the positioning ribs are positioned to partly or completely surround the supporting surface.

12. The tray according to any one of claims 9 to 11, wherein the height of the one or more positioning ribs is from 2.0 mm to 6.0 mm.

13. The tray according to any one of the preceding claims, wherein the supporting surface comprises a central supporting area devoid of fluid retention recesses.

14. The tray according to any one of the preceding claims, wherein the supporting area comprises a central supporting area and the upper surface of the flaps, when the flaps are in the second configuration.

15. The tray according to claim 13 or 14, wherein the central supporting area is concave.

16. The tray according to any one of the preceding claims, wherein the tray comprises or consists of one or more materials selected from amorphous polyethylene terephthalate (APET), polypropylene (PP), high-density polyethylene (HDPE) and low-density polyethylene (LDPE), and expanded polystyrene (EPS).

17. The tray according to claim 16, wherein the tray comprises or consists of amorphous PET.

18. The tray according to any one of the preceding claims, wherein the tray, in the first configuration, is a stackable onto or nestable into a second tray, in the first configuration.

19. A process for manufacturing a tray according to any one of claims 1 to 18, comprising the step of thermoforming one or more tray from a sheet of plastics material.

20. The process according to claim 19 comprising one or more steps selected froma. Extruding or co-extruding a sheet from one or more plastics materials;b. Thermoforming the sheet into one or more trays;c. Separating the trays from each other;d. Trimming the trays;e. Stacking the trays on top of each other;f. Feeding the manufacturing waste back into the manufacturing process.

21. A packaging system comprising a tray according to any one of claims 1 to 18 and a top film configured to cover a product placed on the supporting surface of the tray.

22. The packaging system according to claim 21, wherein the top film comprises or consists of a monolayer or a multilayer film.

23. The packaging system according to claim 21 or 22, wherein the packaging system comprises a bottom support configured to be placed under the tray.

24. The packaging system according to any one of claims 21 to 23, wherein the packaging system is hermetically sealed.

25. The packaging system according to any one of claims 21 to 24, wherein the packaging system is a vacuum packaging system.

26. A process for packing a product in a packaging system according to any one of claims 21 to 25 comprising the step of covering a product and the supporting surface with a top film.

27. The process according to claim 26 comprising the step of placing a product onto the supporting surface of the tray.

28. The process according to claim 26 or 27, comprising the step of placing a bottom film under the tray.

29. The process according to any one of claims 26 to 28 comprising the step of applying vacuum between the supporting surface and the top film.

30. The process according to any one of claims 26 to 29 comprising the step of modifying or controlling the atmosphere between the tray and the top film.

31. The process according to any one of claims 26 to 30 comprising the step of hermetically sealing the packaging system.

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