Improved method for packing a container for storing and transporting banana clusters and container thereof
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2026-01-27
- Publication Date
- 2026-08-13
Smart Images
Figure EP2026052050_13082026_PF_FP_ABST
Abstract
Description
[0001] IMPROVED METHOD FOR PACKING A CONTAINER FOR STORING AND TRANSPORTING BANANA CLUSTERS AND CONTAINER THEREOF TECHNICAL FIELD
[0002] The invention relates to a container for storing and transporting banana clusters. The invention also relates to a method for packing a container for storing and transporting banana clusters, for example a container of standardized dimension storing 18.14 kilograms of banana fruit packed in four lines.
[0003] BACKGROUND OF THE INVENTION
[0004] Bananas are usually packed in boxes of a standardized size, usually made from corrugated cardboard, designed to be shipped from the point of harvest to the point of sale. Said boxes usually comprise a base containing the produce and a lid positioned over the base. The base and / or lid typically comprise apertures to provide ventilation. For added protection of the bananas, a flexible plastic bag is placed in the base portion of the box. The bag protects the fruit against damage caused by friction with paper surfaces and controls dehydration.
[0005] These boxes can be fitted with handles, which also improve ventilation. They can also be used to display products at the point of sale, once the lid has been removed and the bag opened.
[0006] Such packing systems are widely used for packing, shipping, and storing produce such as bananas. They can easily be stacked for transportation on shipping pallets, optionally after having received an overwrap. Some of those packing systems are described in the patent published under number EP 0417947 A1, WO 97 / 11885 A1, WO 2011 / 081636 A1 and WO 2019 / 152756 A1.
[0007] In these packing systems known to the prior art, during the packing process, a paper pad is placed centered inside the bottom component, and then, a plastic bag is placed centered on the paper pad inside the base component, and the open edges of the plastic bag are draped over the sidewalls of the base of the box. Cut segments of banana hands (i.e. , banana clusters) are typically placed inside the bag first in the bottom of the bag in two facing lower fruit rows. Then, both paper pad ends which are covered by the plastic bag are folded towards the base center over these 2 lower fruit lines. Subsequently, clusters of bananas are placed in two facing top rows, atop the lower rows covered by the fold of thepaper pad and plastic bag. The remaining plastic of the bag is then gathered and folded to form a knot which is closed above the rows of bananas usually with a rubber band.
[0008] This prior art packing system presents a risk of accidental perforation or tearing of the flexible bag during the packing process, especially when operator errors occur during the fruit packing process. To ensure the integrity of the bag, sufficiently robust resin formulations are used to produce the bags, and the thickness of the bag is kept sufficiently large, for example superior to about 0.7 mil.
[0009] The plastic bag used during the packing process significantly limits and controls the amount of moisture which is lost to the environment. This bag is typically perforated with ventilation apertures when fruit is sent to short distance destinations, but for long distance destinations it is used a bag without perforations (Banavac bag) - which extend the fruit green life. When using Banavac bags, it is necessary to seal them tightly and make sure that they have not been torn during the packing process, so that they can develop the modified internal atmosphere required to prolong the green life of the fruit. When the fruit arrives at the market, it requires to open these bags to ripen the fruit, because these bags are not perforated and limit the airflow within the bag. To open the bag, a section of plastic bag is pulled from the hand hole and cut to create a hole, prior to introducing the pallets of banana boxes in Ripening Rooms.
[0010] When the bag is perforated, the ventilation apertures are designed to achieve several objectives: improve air flow which helps to cool the fruit during transportation, ensure a good ethylene application around the bananas in ripening rooms, control fruit dehydration, and help to eliminate the excess of heat developed by the fruit during the ripening process. When the bag is perforated, the number and size of the openings control the ventilation of the bag depending on the end application.
[0011] The inventors have developed a new and improved packing system aiming to achieve at least one of the following goals: reduce the risk of tearing of the plastic bag, reduce the amount of plastic material used inside the container, improve internal air flow circulation, improve the packing speed, reduce the cost of the container and reduce the risk of staining of fruit, that may be caused by latex oozing from the tip and crow of the banana clusters.SUMMARY DISCLOSURE OF THE INVENTION
[0012] In this context, the invention relates to a method for packing a container and to a container obtained from said method.
[0013] A first aspect of the present invention concerns a method for filling a container for storing and transporting banana clusters comprising the following steps:
[0014] - providing a box, comprising an interior bottom, the box preferably comprising a bottom portion and a top portion, telescopically mountable on top of the bottom portion,
[0015] - providing a plastic bag having a closed end and an opening,
[0016] - placing the closed end of the plastic bag on said interior bottom
[0017] - providing a flat paper pad,
[0018] - placing the flat paper pad on said interior bottom atop the plastic bag,
[0019] - providing a plastic sheet,
[0020] - placing the plastic sheet on said interior bottom atop the paper pad,
[0021] - providing a plurality of banana clusters,
[0022] - laying down two bottom rows of banana clusters on said interior bottom atop the plastic sheet,
[0023] - wrapping at least partially said paper pad together with the plastic sheet over the top of the two bottom rows of banana clusters,
[0024] - laying down at least one further row of bananas clusters above the two bottom rows of banana clusters, atop said paper pad and said plastic sheet and
[0025] - closing the plastic bag to enclose the paper pad, the plastic sheet and the banana clusters.
[0026] The method for filling a container for storing and transporting banana clusters hereinabove can include any of the following detailed or additional steps:
[0027] - providing a box comprising a bottom portion and a top portion said bottom and top portion being of rectangular construction, wherein the bottom portion comprises a first and second parallel sidewall, a first and second parallel endwall and an interior bottom,
[0028] - providing a plastic bag having a closed end and an opening,
[0029] - placing the plastic bag in the bottom portion, having a step of placing the closed end of the plastic bag in contact with the interior bottom leaving the opening of the bag facing up and a step of folding the edges of the opening over the top of the first and second parallel sidewall and over the top of the first and second parallel endwall, so that a part of the plastic bag is hanging outside on each wall of the bottom portion,
[0030] - providing a flat paper pad having a rectangular shape, said paper pad preferably having a a width and length sufficient to cover the interior bottom and a length sufficient to cover, separate and protect the fruit lines (rows of clusters)- placing the paper pad on the interior bottom portion, atop the plastic bag, with parts of the paper pad pressed against the parallel side walls, optionally with the ends of said parts parallel to the sidewalls,
[0031] - providing a plastic sheet, said paper sheet preferably having a rectangular shape with a width and a length sufficient to cover the interior bottom and the paper pad surface which would be in contact with the fruit,
[0032] - placing the plastic sheet on the interior bottom portion, atop the paper pad, with part of the plastic sheet pressed against interior bottom, and covering all the internal and external paper pad surface,
[0033] - laying down a first bottom row of banana clusters, by placing the crown portion and tip portion of the clusters of the first bottom row on the bottom portion, in contact with the plastic sheet or in contact with a paper napkin if present,
[0034] - laying down a second bottom row of banana clusters, by placing the crown portion of the clusters of the second bottom row on the bottom portion, in contact with the plastic sheet or in contact with a paper napkin if present, wherein the tip portion of the clusters of the second bottom row are placed atop the first bottom row,
[0035] - pulling a first end of the paper pad along with a corresponding first end of the plastic sheet and folding said ends over the first bottom row of clusters, thus exposing the plastic bag pressed against a first side wall,
[0036] - laying down a first top row of banana clusters, by placing the backside of the clusters in contact with the interior of the plastic bag pressed against the first side wall and the tip portion atop the folded first end of the plastic sheet,
[0037] - pulling a second end of the paper pad along with a corresponding second end of the plastic sheet and folding said ends over the second bottom row of clusters, thus exposing the plastic bag pressed against a second side wall,
[0038] - laying down a second top row of banana clusters, by placing the backside of the clusters in contact with the interior of the plastic bag pressed again the second side wall and the tip portion atop the folded second end of the plastic sheet and paper pad, and
[0039] - closing the plastic bag comprising a step of pulling together the lip of the plastic bag and closing said plastic bag using any suitable mean, and
[0040] - forming the box by placing the top portion of the box on the bottom portion of the box.
[0041] In a preferred embodiment, the method of the invention includes all the additional or detailed steps listed above.
[0042] According to a first variant, the plastic bag and the plastic sheet are perforated, and the perforation pattern of the plastic sheet differs from the perforation pattern of the plastic bag.According to a second variant of this first aspect of the invention, which can be combined with said first variant, the thickness of the plastic bag is greater than the thickness of the plastic sheet.
[0043] According to a third variant of this first aspect of the invention, which can be combined with said first variant and / or with said second variant, the thickness of the plastic sheet is lower or equal to about 0.6 mil (thousandths of an inch). Preferably, the thickness of the plastic sheet is superior or equal to about 0.5 mil. In a particular embodiment, the thickness of the plastic sheet is comprised between 0.5 mil and 0.6 mil.
[0044] It is noted that to 0.6 mil corresponds to 15.24 pm (micrometers) and that 0.5 mil corresponds to and 12.7 pm.
[0045] According to a fourth variant of this first aspect of the invention, which can be combined with said first variant and / or with said second variant and / or with said third variant, the thickness of the plastic bag is lower or equal to about 1 mil, preferably lower or equal to 0.6 mil, preferably higher or equal to 0.5 mil. In a particular embodiment, the thickness of the plastic bag is comprised between 0.5 mil and 0.6 mil.
[0046] It is noted that 0.5 mil corresponds to 12.7 pm (micrometers), 0.6 mil corresponds to 15.24 pm, and that 1 mil corresponds to 25.4 pm.
[0047] According to a fifth variant of this first aspect of the invention, which can be combined with said first variant and / or with said second variant and / or with said third variant and / or with said fourth variant, the method comprises the following additional steps, between the steps of placing the plastic sheet and the step of forming a first bottom row of banana clusters: - providing a paper napkin having a rectangular shape, and a width and length about equal to the width and length of the interior bottom and
[0048] - placing the paper napkin on the interior bottom, atop the plastic sheet.
[0049] According to a sixth variant of this first aspect of the invention, which can be combined with said first variant and / or with said second variant and / or with said third variant and / or with said fourth variant and / or with said fifth variant, the plastic bag is made by a polyethylene blown film extrusion process which produces a plastic tube which once cooled, is flattened and wound into rolls.Advantageously, these rolls are then passed through a converting machine which produces the bags by sealing & cutting perpendicularly the tube. If the bag has perforation holes for air circulation, this same converting machine punches the holes.
[0050] According to a seventh variant of this first aspect of the invention, which can be combined with said first variant and / or with said second variant and / or with said third variant and / or with said fourth variant and / or with said fifth variant and / or with said sixth variant the plastic sheet is made of Linear low-density polyethylene (LLDPE).
[0051] According to an eighth variant of this first aspect of the invention, which can be combined with said first variant and / or with said second variant and / or with said third variant and / or with said fourth variant and / or with said fifth variant and / or with said sixth variant and / or with said seventh variant, the plastic bag is made of Linear low-density polyethylene (LLDPE).
[0052] According to a nineth variant of this first aspect of the invention, which can be combined with said first variant and / or with said second variant and / or with said third variant and / or with said fourth variant and / or with said fifth variant and / or with said sixth variant and / or with said seventh variant and / or with said eighth variant, the steps of the method are performed manually.
[0053] A second aspect of the present invention concerns a container characterized in that it comprises:
[0054] - a box, comprising an interior bottom, the box preferably comprising a bottom portion and a top portion, telescopically mounted on one another and
[0055] - a plastic bag having a closed end and an opening,
[0056] - a flat paper pad,
[0057] - a plastic sheet,
[0058] - a plurality of banana clusters
[0059] wherein the closed end of the plastic bag is positioned on said interior bottom and the opening of the plastic bag is folded and closed to enclose the paper pad, the plastic sheet and the banana clusters,
[0060] wherein the flat paper pad is positioned on said interior bottom atop the plastic bag, wherein the plastic sheet is placed on said interior bottom atop the paper pad, wherein two bottom rows of banana clusters are laid down on said interior bottom atop the plastic sheet,
[0061] wherein at least part of the plastic sheet is folded over the ends of the paper pad, wherein said paper pad together with the plastic sheet is at least partially wrapped over thetop of the two bottom rows of banana clusters,
[0062] and wherein at least one further row of bananas clusters is positioned above the two bottom rows of banana clusters, atop said paper pad and said plastic sheet.
[0063] This second aspect of the present invention can be combined with any one or more of the variants of the first aspect.
[0064] BRIEF DESCRIPTION OF THE DRAWINGS
[0065] The figures are intended to illustrate certain aspects of the invention or of prior art. In particular, they are intended to facilitate the description of the invention and certain of its advantageous embodiments, and to enable a person skilled in the art to carry out the invention. They shall not be interpreted as limiting the scope of the invention in any way.
[0066] Figure 1 shows a container for storing and transporting bananas according to a method known to the prior art.
[0067] Figure 2 is a schematic view of a cluster of bananas.
[0068] Figures 3 to 8 illustrate certain embodiments or features of the invention.
[0069] Figure 3 shows schematically a container for storing and transporting banana produced according to particular embodiment of a method of the invention.
[0070] Figure 4 shows schematically a container for storing and transporting bananas produced according to particular embodiment of a method of the invention.
[0071] Figure 5 shows schematically the container of figures 3 and 4 with the top portion, which forms the two-part box.
[0072] Figure 6 shows schematically a plastic sheet used in certain embodiments of the container of the invention.
[0073] Figure 7 shows schematically a plastic bag used in certain embodiments of the container of the invention.
[0074] Figure 8 shows schematically an example of a paper pad used in certain embodiments of the container of the invention.
[0075] The following reference numbers are used in the figures and in the description:
[0076] 110, 111, 112, 113, 114 Banana cluster 119 Tip Portion
[0077] 117 Backside 120 “long” plastic bag (prior art)
[0078] 118 Crown portion 121 “short” plastic bag123, 124 Perforation 181, 182, 183, 184 Long Flaps
[0079] 125, 126 First and second edges (folded) 185, 186 Handholds
[0080] 127 Third edge (sealed) 187, 188 Short Flaps
[0081] 128 Fourth edge (opened) 191 Box Bottom portion
[0082] 130 Plastic Sheet 192 Box Top portion
[0083] 131 First end of the plastic sheet 193 First sidewall
[0084] 132 Second end of the plastic sheet 194 Top of the first sidewall
[0085] 135, 136 Perforations in the plastic sheet 195 Second sidewall
[0086] 140, 144 Paper pad 196 Top of the second sidewall
[0087] 141 , 142, 145, 146 End of the paper pad 197 Endwall
[0088] 148, 149 Perforation in the paper pad 199 Interior bottom
[0089] 150 Paper Napkin
[0090] DETAILED DESCRIPTION OF EMBODIMENTS
[0091] It should first be noted that, as shown in figure 2, each banana cluster 110 is defined as having a crown portion 118, a tip portion 119 and a backside 117. A “banana hand” usually refers to a complete section of the banana bunch. To facilitate packing, a “banana hand” is cut into several “clusters” (parts) of a similar size in the farm.
[0092] During the packing process, the banana clusters 110, 111, 112, 113, 114 are packed into a container 190 comprising a corrugated cardboard box. It should be noted that any suitable cardboard box may be used. In particular, the box can be a parallelepiped, most often a rectangular cuboid, but the invention can be applied to other regular or irregular shapes, too.
[0093] In the particular embodiment presented in figure 5, the cardboard box 190 comprises a bottom portion 191 (also called base) and a top portion 192 (also called lid). This type of two-part box is commonly referred to as a full-telescoping half-slotted container (HSC). The top portion 192 and bottom portion 191 are of approximately equal depth, and top portion 192 telescopically slides over bottom portion 191 to complete the box. Ventilation apertures can be provided on the periphery of both portions of the container, as well as hand slots, 185, 186, for grasping the container. Said hand slots and vent holes are present on the bottom portion as well as on the top portion, the hand slots and vent holes of the two portions are configured to be aligned with one another once the lid is placed onto the bottom. Thetop and bottom portions, 192 and 191, each have long flaps, 181, 182, 183 184, and short flaps, 187 and 188.
[0094] As shown for the top portion 192, the long flaps, 183 and 184 are folded over the short flaps and glued to close each portion. When these flaps are folded over, however, a central ventilation opening will be provided in both top portion 192 and bottom portion 191. Top portion 192, for example, has flaps, 183, 184, 187 and 188, which are folded to define a central ventilation opening through which the bagged banana hands within the box will be visible. The bottom portion 191 is folded in shape in the same manner as the top portion.
[0095] The bottom portion comprises 191 a first and second parallel sidewall, 193 and 195, a first and second parallel endwall (not shown on the figures), and an interior bottom 199. The top edges of the first and second side walls are marked with reference numbers 194 and 196, respectively.
[0096] It should be noted that, in figures 1, 3 and 4, each row of banana clusters is represented by one cluster, 111, 112, 113, 114, of bananas.
[0097] Figure 1 shows an example of a container of banana clusters obtained by a method known to the prior art. According to this method, the bottom portion 191 of two-part box 190 is first placed on a flat working surface (not shown). At this stage, a paper pad 144 may be placed on the interior bottom 199. In an advantageous embodiment the paper pad is rectangular in shape, with a width sufficient to cover most of the length of the interior bottom 199, endwall to endwall, and with enough length to be able to separate and protect the two top fruit lines. The two extremities of the paper pad 144 along its length form a first end 141 and a second end 142. The first end 141 and the second end 142 are pulled up to the side wall and then up and then the paper pad 144 is flattened against the interion bottom 199 and against the interior of the side walls, 193 and 195.
[0098] A plastic bag 120 is then placed on the interior bottom 199, atop the paper pad 140. The plastic bag is flattened against the interior bottom and then flattened against each of the sidewalls, 193 and 195, and endwalls (not shown). The open edges of the plastic bag 120 are pulled up, then to the side and folded over the base top edges, 194 and 196, of the sidewall and over the top edges of the endwalls.
[0099] Subsequently, clusters of bananas are placed inside the bag 120. A first bottom row of clusters represented by cluster 111 is placed on the bottom interior 199, atop the plastic bag 120. A second bottom row of clusters represented by cluster 112 is then placed at leastpartly atop the plastic bag 120. As shown in figure 1, part of cluster 112 of the second bottom row may be placed atop cluster 111 of the first bottom row.
[0100] The packer then proceeds to pull the plastic bag 120 together with the paper pad end 142 inwardly, up and then towards the side of the second sidewall 195, folding both the paper pad 144 and plastic bag 120 to cover the cluster 111 of the first bottom row and partially a section of the cluster 112 of the second bottom row. The packer then pushes down the plastic bag 120 between the first side wall and the first cluster to create space.
[0101] Then, a first top row of clusters of bananas is placed in the space just created. The first top row represented by cluster 113 is placed atop the paper pad end 142 wrapped with the plastic bag 120.
[0102] The same operation with the paper pad 140 is then repeated on the side of the second sidewall 195: the paper pad end 141 together with the plastic bag 120 are pulled inwardly, towards the first sidewall 193, and folded above cluster 112 of the second bottom row and partially above a section of the cluster 113 of the top fruit row located at the first sidewall 193.
[0103] Finaly, a second top row of clusters of bananas is placed. The second top row represented by cluster 114 is placed atop the paper pad end 146 wrapped with plastic bag 120.
[0104] Clusters 113 and 114 of banana are placed in two facing top rows, atop the lower rows covered by the fold of the plastic bag 120 and paper pad 140. To pack the box snuggly, clusters 113 and 114 of the two top rows are pushed down firmly. As shown in figure 1, the crowns of clusters 113 and 114 push against a fold in the plastic bag during this operation. The sharp crowns of the cluster may tear the plastic bag at this stage. The packer handling this step must therefore carefully control the force while pushing down the clusters 113 and 114 of the top rows and / or the plastic bag must be sufficiently strong to withstand the downward force applied by the cluster crown during this step. As it is described with regards to figure 3, avoiding this risk of perforation is one of the problems solved by the present invention.
[0105] The remaining plastic of the bag is collected and rolled into a knot which is tied with a rubber band above the top rows of banana clusters. The plastic bag is then closed. Finaly, top portion 192 (similar to the one shown in figure 5) is telescopically slid over the bottom portion 191 to complete the box.It is noted that the packing system described with regards to figure 1 requires a long plastic bag, for example about 1280 millimeters in length. On the contrary, the packing system of the invention described below requires bags shorter in length, for example equal to or less than 900 mm in length, for example equal to 873 mm in length. The long plastic bag used in the prior art not only produces an excess of plastic waste but also produces an accumulation of plastic when the pad ends are folded to the center of the box, as described above.
[0106] In addition, this accumulation of plastic formed on both short internal endwalls of the box, blocks the ventilation openings, reducing the horizontal air flow pressure through the box and between boxes stacked in pallets. This obstruction by excess of plastic can impede the horizontal air flow supplied by the Ripening Rooms during the fruit ripening process. This accumulation of plastic is not present with the new packing method and container described below, which uses shorter plastic boxes.
[0107] Figure 3 shows a particular example of a container 10, according to the invention, for transporting and / or storing bananas. The method for producing such a container comprises the following steps.
[0108] Firstly, the bottom portion 191 of two-part box 190 is placed on a flat working surface (not shown). The bottom portion 191 comprises a first and second parallel sidewall, 193 and 195, a first and second parallel endwall (not shown), and an interior bottom 199. The top edges of the first and second side walls are marked with reference numbers 194 and 196, respectively.
[0109] A plastic bag 121 is then provided. A particular embodiment of the plastic bag 121 will be described with regards to figure 7. The plastic bag 121 comprises a closed end and an opening. The closed end of the plastic bag is placed in contact with the interior bottom leaving the opening of the bag facing up. The plastic bag 121 is flattened on the interior bottom and then on the sidewalls and endwalls. At this stage, the plastic bag extends upwards beyond the top edges of each of the sidewalls and endwalls. The edges of the opening of the plastic bag 121 are pulled over the top of the first and second parallel sidewall, 164 and 196, and over the top of the first and second parallel endwall and then down so that a part of the plastic bag 121 is hanging outside on each wall of the bottom portion 191.
[0110] A paper pad 144 is then provided. The paper pad 144 has a rectangular shape, and a width sufficient to cover the length of the interior bottom and enough length to cover the cluster tobe placed on top of the pad, once the pad ends are folded towards the center of the base. A particular embodiment of the paper pad 144 will be described with regard to figure 8.
[0111] The paper pad 144 is centrally placed on the interior bottom portion 191, atop the plastic bag 121. The paper pad 144 is pressed against the interior bottom atop the plastic bag 121 and against the parallel side walls, 193 and 195. The ends 145 and 146 are pulled up and remain slightly above the edges of the box, 194 and 196.
[0112] A plastic sheet 130 is then provided. The plastic sheet has a rectangular shape, it is wide enough to cover the paper pad width and long enough to cover the internal paper pad surface and to fold the plastic sheet ends 131 and 132 over the pad ends 145 and 146, in that way that the plastic sheet ends 131 and 132 fall along the external pad surface until the interior bottom 199. Thus, the plastic sheet covers the entire surface of the paper pad that could be in contact with the fruit. A particular embodiment of the plastic sheet 130 will be described with regards to figure 6.
[0113] The plastic sheet 130 is placed centrally on the interior bottom portion 191, atop the paper pad 144, covering all the internal and external paper pad surfaces in contact with the fruit.
[0114] In a particular embodiment shown in figure 4, a paper napkin 150 is provided. The paper napkin has a rectangular shape, and a width and length about equal to the width and length of the interior bottom. The paper napkin may be placed on the interior bottom 199, atop the plastic sheet 130 with the objective to absorb latex - in the case the fruit exudes it. The paper napkin is pressed down to cover at least part of the bottom of the container 10.
[0115] At this point, the next step is to place banana clusters in container 10. In order to optimize the packing process, all the previous steps may be carried out ahead of time.
[0116] A first bottom row of banana clusters is laid down one by one, cluster 111 is placed in contact with the plastic sheet 130, or in contact with a paper napkin if present. The crown portion and tip portion of the clusters are oriented facing down. The crown portion of the cluster is oriented outwardly, while the tip portion of the cluster is oriented inwardly. All other clusters in the row are placed in a similar fashion, side to side.
[0117] A second bottom row of banana clusters is then laid down. Cluster 112 is placed on the bottom portion 191 with its crown portion in contact with the plastic sheet 130 or in contact with a paper napkin if present. The tip portion of cluster 112 is placed atop cluster 111 ofthe first bottom row. All the banana clusters of the second bottom row are placed side by side, in a similar fashion.
[0118] A first end 145 of the paper pad 144 is then pulled together with the folded plastic sheet corresponding to the end 131. Said ends 145 and 131 are folded over the first bottom row of clusters 111, also partially covering the tips of the second row of clusters. This step exposes the plastic bag 121 pressed against the interior of the first side wall 193 and creates a space between said interior wall and said plastic sheet. As shown in figure 3, the plastic sheet 130 has enough length to be folded on the paper pad end 145 and cover all the external pad surface until the interior bottom 199.
[0119] A first top row of banana clusters is then laid down. Cluster 113 is placed with its crown portion and tip portion facing down and inwardly, in contact with the fold of paper pad 144 covered with plastic sheet 130. The backside of cluster 113 is placed in contact with the interior of the plastic bag 121 , against the first side wall 193.
[0120] Contrary to the method of the prior art described with regards to Figure 1 , the crown portion of the top rows of banana cluster does not rest on a fold of the plastic bag. This configuration prevents the risk of tearing in the plastic bag during the packing process.
[0121] A second end 146 of the paper pad 144 is then pulled together with the folded plastic sheet corresponding to the end 132. Said ends 146 and 132 are folded over the second bottom row of clusters 112 and partially covering the tips of the first top row of banana clusters. This step exposes the plastic bag 121 pressed against the interior of the second side wall 195 and creates a space between said interior wall and said plastic sheet. Preferably, as shown in figure 3, the plastic sheet 130 has enough length to be folded over the paper pad ends, 145 and 146, and cover all the external pad surface until the interior bottom 199.
[0122] A second top row of banana clusters is then laid down. Cluster 114 is placed with its crown portion and tip portion facing down and inwardly, in contact with the fold of paper pad 144 covered with plastic sheet 130. The backside of cluster 114 is placed in contact with the interior of plastic bag 121, against the second side wall 195.
[0123] At this stage, the banana clusters of the top rows are gently pressed down to pack the rows of clusters snuggly together. The sides of the plastic bag 121 hanging from each sidewall and endwall of the bottom portion 191 are then pulled together and closed by any suitable means.The plastic bag may be closed using a rubber band, twine, or an adhesive strip.
[0124] Finaly, as shown in figure 5, a top portion 192 is telescopically slid over the bottom portion 191 to complete box 190.
[0125] In the example described above, the packing method is performed manually. However, this method could be adapted to be performed by a packing robot or by a combination of packing robots and human labor, without deviating from the invention.
[0126] Figure 6 shows a particular embodiment of a plastic sheet 130 that can be used in the packing method described in relation to figures 3 and 4. Preferably, plastic sheet 130 is rectangular in shape. Preferably, the plastic sheet 130 is as wide as the interior bottom 199 in order to cover completely the paper pad 144 placed on the box bottom portion 191. Preferably, the plastic sheet 130 is at least as long as the total paper pad surface which would be in contact with the fruit. In other words, the plastic sheet should be sufficiently long and wide to coverall the surface of the interior and exterior area of the paper pad 144 which would be in contact with the fruit.
[0127] In a preferred embodiment, plastic sheet 130 is perforated to allow the free movement of air within the plastic bag 121 and paper pad 144 of container 10.
[0128] According to the prior art, the folded part of the plastic bag 120 is slid underneath the top rows of banana, as shown in figure 1. In this configuration of the prior art, the crown portion of the row of banana cluster rests on the inflexion point of the fold of the plastic bag. This can apply excessive pressure to the fold in the plastic bag 120 and cause the plastic bag to tear. To alleviate this risk, plastic bag 120 is made with thick plastic and / or produced by using a strong and more expensive resin formulation, to reinforce the bag.
[0129] On the contrary, according to the invention as described in figure 3, the crown portion of the top row clusters of bananas do not rest on a plastic bag but rather rest on a plastic sheet 130. In this advantageous configuration, there can be more perforations and / or larger perforation in the plastic sheet 130 compared to the number and size of perforations in the plastic bag 120 used in the prior art. Thus, the internal circulation of air can be improved, compared to the prior art.
[0130] According to the invention as described in figure 3, the plastic bag 121 does not suffer any pressure from the cluster crowns, so it does not break. The pressure of said cluster crownsis instead applied to the plastic sheet, which does not cause issues since the cluster crowns tend to slide on the plastic sheet without causing damage.
[0131] In a preferred embodiment, the thickness of the plastic sheet is higher or equal to about 0.5 mils, preferably lower or equal to about 0.6 mils. Preferably, plastic sheet 130 is made of Linear Low-Density Polyethylene (LLDPE).
[0132] Figure 7 shows a particular embodiment of a plastic bag 121, that can be used in the packing method described in relation with figures 3 and 4. The plastic bag 121 is preferably made by film extrusion process which produces a plastic tube which once cooled, is flattened and wound into rolls. These rolls are then passed through a converting machine which produces the bags by sealing & cutting perpendicularly the continuous tube. If the bag has holes, this same converting machine punches the holes.
[0133] The plastic bag 121 is made from a tubular piece having a first folded edge and second folded edge, 125 and 126, when flattened as shown in figure 7. The tubular piece initially presents two openings. One of said openings is sealed shut, on the third edge 127 of the flattened plastic bag, forming the bottom of the bag. The other opening left as-is, on the fourth edged 128 of the flattened plastic bag, forming the opening of mouth of the plastic bag 121.
[0134] As explained in relation to figures 3 and 4, the banana clusters stored in container 10 do not apply excessive pressure on the plastic bag 121, contrary to the pressure applied by the crown of the top rows clusters in the container packed according to the prior art method shown in figure 1.
[0135] In a particular embodiment, the thickness of the plastic bag 121 is about 0.60 mil (15.24 pm). In another particular embodiment, the thickness of the plastic bag 121 is about 1 mil (25.4 pm).
[0136] According to different embodiments, the plastic bag 121 may or may not comprise perforations, or the number of perforations may vary.
[0137] In a specific embodiment, the plastic bag 121 is about 0.60 mils, perforated and sourced from Polypack (registered trademark).
[0138] In some embodiments, bags without perforation such as Banavac bags may be used. Banavac bags are usually 1 to 1.5 mil bags made from polyethylene. Banavac bags areprimarily used when green life extension is needed and on vessels that do not have a controlled atmosphere.
[0139] While it is always advantageous to facilitate the circulation of air within the plastic bag, the need to circulate air between the outside environment and the interior of the bag will depend on the use case. The need for air circulation can vary depending on the time and distance of travel between the place of harvest and the country of destination, on the need to apply an ethylene treatment through the plastic bag and on the banana variety. Advantageously, the size and number of perforations on the plastic bag 121 can be modified depending on the use case, while keeping the same perforation on the plastic sheet to ensure optimal air circulation within the bag.
[0140] Preferably, the plastic bag 121 is made of Linear Low-Density PolyEthylene (LLDPE).
[0141] It is noted that the plastic bag 120 according to the prior art is typically made of a resin blend of Linear low-density polyethylene and low-density polyethylene.
[0142] According to the prior art, the folded part of the plastic bag 120 is slid underneath the top rows of banana, as shown in figure 1. On the contrary, according to the method of the invention shown in figure 3 and 4, the plastic bag 121 is not folded between the rows of fruit. This difference means that the plastic bag 121 used in the improved packing method according to the invention can be of shorter size than the plastic bag 120 used in the packing method of the prior art.
[0143] For example, for a standard box containing 18.14 kilograms of banana the needed length of the plastic bag for the packing method according to the invention is less than about 1000 mm (millimeters) in length, preferably equal to or less than about 900 mm, for example about 873 mm in length. Whereas the typical length needed for plastic bags used in prior packing methods is about 1280 mm in length.
[0144] In addition, because it is not required in the method according to the invention to fold the plastic bag 121 with the paper pad 144, the width of the plastic bag can also be reduced. For a standard box containing 18.14 kilograms of banana, the width of the plastic bag 120 according to the prior art packing method is typically 1029 mm. For the same box, the width of the plastic bag 121 for the packing method according to the invention is less than about 1000 mm, preferably equal to or less than about 960 mm, for example equal to about 953 mm.This advantageous feature of the packing method of the invention allows for a reduced usage of plastic material and ultimately a reduction of plastic waste, when the plastic bag is disposed of.
[0145] In addition, as explained before, the long plastic bag used in the prior produces an accumulation of plastic when the pad ends are folded to the center of the box. This accumulation of plastic blocks the air flow. The comparatively shorter bags used in the packing method according to the invention do not produce such an accumulation of plastic and therefore improve airflow.
[0146] Figure 8 shows a particular embodiment of a paper pad 144, that can be used in the packing method described in relation to figures 3 and 4. The paper pad is preferably of rectangular shape with a width similar to the length of the interior bottom 199 of the box bottom portion 191 and a length suitable to protect the fruit rows from each other avoiding interactions between fruit lines (rows) which could cause fruit damages. Preferably, the paper pad 144 is shorter in length than the plastic sheet 130, to allow the ends, 131 and 132, of the plastic sheet 130, to be folded around the ends, 145 and 146, of the paper pad 144. Any direct contact between the bananas and the paper pad 144 should be avoided as it produces scarring by friction to the fruit, and for this reason the paper pad 144 is protected by said plastic sheet 130.
[0147] In preferred embodiments the paper pad is perforated, to allow better circulation of air within the plastic bag 121 and the plastic sheet 130.
[0148] The invention as it has just been described may be modified within the scope of the claims.
Claims
CLAIMS1. A method for filling in a container for storing and transporting banana clusters characterized in that it comprises the following steps:- providing a box, comprising an interior bottom, the box preferably comprising a bottom portion and a top portion, telescopically mountable on top of the bottom portion,- providing a plastic bag having a closed end and an opening,- placing the closed end of the plastic bag on said interior bottom- providing a flat paper pad,- placing the flat paper pad on said interior bottom atop the plastic bag,- providing a plastic sheet,- placing the plastic sheet on said interior bottom atop the paper pad,- providing a plurality of banana clusters,- laying down two bottom rows of banana clusters on said interior bottom atop the plastic sheet,- wrapping at least partially said paper pad together with the plastic sheet over the top of the two bottom rows of banana clusters,- laying down at least one further row of bananas clusters above the two bottom rows of banana clusters, atop said paper pad and said plastic sheet and- closing the plastic bag to enclose the paper pad, the plastic sheet and the banana clusters.
2. The method according to claim 1, characterized in that it comprises the following steps: - providing a box comprising a bottom portion and a top portion said bottom and top portion being of rectangular construction, wherein the bottom portion comprises a first and second parallel sidewall, a first and second parallel endwall and an interior bottom,- providing a plastic bag having a closed end and an opening,- a step of placing the plastic bag in the bottom portion, having a step of placing the closed end of the plastic bag in contact with the interior bottom leaving the opening of the bag facing up and a step of folding the edges of the opening over the top of the first and second parallel sidewall and over the top of the first and second parallel endwall,- providing a flat paper pad,- placing the paper pad on the interior bottom portion, atop the plastic bag, with parts of the paper pad pressed against the parallel side walls, optionally with the ends of said parts parallel to the sidewalls,- providing a plastic sheet having a rectangular shape with a width and a length sufficient to cover the interior bottom and the paper pad surface which would be in contact with the fruit,- placing the plastic sheet on the interior bottom portion, atop the paper pad, with part of the plastic sheet pressed against interior bottom, and covering all the internal and external paper pad surface,- laying down a first bottom row of banana clusters, by placing the crown portion and tip portion of the clusters of the first bottom row on the bottom portion, in contact with the plastic sheet or in contact with a paper napkin if present,- laying down a second bottom row of banana clusters, by placing the crown portion of the clusters of the second bottom row on the bottom portion, in contact with the plastic sheet or in contact with a paper napkin if present, wherein the tip portion of the clusters of the second bottom row are placed atop the first bottom row,- pulling a first end of the paper pad along with a corresponding first end of the plastic sheet and folding said ends over the first bottom row of clusters,- laying down a first top row of banana clusters, by placing the backside of the clusters in contact with the interior of the plastic bag, pressed against the first side wall and the tip portion and crown portion atop the folded first end of the plastic sheet,- pulling a second end of the paper pad along with a corresponding second end of the plastic sheet and folding said ends over the second bottom row of clusters,- laying down a second top row of banana clusters, by placing the backside of the clusters in contact with the interior of the plastic bag pressed again the second side wall and the tip portion and crown portion atop the plastic sheet, and- closing the plastic bag comprising a step of pulling together the lip of the plastic bag and closing said plastic bag using any suitable mean, and- forming the box by placing the top portion of the box on the bottom portion of the box.
3. The method according to any of the claims 1 or 2, wherein the plastic bag and the plastic sheet are perforated, and wherein the perforation pattern of the plastic sheet differs from the perforation pattern of the plastic bag.
4. The method according to any of the claims 1 or 2, wherein the plastic bag does not comprise perforation and wherein the plastic sheet is perforated,5. The method according to any of the claims 1 to 4, wherein the thickness of the plastic bag is greater than the thickness of the plastic sheet.
6. The method according to any of the claims 1 to 5, wherein the thickness of the plastic sheet is lower or equal to about 0.6 mil, preferably comprised between about 0.5 mil and about 0.6 mil.
7. The method according to any of the claims 1 to 6, wherein the thickness of the plastic bag is lower or equal to about 1 mil, preferably lower or equal to 0.6 mil, preferably comprised between about 0.5 mil and about 0.6 mil.
8. The method according to any of the claims 1 to 7, comprising the additional steps between the steps of placing the plastic sheet and the step of forming a first bottom row of banana clusters:- providing a paper napkin having a rectangular shape, and a width and length about equal to the width and length of the interior bottom and- placing the paper napkin on the interior bottom, atop the plastic sheet.
9. The method according to any of the claims 1 to 8, wherein the plastic bag is made by a polyethylene blown film extrusion process which produces a plastic tube which once cooled, is flattened and wound into rolls.
10. The method according to any of the claims 1 to 9, wherein the plastic sheet is made of Linear low-density polyethylene (LLDPE).
11. The method according to any of the claims 1 to 10, wherein the plastic bag is made of Linear low-density polyethylene (LLDPE).
12. The method according to any of the claims 1 to 11 , wherein the steps of the method are performed manually.
13. A container characterized in that it comprises:- a box, comprising an interior bottom, the box preferably comprising a bottom portion and a top portion, telescopically mountable on top of the bottom portion,- a plastic bag having a closed end and an opening,- a flat paper pad,- a plastic sheet and- a plurality of banana clusters,wherein the closed end of the plastic bag is positioned on said interior bottom and theopening of the plastic bag is folded and closed to enclose the paper pad, the plastic sheet and the banana clusters,wherein the flat paper pad is positioned on said interior bottom atop the plastic bag, wherein the plastic sheet is placed on said interior bottom atop the paper pad, wherein two bottom rows of banana clusters are laid down on said interior bottom atop the plastic sheet,wherein at least part of the plastic sheet is folded over the ends of the paper pad, wherein said paper pad together with the plastic sheet is at least partially wrapped over the top of the two bottom rows of banana clusters,and wherein at least one further row of bananas clusters is positioned above the two bottom rows of banana clusters, atop said paper pad and said plastic sheet.