WO1997039951A1 - Flat pack vacuum sealed seafood package and process - Google Patents

Flat pack vacuum sealed seafood package and process Download PDF

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Publication number
WO1997039951A1
WO1997039951A1 PCT/US1997/006827 US9706827W WO9739951A1 WO 1997039951 A1 WO1997039951 A1 WO 1997039951A1 US 9706827 W US9706827 W US 9706827W WO 9739951 A1 WO9739951 A1 WO 9739951A1
Authority
WO
WIPO (PCT)
Prior art keywords
seafood
bag
package
palletized
pallet
Prior art date
Application number
PCT/US1997/006827
Other languages
French (fr)
Inventor
Nicholas Guarino
Original Assignee
Carnival Brand Seafood Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US08/637,610 external-priority patent/US5817353A/en
Priority claimed from US08/731,596 external-priority patent/US5863576A/en
Priority claimed from US08/746,031 external-priority patent/US5863578A/en
Priority claimed from US08/746,161 external-priority patent/US5827554A/en
Application filed by Carnival Brand Seafood Company filed Critical Carnival Brand Seafood Company
Priority to AU28091/97A priority Critical patent/AU2809197A/en
Publication of WO1997039951A1 publication Critical patent/WO1997039951A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65BMACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B25/00Packaging other articles presenting special problems
    • B65B25/06Packaging slices or specially-shaped pieces of meat, cheese, or other plastic or tacky products
    • B65B25/061Packaging slices or specially-shaped pieces of meat, cheese, or other plastic or tacky products of fish
    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23BPRESERVING, e.g. BY CANNING, MEAT, FISH, EGGS, FRUIT, VEGETABLES, EDIBLE SEEDS; CHEMICAL RIPENING OF FRUIT OR VEGETABLES; THE PRESERVED, RIPENED, OR CANNED PRODUCTS
    • A23B4/00General methods for preserving meat, sausages, fish or fish products
    • A23B4/06Freezing; Subsequent thawing; Cooling
    • A23B4/062Freezing; Subsequent thawing; Cooling the materials being transported through or in the apparatus with or without shaping, e.g. in the form of powder, granules or flakes
    • A23B4/064Freezing; Subsequent thawing; Cooling the materials being transported through or in the apparatus with or without shaping, e.g. in the form of powder, granules or flakes with packages or with shaping in the form of blocks or portions
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2581/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D2581/34Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within
    • B65D2581/3401Cooking or heating method specially adapted to the contents of the package
    • B65D2581/3402Cooking or heating method specially adapted to the contents of the package characterised by the type of product to be heated or cooked
    • B65D2581/3424Cooking fish or shellfish

Definitions

  • This invention relates to the field of seafood packaging and preservation, and in particular, to vacuum packed seafood packaging and related preservation techniques for fish and shell fish products, which packaging and techniques can be adapted for both conventional food preparation and microwave food preparation in at least part of the original packaging.
  • Seafood packaging in accordance with the inventive arrangements taught herein permits the vacuum sealed packaging of seafood products, for example fish and shell fish, with and without shells, to be presented to consumers in attractive packaging while maintaining the integrity of the vacuum packaging to provide a better packaged product than in the past.
  • the seafood product is preferably packed in a flat, single layer orientation which enables the product to be successfully packaged in the first instance, and thereafter, viewed by a consumer in its entirety or through a window cut in an outer packaging box.
  • a pallet for the seafood product has a rough surface for holding the seafood product in the flat orientation and a smooth surface to facilitate placing the pallet and seafood product in a bag or envelope.
  • the packaged seafood product can be microwave cooked in its original vacuum sealed package without any need to rupture or vent the package until the microwave cooking is complete.
  • the rough surface of the pallet can be provided with a reflective coating or material which promotes microwave cooking but which, due to the roughness of the surface, is not so reflective as to impede the microwave cooking process or damage the microwave cooking unit.
  • the pallet can also have raised sides which help to protect the package.
  • the sides separate the seafood product from direct contact with the clear packaging during vacuum sealing to prevent puncturing.
  • the sides are an area of particular stress as the covering bag fits fairly tightly around the seafood product.
  • a process for packaging seafood in accordance with an inventive arrangement comprises the steps of: placing seafood on a pallet in a flat orientation; and, vacuum sealing the palletized seafood in a transparent bag.
  • the process can further comprise the step of freezing the vacuum sealed, palletized seafood, for example by flash freezing.
  • the process can also further comprise the steps of: enveloping the palletized seafood in a three-sided bag having an open side for receiving the pallet; and, closing the open side during the vacuum sealing.
  • the process can further comprise the steps of: placing the palletized seafood onto a first sheet; covering the palletized seafood with a second sheet; and, sealing the first and second sheets to one another along respective edges to form an envelope for the vacuum.
  • the process can further comprise the step of placing the bag within an outer package, for example, an outer package having an opening for viewing the palletized seafood product vacuum sealed in the bag.
  • the method further comprises the step of microwave cooking the seafood product in the bag without rupturing the vacuum seal.
  • the microwave cooking capability can be enhanced by the steps of: providing the rough surface of the pallet with a microwave reflecting material; and, enveloping the palletized seafood product in a two ply bag having a first ply for strength and a second ply for temperature resistance.
  • a seafood package can be made in accordance with the foregoing process steps.
  • a package for seafood comprises: a pallet upon which seafood is positioned in a flat orientation; a transparent bag vacuum sealing the palletized seafood product; and, an outer container for receiving the vacuum sealed bag.
  • the package the bag comprises upper and lower transparent sheets disposed above and below the pallet and sealed along respective edges, the palletized seafood being vacuum sealed between the upper and lower sheets.
  • the pallet advantageously comprises a rough upper surface for holding the seafood product in the desired orientation on the pallet.
  • the bag has three closed sides and one open side for receiving the palletized seafood product.
  • the pallet also has the upper rough surface, and advantageously further comprises a smooth lower surface for facilitating sliding the pallet into the bag.
  • the pallet can further comprise a flat portion having sides extending upwardly at approximately 90 degrees from the flat portion, to provide extra protection against penetration of the clear bag, for example made from plastic sheet material.
  • the outer container can have an opening for viewing the vacuum sealed, palletized seafood product.
  • the bag comprises a two ply bag having a first ply for strength and a second ply for temperature resistance. Further, the rough surface comprises a microwave reflecting coating.
  • the package can accommodate, without limitation, one or more of the following seafood products: shrimp; shell-on shrimp; lobster; shell-on lobster; fish; calamari; and, conch.
  • Figure l is an exploded view, in perspective, illustrating packaging for a seafood product, in this case shrimp, in accordance with an inventive arrangement.
  • Figure 2 is an exploded view, in perspective, illustrating packaging for a seafood product, in this case lobster, in accordance with an inventive arrangement.
  • Figure 3 is a perspective view of the shrimp as packaged in Figure 1.
  • Figure 4 is a cross sectional view taken along the lines 4-4 of Figure 3.
  • Figure 5 is a cross-section view corresponding to Figure 4, but illustrating packaged lobster as shown in Figure 2.
  • Figure 6 shows an alternative embodiment whereby the seafood product, in this case lobster, is marketed only in the bag.
  • Figure 7 shows the steps of the process by which a seafood product is packaged in accordance with the inventive arrangement.
  • Figure 8 shows the steps of the process by which a seafood product is packaged and subsequently microwave cooked in accordance with another inventive arrangement.
  • a fish or shell fish, as a packaged product 12 is shown in the drawings as either shrimp or lobster, as indicated.
  • the packaging of shrimp and lobster is illustrated in Figures l and 2 respectively, and is generally illustrative of the packaging and packaging process for all seafood products.
  • Seafood to be packaged as the product 12 in the package 10 are first carefully positioned on a pallet 14 in a relatively flat orientation as shown. The pallet 14 can then be inserted into a transparent envelope or bag of packaging 16 and slid within as shown. Vacuum can then be applied and the envelope or bag 16 can be sealed by the vacuum processing equipment (not shown) .
  • a vacuum is created as vacuum means in the vacuum processing equipment causes the air to be sucked from within prior to the sealing of the end 18 of bag 16, as is standard practice in vacuum packaging of food stuffs.
  • Shrimp as one example of a seafood product 12, is typically packaged without heads, but with tails and within the shell.
  • the envelope or bag 16 can be of 2-ply construction, comprising polypropylene and nylon plies.
  • the polypropylene ply enables the bag or envelope to tolerate temperature extremes and the nylon ply contributes to strength. Equivalent material are also available.
  • the envelope or bag 16 containing the shell fish product can now be placed within an outer package or container 10, having a window or opening 20 for example, permitting inspection of the shrimp shell fish product 12. It is important for salability that the shell fish product 12 be packaged with the shells on. Accordingly, it is also important that the pallet 14 maintain alignment of the shell fish product 12 to prevent penetration of the envelope 16 by sharp edges of the shells.
  • the pallet 14 can be constructed of plastic with some rigidity and thereby enable the product 12, also shown in Figures 3-6, to be so positioned that there is no turning, sliding, twisting, bunching or other disorientation of the product 12 that would bring sharp shell edges into contact with the protective film or envelope 16.
  • the pallet 14 may have side edges 21 which help to keep the desired orientation of the fish, shrimp or lobster and help to prevent puncturing of the envelope 16.
  • the bag as sealed will be very tight across the top of lobster, to help hold the lobster in a side by side orientation.
  • packaged lobster are shown extending slightly upward through opening 20 by virtue of their shell configuration, but still sealed within bag 16 as the frozen lobster are presented for sale in commercial establishments such as grocery chains.
  • the pallet side structure 21 helps to protect the bag seal by acting as a buffer between the edges and tails of the fish or shrimp, lobster and the sides of bag 16.
  • the product 12 needs to be packed flat, both for appearance and to prevent the penetration of the plastic film structure of envelope 16.
  • the product 12 can be placed on pallet 14 by hand, machine (not shown) , or by a combination of both. It is important that the product lie flat, and as part of the packaging process, downward pressure can be exerted on the product to achieve a perfectly flat orientation. The risk of shrimp shells or tail structure penetrating the envelope 16 is increased if the flat orientation is lost.
  • the flat orientation means effectively that the shrimp 12 are lying on their sides in a somewhat natural curled position so they can be placed in close alignment one to another, as shown in Figures 1, 3 and 4.
  • Lobster can be packaged one to a bag or placed side by side, either widthwise or lengthwise, depending on size.
  • the best orientation is to have the lobster outer shell facing upwardly and the inner shell facing downwardly, as shown in Figures 2, 5 and 6.
  • the lobster may extend upwardly so as to bulge through the box 20.
  • the pallet 14 has two very different surfaces.
  • the top surface 22 onto which the product 12 will be positioned is matted or roughened to substantially prevent the product 12 from sliding and becoming disarrayed.
  • the bottom surface 24 is smooth, as best seen on the sides 21 which are turned up at an approximate 90 degree angle. The smoothness facilitates the handling of the pallet 14, and in particular, the sliding of the pallet 14 within envelope 16 prior to the vacuum sealing of the envelope by sealing edge or end 18.
  • the bag 16 is placed within package or container 10, which is preferably made of cardboard or a like substitute.
  • the container or cardboard box 10 has a top portion 23, a bottom 25 portion, sides 27, and ends 29.
  • the opening 20 in top portion 23 is cut in such a way to enable the product within to be viewed.
  • the container 10 is closed by tucking in side flaps 26 and end flap 28.
  • the packaged product 12 can be easily viewed through opening 20 as the single layer of flat packed frozen fish, shrimp or lobster are presented for sale in commercial establishments such as grocery chains.
  • the packages 10 can be conveniently stacked within freezer compartments to present an attractive product for purchasers.
  • the packaged product 12 are seen within bag 16, which in turn is within package 10.
  • Sealed edges 30 of the bag 16 can be seen tucked so as to fit snugly within the package 10.
  • the sides 21 of pallet 14 are shown serving as a buffer between sides of bag 16 and the shrimp 12, particularly the outer shrimp shell and jagged tail structure. This applies to the heads, fins, bones and teeth of seafood and other shell configurations such as lobster shells, as shown in Figure 5.
  • lobster, as shown, or other seafood products can be marketed in the envelope or bag 16 without being placed within the container 10.
  • Sales indicia and literature may be placed on the bottom of the pallet 14, or bag, or on a sales page inserted within the bag 16 or attached on the outside.
  • Sales and product information can be placed on the bottom 50 of the packaged product. This can be, for example, a sticker, a sheet inserted within the bag 16 or printing directly on the bottom of the bag. In either case, the package, when turned over, allows clear visibility of the product within.
  • Step 1 the product 12, for example shrimp or lobster, are placed on the pallet, which can be substantially like pallet
  • the pallet 14 may be slid onto a sheet of plastic film and another sheet placed on top.
  • Step 3A Either sheets extending from rolls or discrete sheets can be used.
  • the edges of top and bottom sheets will be joined together and heat sealed simultaneously with the vacuuming of the then-formed bag as represented in Step 3A.
  • machinery well-known in packaging food stuffs can be used to create a vacuum within bag 16, sealing edge 18 in the process.
  • the top and bottom sheets can be sealed on four sides, preferably by a standard heat sealing process as part of the vacuum process.
  • the vacuum is applied before the four edges are sealed to create the vacuum packed shrimp within bag 16.
  • Step 4 the sealed bag 16 is placed within box or package 10 and the flaps 26, 28 as shown in Figures 1 and 2, closed to complete the packing process.
  • Step 4 can be conducted by hand or by machine, with the latter process being undertaken by packing machinery well known in the food stuffs industry.
  • the packaged product is immediately subjected to flash freezing to preserve the quality and to prevent the formation of bacteria, mold, and yeast and botulism, enabling the product to be shipped and sold in frozen form with greatly increased shelf life.
  • Standard industry equipment is used. While heretofore reference has been made repeatedly to shell-on shrimp, it must be recognized that the process applies to other seafood, as for example, head-on shrimp, lobster, conch, calamari and fish, both whole and fillets.
  • the sealed bag with lobster contained within can then be placed in an outer package, preferably of cardboard, which will stabilize the bag within and help to hold the lobster in a desired orientation.
  • the outer package is designed for retail acceptance and will likely include a window so that the lobster may be examined within the inner package. This outer package may be removed when microwave cooking takes place.
  • the lobster may also be marketed in the sealed clear bag without the outer package. Sales information can be placed on the bottom of the pallet, which will be seen through the transparent bag material, or on the bag itself.
  • seafood products packaged as taught herein are also suitable for subsequent microwave cooking in the envelope or bag 16.
  • the packaged seafood product is expected to remain in a frozen state through the entire distribution chain, wholesale and retail, until the approximate time of consumption by the consumer.
  • the packaged seafood product can be placed in a microwave cooking unit.
  • the bag or package 16 as described herein will retain its integrity through the microwave cooking process and will not rupture during the microwave cooking process.
  • the resulting locked-in moisture will provide the basis for steaming the seafood product, for example shrimp or lobster, within the bag or package.
  • the seafood product can then be removed by rupturing the bag, served and eaten.
  • the flat orientation of the seafood product in the packaging is not only attractive, but enables the product to be successfully and subsequently microwave cooked without removal from the bag or envelope until completion of the microwave cooking. Unlike other microwave cooking techniques which require venting of the bag or envelope in which the frozen food product is stored, the bag or envelope according to the inventive arrangement, maintains its integrity throughout the microwave cooking process.
  • the matted or rough side of the pallet can also be coated with a reflective material which promotes microwave cooking but which is not so reflective that it becomes detrimental to the microwave cooking process. Due to the roughness of the surface, the reflective coating does not interfere with the microwave cooking, as the microwaves are not directed back to the microwave source, but are sufficiently indirectly reflected.
  • the coating can be a reflective foil, for example a gold foil.
  • Step 1 the seafood product, for example shrimp or seafood, are placed on the pallet which may be substantially like pallet 14 of Figures 1 and 2, with or without sides 21.
  • the seafood product can be placed on pallet 14 by hand, machine (not shown) , or by a combination of both. It is important that the seafood product lie flat, in a single layer, and as part of the process, it is expected that downward pressure will be exerted on the seafood products to achieve a substantially flat orientation.
  • the flat orientation reduces the risk of the seafood product penetrating the envelope or bag 16, which would interfere with and degrade the subsequent microwave cooking.
  • the pallet 14 is then enveloped by bag 16 as shown in Step 2. If three sides of the bag are sealed already, as shown in Step 2 and in Figures 1 and 2, the pallet 14 is pushed into the bag 16 as facilitated by the smooth surface 24 of the bottom of pallet 14. Either machine or a by-hand process may be used in placing the pallet 14 within the bag 16. As shown in Alternative Step 2, the pallet 14 may be slid onto a bottom sheet of plastic film and another sheet placed on top. Either sheets extending from rolls or discrete sheets can be used. The edges of top and bottom sheets will be joined together and heat sealed simultaneously with the vacuuming of the then-formed bag as represented in Step 3A.
  • Step 3 machinery well-known in packaging food stuffs can be used to create a vacuum within bag 16, sealing edge 18 in the process.
  • the top and bottom sheets can be sealed on four sides, preferably by a standard heat sealing process as part of the vacuum process.
  • the vacuum is applied before the four edges are sealed to create the vacuum packed shrimp within package or bag 16.
  • the sealed bag or package 16 is placed within box or outer package 10 and the flaps 26, 28 as shown in Figures 1 and 2, closed to complete the packing process.
  • Step 4 can be conducted by hand or by machine, with the latter process being undertaken by packing machinery well known in the food stuffs industry.
  • the packaged seafood product is immediately subjected to flash freezing to preserve the quality and to prevent the formation of bacteria, mold, and yeast and botulism thus enabling the product to be shipped and sold in frozen form with greatly increased shelf life.
  • Standard industry equipment is used such as to blast freeze, contact freeze or tunnel freeze the product.
  • the package, bag or envelope 16 is removed from the outer package 10 and placed in its sealed condition in a microwave cooking unit.
  • the seafood product will be effectively steamed as the package or bag 16 is designed to withstand the pressure of the steaming process with the bag 16 effectively becoming a pressure cooker.
  • the seafood product will then be ready for consumption as the steam penetrates into the shrimp, effectively steaming the product.
  • the length of time of microwave cooking depends on the characteristics of the microwave cooking unit and the quantity of seafood product being cooked. Generally, it is expected that the time of microwave cooking will be from two to ten minutes, with application of from approximately 400 to 3,000 watts.
  • condiments, sauces and the like can be used to coat or marinate the seafood product, or can be placed in the envelope or bag 16, prior to the vacuum sealing.
  • the seafood product is vacuum packed in a negative pressure situation prior to freezing. The freezing does not affect the negative pressure within which the seafood is packed. Subsequently, upon microwave cooking the seafood in the unruptured envelope or bag 16, the expanding steam effectively turns the bag into a pressure cooking vessel.

Abstract

A process for packaging seafood comprises the steps of: placing seafood (12) on a rough surface (22) of a pallet (14) in a flat orientation, the surface being optionally microwave reflective; vacuum sealing the palletized seafood in a transparent bag (16), optionally having a first ply for strength and a second ply for temperature resistance; flash freezing the vacuum sealed seafood; and microwave cooking the vacuum sealed seafood in the bag without rupturing the vacuum seal. A package for seafood comprises: a pallet having a rough surface upon which seafood is positioned in a flat orientation, the surface being optionally microwave reflective; and, a transparent bag, optionally having a first ply for strength and a second ply for temperature resistance, in which the palletized seafood is vacuum sealed; and, an outer container (10) for receiving the vacuum sealed bag, the bag being adapted for microwave cooking without rupturing the vacuum seal.

Description

FLAT PACK VACUUM SEALED SEAFOOD PACKAGE AND PROCESS
Background of the Invention l. Field of the Invention
This invention relates to the field of seafood packaging and preservation, and in particular, to vacuum packed seafood packaging and related preservation techniques for fish and shell fish products, which packaging and techniques can be adapted for both conventional food preparation and microwave food preparation in at least part of the original packaging. 2. Description of Related Art
Heretofore, packaging of shell fish in buyer-friendly containers having a good visibility of the product has been limited as the shells of the product were known to penetrate clear packaging, making it inappropriate to vacuum seal the product in marketable flat packaging for retail use. A similar problem has existed with respect to finned fish, whose fins and bony structure can be expected to threaten the integrity of the clear packaging.
With vacuum packaging of any seafood product, there is also a significant concern with the potential for adulteration of the seafood product from mold, yeast, bacteria, and especially, botulism. Seafood companies have avoided even attempting to produce a vacuum packaged seafood product in a clear packaging material, even though processes have been tried before to eliminate the threat of botulism. Examples of such processes are nitrogen flushing and radiation. Notwithstanding the promise of such processes, these attempts have not been successful, primarily due to of problems associated with the integrity of the packaging, which can lead to the adulteration.
While vacuum sealing has been successfully used for packaging shell fish without the shells and other fish in bulk, flat packing shell-on shrimp, shell-on lobster and other seafood in vacuum sealed containers suitable for retail has not been successfully implemented, explaining the absence of the use of such packaging in the marketplace. While vacuum packaging has been used for a variety of vegetables and meats, this use has not been extended successfully to retail packaging of shell-on shrimp, lobster and other seafood. An example of vacuum packaging technique of food stuffs is found in US 5,473,866.
Another and related failure of prior art packaging is the inability to package fish and shell fish products, for example shrimp and lobster, in packages adapted for microwave preparation. The absence of plastics kinds of packaging material and the manner in which the fish and shell fish products are stacked is not suitable for microwave preparation, either in the original packaging, or in an inner package of an outer package. A seafood vacuum pack system is disclosed in US 4,835,942 but this patent teaches away from the subject invention by virtue of a stacking technique used at the periphery of the packages. Likewise, US 4,964,507 teaches the use of a "protruding-up curved section" of a case which is also contrary to the subject invention.
Further, with prior packaging, the packaged product has not been suitable for microwave cooking the product directly in its shipping and sales package. While vacuum packaging has been used for a variety of vegetables and meats, this usage has not extended successfully to retail packaging of shrimp and other seafood. An example of vacuum packaging technique of food stuffs is found in US 5,473,866.
A seafood vacuum-pack system is disclosed in US 4,835,942 wherein the shrimp are intentionally stacked one above the other at the periphery of the packages. Likewise, US
4,964,507 teaches the use of a "protruding-up curved section".
Summary of the Invention Seafood packaging in accordance with the inventive arrangements taught herein permits the vacuum sealed packaging of seafood products, for example fish and shell fish, with and without shells, to be presented to consumers in attractive packaging while maintaining the integrity of the vacuum packaging to provide a better packaged product than in the past. The seafood product is preferably packed in a flat, single layer orientation which enables the product to be successfully packaged in the first instance, and thereafter, viewed by a consumer in its entirety or through a window cut in an outer packaging box.
A pallet for the seafood product has a rough surface for holding the seafood product in the flat orientation and a smooth surface to facilitate placing the pallet and seafood product in a bag or envelope.
The packaged seafood product can be microwave cooked in its original vacuum sealed package without any need to rupture or vent the package until the microwave cooking is complete. Advantageously, the rough surface of the pallet can be provided with a reflective coating or material which promotes microwave cooking but which, due to the roughness of the surface, is not so reflective as to impede the microwave cooking process or damage the microwave cooking unit.
The pallet can also have raised sides which help to protect the package. The sides separate the seafood product from direct contact with the clear packaging during vacuum sealing to prevent puncturing. The sides are an area of particular stress as the covering bag fits fairly tightly around the seafood product.
In accordance with the foregoing, a process for packaging seafood in accordance with an inventive arrangement comprises the steps of: placing seafood on a pallet in a flat orientation; and, vacuum sealing the palletized seafood in a transparent bag. The process can further comprise the step of freezing the vacuum sealed, palletized seafood, for example by flash freezing.
The process can also further comprise the steps of: enveloping the palletized seafood in a three-sided bag having an open side for receiving the pallet; and, closing the open side during the vacuum sealing. Alternatively, the process can further comprise the steps of: placing the palletized seafood onto a first sheet; covering the palletized seafood with a second sheet; and, sealing the first and second sheets to one another along respective edges to form an envelope for the vacuum.
In either case, the process can further comprise the step of placing the bag within an outer package, for example, an outer package having an opening for viewing the palletized seafood product vacuum sealed in the bag.
In accordance with another inventive arrangement, the method further comprises the step of microwave cooking the seafood product in the bag without rupturing the vacuum seal. The microwave cooking capability can be enhanced by the steps of: providing the rough surface of the pallet with a microwave reflecting material; and, enveloping the palletized seafood product in a two ply bag having a first ply for strength and a second ply for temperature resistance. In accordance with still another inventive arrangement, a seafood package can be made in accordance with the foregoing process steps.
In accordance with yet another inventive arrangement, a package for seafood comprises: a pallet upon which seafood is positioned in a flat orientation; a transparent bag vacuum sealing the palletized seafood product; and, an outer container for receiving the vacuum sealed bag.
In one embodiment, the package the bag comprises upper and lower transparent sheets disposed above and below the pallet and sealed along respective edges, the palletized seafood being vacuum sealed between the upper and lower sheets. The pallet advantageously comprises a rough upper surface for holding the seafood product in the desired orientation on the pallet. In another embodiment, the bag has three closed sides and one open side for receiving the palletized seafood product. In this embodiment. The pallet also has the upper rough surface, and advantageously further comprises a smooth lower surface for facilitating sliding the pallet into the bag. The pallet can further comprise a flat portion having sides extending upwardly at approximately 90 degrees from the flat portion, to provide extra protection against penetration of the clear bag, for example made from plastic sheet material. The outer container can have an opening for viewing the vacuum sealed, palletized seafood product.
In accordance with an embodiment of the inventive microwave cooking arrangement, the bag comprises a two ply bag having a first ply for strength and a second ply for temperature resistance. Further, the rough surface comprises a microwave reflecting coating.
In accordance with all of the inventive arrangements taught herein, the package can accommodate, without limitation, one or more of the following seafood products: shrimp; shell-on shrimp; lobster; shell-on lobster; fish; calamari; and, conch.
Brief Description of the Drawings Figure l is an exploded view, in perspective, illustrating packaging for a seafood product, in this case shrimp, in accordance with an inventive arrangement. Figure 2 is an exploded view, in perspective, illustrating packaging for a seafood product, in this case lobster, in accordance with an inventive arrangement.
Figure 3 is a perspective view of the shrimp as packaged in Figure 1. Figure 4 is a cross sectional view taken along the lines 4-4 of Figure 3.
Figure 5 is a cross-section view corresponding to Figure 4, but illustrating packaged lobster as shown in Figure 2. Figure 6 shows an alternative embodiment whereby the seafood product, in this case lobster, is marketed only in the bag.
Figure 7 shows the steps of the process by which a seafood product is packaged in accordance with the inventive arrangement.
Figure 8 shows the steps of the process by which a seafood product is packaged and subsequently microwave cooked in accordance with another inventive arrangement. Detailed Description of the Preferred Embodiments
Fish and shell fish can be packaged in accordance with the inventive arrangements taught herein. A fish or shell fish, as a packaged product 12, is shown in the drawings as either shrimp or lobster, as indicated. The packaging of shrimp and lobster is illustrated in Figures l and 2 respectively, and is generally illustrative of the packaging and packaging process for all seafood products. Seafood to be packaged as the product 12 in the package 10, are first carefully positioned on a pallet 14 in a relatively flat orientation as shown. The pallet 14 can then be inserted into a transparent envelope or bag of packaging 16 and slid within as shown. Vacuum can then be applied and the envelope or bag 16 can be sealed by the vacuum processing equipment (not shown) . More specifically, a vacuum is created as vacuum means in the vacuum processing equipment causes the air to be sucked from within prior to the sealing of the end 18 of bag 16, as is standard practice in vacuum packaging of food stuffs. Shrimp, as one example of a seafood product 12, is typically packaged without heads, but with tails and within the shell.
The envelope or bag 16 can be of 2-ply construction, comprising polypropylene and nylon plies. The polypropylene ply enables the bag or envelope to tolerate temperature extremes and the nylon ply contributes to strength. Equivalent material are also available. The envelope or bag 16 containing the shell fish product can now be placed within an outer package or container 10, having a window or opening 20 for example, permitting inspection of the shrimp shell fish product 12. It is important for salability that the shell fish product 12 be packaged with the shells on. Accordingly, it is also important that the pallet 14 maintain alignment of the shell fish product 12 to prevent penetration of the envelope 16 by sharp edges of the shells. Specifically, the pallet 14 can be constructed of plastic with some rigidity and thereby enable the product 12, also shown in Figures 3-6, to be so positioned that there is no turning, sliding, twisting, bunching or other disorientation of the product 12 that would bring sharp shell edges into contact with the protective film or envelope 16.
As also shown in Figures 1 and 2, the pallet 14 may have side edges 21 which help to keep the desired orientation of the fish, shrimp or lobster and help to prevent puncturing of the envelope 16. The bag as sealed will be very tight across the top of lobster, to help hold the lobster in a side by side orientation. As can be seen in Figure 5, packaged lobster are shown extending slightly upward through opening 20 by virtue of their shell configuration, but still sealed within bag 16 as the frozen lobster are presented for sale in commercial establishments such as grocery chains.
In particular, as the bag 16 is sealed and then inserted into package 10, stress points might exist along its sides. The pallet side structure 21 helps to protect the bag seal by acting as a buffer between the edges and tails of the fish or shrimp, lobster and the sides of bag 16.
The product 12 needs to be packed flat, both for appearance and to prevent the penetration of the plastic film structure of envelope 16. The product 12 can be placed on pallet 14 by hand, machine (not shown) , or by a combination of both. It is important that the product lie flat, and as part of the packaging process, downward pressure can be exerted on the product to achieve a perfectly flat orientation. The risk of shrimp shells or tail structure penetrating the envelope 16 is increased if the flat orientation is lost. The flat orientation means effectively that the shrimp 12 are lying on their sides in a somewhat natural curled position so they can be placed in close alignment one to another, as shown in Figures 1, 3 and 4.
Lobster can be packaged one to a bag or placed side by side, either widthwise or lengthwise, depending on size. In the case of lobster, the best orientation is to have the lobster outer shell facing upwardly and the inner shell facing downwardly, as shown in Figures 2, 5 and 6. The lobster may extend upwardly so as to bulge through the box 20. In order to maintain the orientation of the palletized seafood product 12, and in order to facilitate the packaging process, the pallet 14 has two very different surfaces. The top surface 22 onto which the product 12 will be positioned, is matted or roughened to substantially prevent the product 12 from sliding and becoming disarrayed. The bottom surface 24 is smooth, as best seen on the sides 21 which are turned up at an approximate 90 degree angle. The smoothness facilitates the handling of the pallet 14, and in particular, the sliding of the pallet 14 within envelope 16 prior to the vacuum sealing of the envelope by sealing edge or end 18.
It will be appreciated that other seafood products, such as fish, conch, and calamari may be substituted in place of shrimp or lobster. Although shells may not be present, the bony nature of fish and protruding fins, teeth and scales raise the same concerns as shells. A flat product orientation is once again necessary to prevent the puncturing of the envelope 12 and to allow the consumer to view the product.
As can further be seen in Figure 1, once the product 12, on pallet 14, is placed within the envelope or bag 16 and sealed, the bag 16 is placed within package or container 10, which is preferably made of cardboard or a like substitute. The container or cardboard box 10 has a top portion 23, a bottom 25 portion, sides 27, and ends 29. The opening 20 in top portion 23 is cut in such a way to enable the product within to be viewed. Once the bag 16 is placed within package or container 10, the container 10 is closed by tucking in side flaps 26 and end flap 28.
As can be seen in Figure 3, the packaged product 12 can be easily viewed through opening 20 as the single layer of flat packed frozen fish, shrimp or lobster are presented for sale in commercial establishments such as grocery chains. The packages 10 can be conveniently stacked within freezer compartments to present an attractive product for purchasers. With reference to Figure 4, the packaged product 12 are seen within bag 16, which in turn is within package 10.
Sealed edges 30 of the bag 16 can be seen tucked so as to fit snugly within the package 10. The sides 21 of pallet 14 are shown serving as a buffer between sides of bag 16 and the shrimp 12, particularly the outer shrimp shell and jagged tail structure. This applies to the heads, fins, bones and teeth of seafood and other shell configurations such as lobster shells, as shown in Figure 5.
Other products need to be carefully oriented to minimize the likelihood of puncturing of bag 16. For example, fish need to be positioned so that the fins, tail, and bone structure are oriented toward the pallet structure and away from the bag.
In an alternative embodiment, shown in Figure 6, lobster, as shown, or other seafood products can be marketed in the envelope or bag 16 without being placed within the container 10. Sales indicia and literature may be placed on the bottom of the pallet 14, or bag, or on a sales page inserted within the bag 16 or attached on the outside. Sales and product information can be placed on the bottom 50 of the packaged product. This can be, for example, a sticker, a sheet inserted within the bag 16 or printing directly on the bottom of the bag. In either case, the package, when turned over, allows clear visibility of the product within.
The key steps of the packing process are shown Figure 7. In Step 1, the product 12, for example shrimp or lobster, are placed on the pallet, which can be substantially like pallet
14 Figures 1 and 2, with or without sides 21.
The pallet 14 is then enclosed in bag 16 as shown in Step
2. If three sides of the bag are sealed already, as shown in Step 2 and in Figure 1, the pallet 14 is pushed into the bag
16 as facilitated by the smooth surface 24 of the bottom of pallet 14. Either machine or a by-hand process may be used in placing the pallet 14 within the bag 16.
As shown in Alternative Step 2, the pallet 14 may be slid onto a sheet of plastic film and another sheet placed on top.
Either sheets extending from rolls or discrete sheets can be used. The edges of top and bottom sheets will be joined together and heat sealed simultaneously with the vacuuming of the then-formed bag as represented in Step 3A. As shown in Step 3, machinery well-known in packaging food stuffs can be used to create a vacuum within bag 16, sealing edge 18 in the process.
Alternatively, as shown in Step 3A and discussed above, the top and bottom sheets can be sealed on four sides, preferably by a standard heat sealing process as part of the vacuum process. The vacuum is applied before the four edges are sealed to create the vacuum packed shrimp within bag 16. In Step 4 the sealed bag 16 is placed within box or package 10 and the flaps 26, 28 as shown in Figures 1 and 2, closed to complete the packing process. Step 4 can be conducted by hand or by machine, with the latter process being undertaken by packing machinery well known in the food stuffs industry.
At this juncture, the packaged product is immediately subjected to flash freezing to preserve the quality and to prevent the formation of bacteria, mold, and yeast and botulism, enabling the product to be shipped and sold in frozen form with greatly increased shelf life. Standard industry equipment is used. While heretofore reference has been made repeatedly to shell-on shrimp, it must be recognized that the process applies to other seafood, as for example, head-on shrimp, lobster, conch, calamari and fish, both whole and fillets.
The sealed bag with lobster contained within can then be placed in an outer package, preferably of cardboard, which will stabilize the bag within and help to hold the lobster in a desired orientation. The outer package is designed for retail acceptance and will likely include a window so that the lobster may be examined within the inner package. This outer package may be removed when microwave cooking takes place.
The lobster may also be marketed in the sealed clear bag without the outer package. Sales information can be placed on the bottom of the pallet, which will be seen through the transparent bag material, or on the bag itself. In accordance with another inventive arrangement, seafood products packaged as taught herein are also suitable for subsequent microwave cooking in the envelope or bag 16. In accordance with this inventive arrangement, the packaged seafood product is expected to remain in a frozen state through the entire distribution chain, wholesale and retail, until the approximate time of consumption by the consumer.
Immediately prior to consumption, for example, the packaged seafood product can be placed in a microwave cooking unit. The bag or package 16 as described herein will retain its integrity through the microwave cooking process and will not rupture during the microwave cooking process. As the frozen product is thawed, the resulting locked-in moisture will provide the basis for steaming the seafood product, for example shrimp or lobster, within the bag or package. The seafood product can then be removed by rupturing the bag, served and eaten.
The flat orientation of the seafood product in the packaging is not only attractive, but enables the product to be successfully and subsequently microwave cooked without removal from the bag or envelope until completion of the microwave cooking. Unlike other microwave cooking techniques which require venting of the bag or envelope in which the frozen food product is stored, the bag or envelope according to the inventive arrangement, maintains its integrity throughout the microwave cooking process.
The matted or rough side of the pallet can also be coated with a reflective material which promotes microwave cooking but which is not so reflective that it becomes detrimental to the microwave cooking process. Due to the roughness of the surface, the reflective coating does not interfere with the microwave cooking, as the microwaves are not directed back to the microwave source, but are sufficiently indirectly reflected. The coating can be a reflective foil, for example a gold foil.
In accordance with the general packaging process taught herein, it is necessary that the bag or envelope fit tightly to help hold the seafood product in the flat, single layer orientation for proper packaging and proper microwave cooking. With reference to Figure 8, the key steps of the process from packing to microwave cooking are presented. In Step 1, the seafood product, for example shrimp or seafood, are placed on the pallet which may be substantially like pallet 14 of Figures 1 and 2, with or without sides 21. The seafood product can be placed on pallet 14 by hand, machine (not shown) , or by a combination of both. It is important that the seafood product lie flat, in a single layer, and as part of the process, it is expected that downward pressure will be exerted on the seafood products to achieve a substantially flat orientation. The flat orientation reduces the risk of the seafood product penetrating the envelope or bag 16, which would interfere with and degrade the subsequent microwave cooking.
The pallet 14 is then enveloped by bag 16 as shown in Step 2. If three sides of the bag are sealed already, as shown in Step 2 and in Figures 1 and 2, the pallet 14 is pushed into the bag 16 as facilitated by the smooth surface 24 of the bottom of pallet 14. Either machine or a by-hand process may be used in placing the pallet 14 within the bag 16. As shown in Alternative Step 2, the pallet 14 may be slid onto a bottom sheet of plastic film and another sheet placed on top. Either sheets extending from rolls or discrete sheets can be used. The edges of top and bottom sheets will be joined together and heat sealed simultaneously with the vacuuming of the then-formed bag as represented in Step 3A.
In Step 3, machinery well-known in packaging food stuffs can be used to create a vacuum within bag 16, sealing edge 18 in the process.
Alternatively, as shown in Step 3A and discussed above, the top and bottom sheets can be sealed on four sides, preferably by a standard heat sealing process as part of the vacuum process. The vacuum is applied before the four edges are sealed to create the vacuum packed shrimp within package or bag 16. In Step 4 the sealed bag or package 16 is placed within box or outer package 10 and the flaps 26, 28 as shown in Figures 1 and 2, closed to complete the packing process. Step 4 can be conducted by hand or by machine, with the latter process being undertaken by packing machinery well known in the food stuffs industry.
At this juncture the packaged seafood product is immediately subjected to flash freezing to preserve the quality and to prevent the formation of bacteria, mold, and yeast and botulism thus enabling the product to be shipped and sold in frozen form with greatly increased shelf life. Standard industry equipment is used such as to blast freeze, contact freeze or tunnel freeze the product.
At the end of the distribution chain, and as shown in Step 5, the package, bag or envelope 16 is removed from the outer package 10 and placed in its sealed condition in a microwave cooking unit. The seafood product will be effectively steamed as the package or bag 16 is designed to withstand the pressure of the steaming process with the bag 16 effectively becoming a pressure cooker. The seafood product will then be ready for consumption as the steam penetrates into the shrimp, effectively steaming the product. The length of time of microwave cooking depends on the characteristics of the microwave cooking unit and the quantity of seafood product being cooked. Generally, it is expected that the time of microwave cooking will be from two to ten minutes, with application of from approximately 400 to 3,000 watts.
In the alternative embodiment wherein the seafood product is marketed in the package or bag 16 without being placed within the outer container 10, there is of course no need to remove the package or bag 10 from the outer package 10 which does not exist.
Advantageously, condiments, sauces and the like can be used to coat or marinate the seafood product, or can be placed in the envelope or bag 16, prior to the vacuum sealing. Viewing the overall steps from packing to microwave cooking, the seafood product is vacuum packed in a negative pressure situation prior to freezing. The freezing does not affect the negative pressure within which the seafood is packed. Subsequently, upon microwave cooking the seafood in the unruptured envelope or bag 16, the expanding steam effectively turns the bag into a pressure cooking vessel.

Claims

What is claimed is:
1. A process for packaging seafood, comprising the steps of: placing seafood on a pallet in a flat orientation; and, vacuum sealing said palletized seafood in a transparent bag.
2. The process of claim 1, further comprising the step of freezing said vacuum sealed, palletized seafood.
3. The process of claims 1-2, further comprising the step of flash freezing said vacuum sealed, palletized seafood.
4. The process of claims 1-3, comprising the steps of: enveloping said palletized in a three-sided bag having an open side for receiving said pallet; and, closing said open side during said vacuum sealing.
5. The process of claims 1-3, comprising the steps of: placing said palletized seafood onto a first sheet; covering said palletized seafood with a second sheet; and, sealing said first and second sheets to one another along respective edges to form an envelope for said vacuum sealing.
6. The process of claims 1-5, further comprising the step of placing said vacuum sealed bag within an outer package.
7. The process of claim 6, comprising the step of placing said vacuum sealed bag within an outer package having an opening for viewing said palletized seafood product vacuum sealed in said bag.
8. The process of claims 1-7, comprising the step of placing said seafood product on a rough surface of said pallet.
9. The process of claim 8, further comprising the step of coating said rough surface with a microwave reflecting material.
10. The process of claims 1-9, comprising the step of enveloping said palletized seafood product in a two ply bag having a first ply for strength and a second ply for temperature resistance.
11. The process of claims 1-10, further comprising the step of microwave cooking said seafood product in said bag without rupturing said vacuum seal.
12. The process of claims 1-11, comprising the step of placing at least one of the following seafood products on the pallet for said vacuum sealing: shell-on shrimp; lobster; fish; calamari; and, conch.
13. A seafood package, made in accordance with the process steps of claims 1-12.
14. A package for seafood, comprising: a pallet upon which seafood is positioned in a flat orientation; a transparent bag enveloping said palletized seafood, said palletized seafood being vacuum sealed in said bag; and, an outer container for receiving said vacuum sealed bag.
15. The package of claim 14, wherein said bag comprises upper and lower transparent sheets disposed above and below said pallet and sealed along respective edges, said palletized seafood being vacuum sealed between said upper and lower sheets.
16. The package of claims 14 or 15, wherein said pallet has a rough upper surface for holding said seafood product in said orientation.
17. The package of claim 14, wherein said bag has three closed sides and one open side for receiving said palletized seafood product.
18. The package of claims 17, wherein said pallet has a rough upper surface for holding said seafood product in said orientation and a smooth lower surface facilitating sliding of said palletized seafood into said bag.
19. The package of claims 16-18, wherein said rough surface comprises a microwave reflecting coating.
20. The package of claims 14-19, wherein said pallet comprises a flat portion having sides extending upwardly at approximately 90 degrees from said flat portion.
21. The package of claims 14-20, wherein said outer container has an opening for viewing said vacuum sealed, palletized seafood product.
22. The package of claims 14-21, wherein said bag comprises a two ply bag having a first ply for strength and a second ply for temperature resistance.
23. The package of claims 14-22, wherein said package is specifically adapted for at least one of the following seafood products: shell-on shrimp; lobster; fish; calamari; and, conch.
Figure imgf000021_0001
PCT/US1997/006827 1996-04-25 1997-04-24 Flat pack vacuum sealed seafood package and process WO1997039951A1 (en)

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Applications Claiming Priority (8)

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US08/637,610 1996-04-25
US08/637,610 US5817353A (en) 1996-04-25 1996-04-25 Flat pack vacuum packed seafood package and process
US08/731,596 US5863576A (en) 1996-04-25 1996-10-15 Vacuum packed microwaveable lobster package and process
US08/731,596 1996-10-16
US08/746,031 US5863578A (en) 1996-04-25 1996-11-06 Microwaveable vacuum packed seafood package and process
US08/746,031 1996-11-06
US08/746,161 1996-11-06
US08/746,161 US5827554A (en) 1996-04-25 1996-11-06 Flat pack vacuum packed seafood package and process for producing microwaveable shrimp

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EP1731430A1 (en) * 2005-06-10 2006-12-13 Fortune Frozen Foods, Co Ltd Method of preserving a fish meat product
EP1785036A1 (en) * 2005-11-14 2007-05-16 Fortune Frozen Foods, Co Ltd Method of preserving fish
CN103478875A (en) * 2013-09-24 2014-01-01 张继军 Processing technique for frozen foods
EP3667208A1 (en) * 2018-12-14 2020-06-17 Keohane Seafood Unlimited Company Process for shelf-life extension of fish

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US4230729A (en) * 1979-03-16 1980-10-28 Hoelzel Jr Fred L One piece, collapsible package
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FR2855157A1 (en) * 2003-05-23 2004-11-26 Christian Courtonne Shellfish e.g. crustacean, package, has container in which shellfishes are arranged, where container has protection device that is inserted between shellfishes and cover of container
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EP1785036A1 (en) * 2005-11-14 2007-05-16 Fortune Frozen Foods, Co Ltd Method of preserving fish
CN103478875A (en) * 2013-09-24 2014-01-01 张继军 Processing technique for frozen foods
EP3667208A1 (en) * 2018-12-14 2020-06-17 Keohane Seafood Unlimited Company Process for shelf-life extension of fish

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