Structures and processes for packaging perishable and other products

Abstract

Packaging and processes for facilitating fast, efficient, and reliable production line packaging of products, and more particularly perishable products including meat products. Product trays according to the present invention are formed of non-foam plastic material with three dimensional structure and configuration that imparts an esthetically pleasing appearance and feel to the customer at the point of sale, as well as offering to the consumer a container that is microwavable, dishwasher safe and freezer safe in addition, if desired, to being recyclable. Such packaging and processes are particularly useful in newly emerging automated supply chains where inventory sales are tracked to support centralized processing of meat and other perishable products at centralized facilities for shipment to geographically distant points of safe. In these situations, the packaging must present the requisite esthetic, convenience and performance qualities to the customer at the point of sale even after having been loaded into a shipment container, transported often by truck over hundreds of miles, unpacked and placed in the product display case. Non-foam containers according to the present invention can accomplish these results by featuring separation structure to permit manufacture, storage, stacking, shipment, and dispensing on processing lines with minimum chance or potential of the sort of locking together which can otherwise occur with non-foam containers.

1 - 29 . (canceled)  
   
   
       30 . A plurality of meat product combinations, the meat product combinations adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 A. a first meat product combination adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 i. a first nonfoam tray having a bottom and walls; 
 the tray having a plurality of separation structures;  
 the separation structures adapted to cause the tray to denest automatically from other trays during assembly of the combination;  
 
 ii. a case ready meat product ready to be displayed for sale in a display case at a retail point of sale placed within the first tray;  
 iii. a first closure providing closure to the first tray and sealing the case ready meat product from outside atmosphere;  
   B. a second meat product combination adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 i. a second nonfoam tray having a bottom and walls; 
 the tray having a plurality of separation structures;  
 whereby the separation structures on the second tray are positioned at locations on the second tray different than the positions on the first tray at which corresponding separation structures on the first tray are located;  
 the separation structures adapted to cause the tray to denest automatically from other trays during assembly of the combination;  
 
 ii. a case ready meat product ready to be displayed for sale in a display case at a retail point of sale placed within the second tray;  
 iii. a second closure providing closure to the second tray and sealing the case ready meat product from outside atmosphere;  
   C. whereby the meat product combinations are assembled on a common production line.    
   
   
       31 . A plurality of combinations according to  claim 30  wherein the separation structures comprise lugs located on said walls of said trays.  
   
   
       32 . A plurality of combinations according to  claim 31  wherein each tray contains at least 4 lugs.  
   
   
       33 . A plurality of combinations according to  claim 30  wherein at least some of the separation structures on the first tray are different in shape from at least some of the separation structures on the second tray.  
   
   
       34 . A plurality of combinations according to  claim 30  wherein the closures comprise film.  
   
   
       35 . A plurality of combinations according to  claim 30  wherein the trays are formed of material adapted to withstand automatic dishwasher cleaning and cooking of the meat product in the trays in an oven without substantial deformation of the trays.  
   
   
       36 . A plurality of combinations according to  claim 35 , wherein the oven is a microwave oven.  
   
   
       37 . A plurality of combinations according to  claim 35 , wherein the oven is a conventional oven.  
   
   
       38 . A plurality of combinations according to  claim 30 , wherein the trays comprise a gas barrier.  
   
   
       39 . A plurality of meat product combinations adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 A. a first meat product combination adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 i. a first nonfoam tray having a bottom and walls; 
 the tray having a plurality of separation structures;  
 the separation structures adapted to cause the tray to denest automatically from other trays during assembly of the combination;  
 
 ii. a case ready meat product ready to be displayed for sale in a display case at a retail point of sale placed within the first tray;  
 iii. a first closure providing closure to the first tray and sealing the case ready meat product from outside atmosphere;  
   B. a second meat product combination adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 i. a second nonfoam tray having a bottom and walls; 
 the tray having a plurality of separation structures;  
 whereby at least some of the separation structures on the second tray are different in shape from at least some of the separation structures on the first tray;  
 the separation structures adapted to cause the tray to denest automatically from other trays during assembly of the combination;  
 
 ii. a case ready meat product ready to be displayed for sale in a display case at a retail point of sale placed within the second tray;  
 iii. a second closure providing closure to the second tray and sealing the case ready meat product from outside atmosphere;  
   C. whereby the meat product combinations are assembled on a common production line.    
   
   
       40 . A plurality of combinations according to  claim 39  wherein the separation structures comprise lugs located on said walls of said trays.  
   
   
       41 . A plurality of combinations according to  claim 40  wherein each tray contains at least 4 lugs.  
   
   
       42 . A plurality of combinations according to  claim 39  wherein at least some of the separation structures on the first tray are located at the same locations on the first tray as at least some of the separation structures are located on the second tray.  
   
   
       43 . A plurality of combinations according to  claim 39  wherein at least some of the separation structures on the first tray are not located at the same locations on the first tray as at least some of the separation structures are located on the second tray.  
   
   
       44 . A plurality of combinations according to  claim 39  in which the closures comprise film.  
   
   
       45 . A plurality of combinations according to  claim 39  wherein the trays are formed of material adapted to withstand automatic dishwasher cleaning and cooking of the meat product in the trays in an oven without substantial deformation of the trays.  
   
   
       46 . A plurality of combinations according to  claim 45 , wherein the oven is a microwave oven.  
   
   
       47 . A plurality of combinations according to  claim 45 , wherein the oven is a conventional oven.  
   
   
       48 . A plurality of combinations according to  claim 39 , wherein the trays comprise a gas barrier.  
   
   
       49 . A plurality of meat product combinations adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 A. a first meat product combination adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 i. a first nonfoam container means having a bottom and walls; 
 the container means having a plurality of separation means;  
 the separation means adapted to cause the container means to denest automatically from other container means during assembly of the combination;  
 
 ii. a case ready meat product adapted to be displayed for sale in a display case at a retail point of sale placed within the first container means;  
 iii. a first closure means providing closure to the first container means and sealing the case ready meat product from outside atmosphere;  
   B. a second meat product combination adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 i. a second nonfoam container means having a bottom and walls; 
 the container means having a plurality of separation means;  
 whereby the separation means on the second container means are positioned at locations on the second container means different than the positions on the first container means at which corresponding separation means on the first container means are located;  
 the separation means adapted to cause the container means to denest automatically from other container means during assembly of the combination;  
 
 ii. a case ready meat product adapted to be displayed for sale in a display case at a retail point of sale placed within the second container means;  
 iii. a second closure means providing closure to the second container means and sealing the case ready meat product from outside atmosphere;  
   C. whereby the meat product combinations are assembled on a common production line.    
   
   
       50 . A plurality of combinations according to  claim 49  wherein the separation means comprise lugs located on said walls of said container means.  
   
   
       51 . A plurality of combinations according to  claim 49  wherein each container means contains at least 4 lugs.  
   
   
       52 . A plurality of combinations according to  claim 49  wherein at least some of the separation means on the first container means are different in shape from at least some of the separation means on the second container means.  
   
   
       53 . A plurality of combinations according to  claim 49  wherein the container means are formed of material adapted to withstand automatic dishwasher cleaning and cooking of the meat product in the container means in an oven without substantial deformation of the container means.  
   
   
       54 . A plurality of combinations according to  claim 53 , wherein the oven is a microwave oven.  
   
   
       55 . A plurality of combinations according to  claim 53 , wherein the oven is a conventional oven.  
   
   
       56 . A plurality of combinations according to  claim 49 , wherein the trays comprise a gas barrier.  
   
   
       57 . A plurality of meat product combinations adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 A. a first meat product combination adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 i. a first nonfoam container means having a bottom and walls; 
 the container means having a plurality of separation means;  
 the separation means adapted to cause the container means to denest automatically from other container means during assembly of the combination;  
 
 ii. a case ready meat product ready to be displayed for sale in a display case at a retail point of sale placed within the first container means;  
 iii. a first closure providing closure to the first container means and sealing the case ready meat product from outside atmosphere;  
   B. a second meat product combination adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 i. a second nonfoam container means having a bottom and walls; 
 the container means having a plurality of separation means;  
 whereby at least some of the separation means on the second container means are different in shape from at least some of the separation means on the first container means;  
 the separation means adapted to cause the container means to denest automatically from other container means during assembly of the combination;  
 
 ii. a case ready meat product ready to be displayed for sale in a display case at a retail point of sale placed within the second container means;  
 iii. a second closure providing closure to the second container means and sealing the case ready meat product from outside atmosphere;  
   C. whereby the meat product combinations are assembled on a common production line.    
   
   
       58 . A plurality of combinations according to  claim 57  wherein the separation means comprise lugs located on said walls of said container means.  
   
   
       59 . A plurality of combinations according to  claim 58  wherein each container means contains at least 4 lugs.  
   
   
       60 . A plurality of combinations according to  claim 57  wherein at least some of the separation means on the first container means are located at the same locations on the first container means as at least some of the separation means are located on the second container means.  
   
   
       61 . A plurality of combinations according to  claim 57  wherein at least some of the separation means on the first container means are not located at the same locations on the first container means as at least some of the separation means are located on the second container means.  
   
   
       62 . A plurality of combinations according to  claim 57  wherein the container means are formed of material adapted to withstand automatic dishwasher cleaning and cooking of the meat product in the container means in an oven without substantial deformation of the container means.  
   
   
       63 . A plurality of combinations according to  claim 62 , wherein the oven is a microwave oven.  
   
   
       64 . A plurality of combinations according to  claim 62 , wherein the oven is a conventional oven.  
   
   
       65 . A plurality of combinations according to  claim 57 , wherein the trays comprise a gas barrier.  
   
   
       66 . A plurality of meat product combinations, the meat product combinations adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 A. a first meat product combination adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 i. a first nonfoam tray having a bottom and walls; 
 the tray having a plurality of separation structures;  
 the separation structures adapted to cause the tray to denest automatically from other trays during assembly of the combination;  
 
 ii. a case ready meat product ready to be displayed for sale in a display case at a retail point of sale placed within the first tray;  
 iii. a first closure providing closure to the first tray and sealing the case ready meat product from outside atmosphere;  
   B. a second meat product combination adapted to be displayed for sale in a display case at a retail point of sale, comprising: 
 i. a second nonfoam tray having a bottom and walls; 
 the tray having a plurality of separation structures;  
 whereby the separation structures on the first tray are adapted not to nest with separation structures on the second tray;  
 the separation structures adapted to cause the tray to denest automatically from other trays during assembly of the combination;  
 
 ii. a case ready meat product ready to be displayed for sale in a display case at a retail point of sale placed within the second tray;  
 iii. a second closure providing closure to the second tray and sealing the case ready meat product from outside atmosphere;  
   C. whereby the meat product combinations are assembled on a common production line.    
   
   
       67 . A plurality of combinations according to  claim 66  wherein at least some of the separation structures on the first tray are positioned on the first tray at locations different than the positions on the second tray at which at least some of the separation structures on the second tray are located, in order to cause separation structures on the first tray not to nest with separation structures on the second tray.  
   
   
       68 . A plurality of combinations according to  claim 66  wherein at least some of the separation structures on the first tray are shaped differently from at least some of the separation structures on the second tray, in order to cause separation structures on the first tray not to nest with separation structures on the second tray.  
   
   
       69 . A plurality of combinations according to  claim 66  wherein the separation structures comprise lugs located on said walls of said trays.  
   
   
       70 . A plurality of combinations according to  claim 69  wherein each tray contains at least 4 lugs.  
   
   
       71 . A plurality of combinations according to  claim 66  wherein the separation structures feature the same shape on all trays and are located in the same position on all trays.  
   
   
       72 . A plurality of combinations according to  claim 66  wherein the trays are formed of material adapted to withstand automatic dishwasher cleaning and cooking of the meat product in the trays in an oven without substantial deformation of the trays.  
   
   
       73 . A plurality of combinations according to  claim 72 , wherein the oven is a microwave oven.  
   
   
       74 . A plurality of combinations according to  claim 72 , wherein the oven is a conventional oven.  
   
   
       75 . A plurality of combinations according to  claim 66 , wherein the trays comprise a gas barrier.