Flexible packaging system and method of use to eliminate valved coffee bag vacuumization due to change in atmospheric pressure

Abstract

A packaging system and method of use for packaging coffee in individual valved packages is disclosed. The individual valved packages are disposed within a secondary package formed of a flexible material and including a one-way pressure relief valve. The valve of the secondary package is set to open so that the secondary package internal pressure never drops below the operating pressure of the primary package degassing valves. The secondary package is disposed within a rigid container, e.g., a corrugated carton. The system and method enables shipping of the coffee packages permitting them to degass without vacuumization (bricking) irrespective of changes in atmospheric pressure encountered during the transport of the system.

What is claimed is: 
     
         1 . A packaging system for shipping packages containing a product which degasses, said system comprising a plurality of primary packages, a secondary package and a rigid container, each of said primary packages being formed of a flexible material and enclosing the product therein and including a one-way, degassing valve to enable gasses produced by the product to exit said primary package without air entering said primary package through said degassing valve, each of said degassing valves of said primary packages having a predetermined operating pressure at which the gasses produced by the product are enabled to pass out of said primary package through said valve, said secondary package being formed of a flexible material and arranged to hold a plurality of said primary packages therein, said rigid container being arranged to hold said secondary package with said primary packages therein, said secondary package including a one-way pressure release valve having an appropriate opening pressure to control gas release during the shipment of said primary packages in said rigid container so that the secondary package internal pressure never drops below the operating pressure of said primary package degassing valves. 
     
     
         2 . The packaging system of  claim 1  wherein the product is coffee. 
     
     
         3 . The packaging system of  claim 2  wherein said secondary package is formed of a gas barrier material to prevent escape of gasses from said primary packages by transmission through said secondary package during shipment or storage. 
     
     
         4 . The packaging system of  claim 3  wherein said secondary package is formed of a 5-layer coextrusion of polyethylene—tie—EVOH—tie—polyethylene. 
     
     
         5 . The packaging system of  claim 1  wherein said rigid container comprises a corrugated carton. 
     
     
         6 . The packaging system of  claim 2  wherein said opening pressure of said degassing valves of said primary packages is approximately 0.1 PSI. 
     
     
         7 . The packaging system of  claim 5  wherein said secondary package is formed of a gas barrier material to prevent escape of gasses from said primary packages by transmission through said secondary package during shipment or storage. 
     
     
         8 . The packaging system of  claim 7  wherein said secondary package is formed of a 5-layer coextrusion of polyethylene—tie—EVOH—tie—polyethylene. 
     
     
         9 . The packaging system of  claim 6  wherein said secondary package is formed of a gas barrier material to prevent escape of gasses from said primary packages by transmission through said secondary package during shipment or storage. 
     
     
         10 . The packaging system of  claim 9  wherein said secondary package is formed of a 5-layer coextrusion of polyethylene—tie—EVOH—tie—polyethylene. 
     
     
         11 . The packaging system of  claim 1  wherein said primary packages are gusseted packages. 
     
     
         12 . A method of packing packages of a product which degasses, said method comprising:
 a) providing a plurality of primary flexible packages, each of said primary flexible packages being formed of a flexible material and enclosing the product therein, with each of said primary packages including a one-way, degassing valve to enable gasses produced by the product to exit said primary package without air entering said primary package through said degassing valve, each of said degassing valves of said primary packages having a predetermined operating pressure at which the gasses produced by the product are enabled to pass out of said secondary package through said valve;   b) disposing a plurality of said primary packages in a secondary package, said secondary package being formed of a flexible material and including a one-way pressure release valve having an appropriate opening pressure to control gas release during the shipment of said primary packages so that the internal pressure in said secondary package never drops below the operating pressure of said primary package degassing valves; and   c) disposing said secondary package with said primary packages therein within the interior of a rigid container for protecting said packages during shipment or storage.   
     
     
         13 . The method of  claim 12  additionally comprising:
 d) shipping said packages. 
 
     
     
         14 . The method of  claim 12  wherein said product is coffee. 
     
     
         15 . The method of  claim 12  wherein said secondary package is formed of a gas barrier material to prevent escape of gasses from the primary package by transmission through the secondary package. 
     
     
         16 . The method of  claim 14  wherein said secondary package is formed of a gas barrier material to prevent escape of gasses from the primary package by transmission through the secondary package during shipment or storage. 
     
     
         17 . The method of  claim 16  wherein said secondary package is formed of a S-layer coextrusion of polyethylene—tie—EVOH—tie—polyethylene. 
     
     
         18 . The method of  claim 12  wherein said container comprises a corrugated carton. 
     
     
         19 . The method of  claim 14  wherein said opening pressure of said degassing valves of said primary packages is approximately 0.1 PSI. 
     
     
         20 . The method of  claim 18  wherein said opening pressure of said degassing valves of said primary packages is approximately 0.1 PSI.