Container for transport and storage of food products

Abstract

Systems and methods for providing compostable food containers which preserve the quality of a food product for an extended duration of time, and which optionally allow for cooking of the food product therein. In some implementations, the food containers are sturdy, stackable, insulating, and require minimal or no manual labor to assemble. In some implementations, the food container includes a base and a cover which cooperate to form a closed chamber for supporting, protecting, insulating and optionally cooking a food product, such as a pizza. The base and cover may each be formed of a single layer of material including, but not limited to, molded sugarcane fiber (“bagasse”), molded wood fiber, molded bamboo fiber, molded paper or plastic.

1 . A food container comprising:
 a compostable fiber base including an upwardly facing food receiving portion that receives a food product, the food receiving portion having an inner surface, a plurality of radial channels running radially in the inner surface, and a corresponding plurality of sector portions of the food receiving portion delineated by the plurality of radial channels; and   a compostable fiber cover selectively engageable with the base, the cover including a substantially downward facing interior surface and a substantially upward facing exterior surface, the cover sized and shaped to provide an interior chamber which protects the food product, the cover including a peripheral sidewall having an inner surface, a smooth portion of the inner surface, and a rough portion of the inner surface.   
     
     
         2 . The food container of  claim 1  wherein the smooth portion and the rough portion of the inner surface promote increased condensation of vapor within the interior chamber and direct condensed liquid into specific regions of the food container. 
     
     
         3 . The food container of  claim 1  wherein the smooth portion of the inner surface is located above the rough portion of the inner surface. 
     
     
         4 . The food container of  claim 1  wherein a material of the sidewall is porous. 
     
     
         5 . The food container of  claim 1  wherein a material of the sidewall is capable of absorbing or adsorbing liquid. 
     
     
         6 . The food container of  claim 1  wherein the smooth portion of the inner surface of the sidewall is sloped so that water condensed onto the smooth portion of the inner surface of the sidewall flows down the sidewall. 
     
     
         7 . The food container of  claim 1  wherein the smooth portion of the inner surface of the sidewall is contiguous. 
     
     
         8 . The food container of  claim 1  wherein the smooth portion of the inner surface of the sidewall is non-contiguous. 
     
     
         9 . The food container of  claim 8  wherein the smooth portion of the inner surface of the sidewall is contiguous. 
     
     
         10 . The food container of  claim 1  wherein the smooth portion of the inner surface of the sidewall is hydrophobic. 
     
     
         11 . The food container of  claim 1  wherein a material of the sidewall is hydrophobic. 
     
     
         12 . The food container of  claim 1  wherein the smooth portion of the inner surface is connected with one or more channels or recessed areas for collecting condensed water. 
     
     
         13 . The food container of  claim 1 , further comprising a coating material applied to the smooth portion of the inner surface, the coating material different than the compostable fiber material of the cover. 
     
     
         14 . The food container of  claim 13 , wherein the coating material is hydrophobic. 
     
     
         15 . The food container of  claim 1 , further comprising a laminating material that is laminated to the smooth portion of the inner surface, the laminating material different than the compostable fiber material of the cover. 
     
     
         16 . The food container of  claim 15 , wherein the laminating material is hydrophobic. 
     
     
         17 . The food container of  claim 1  wherein each of the sector portions of the food receiving portion includes a plurality of circumferentially extending ribs that extend upward relative to other portions of the food receiving portion. 
     
     
         18 . The food container of  claim 1  wherein the fiber cover has an overall height of at least 2.5 inches. 
     
     
         19 . The food container of  claim 1  wherein the fiber base includes a raised peripheral rim disposed about a perimeter of the food receiving portion, the raised peripheral rim including a plurality of cutting notches formed therein. 
     
     
         20 . The food container of  claim 19  wherein the raised peripheral rim is thicker at locations below the cutting notches than at other portions of the raised peripheral rim. 
     
     
         21 . A method of forming a food container comprising:
 molding a compostable fiber base including an upwardly facing food receiving portion that receives a food product, the food receiving portion having an inner surface, a plurality of radial channels running radially in the inner surface, and a corresponding plurality of sector portions of the food receiving portion delineated by the plurality of radial channels; and   molding a compostable fiber cover selectively engageable with the base, the cover including a substantially downward facing interior surface and a substantially upward facing exterior surface, the cover sized and shaped to provide an interior chamber which protects the food product, the cover including a peripheral sidewall having an inner surface, a smooth portion of the inner surface, and a rough portion of the inner surface.   
     
     
         22 . The method of  claim 21  wherein the smooth portion of the inner surface is molded against a polished metal surface and the rough portion of the inner surface is molded against a mesh material. 
     
     
         23 . The method of  claim 21 , further comprising:
 positioning a food item on the food receiving portion of the fiber base;   engaging the fiber cover with the fiber base such that the food item is within the interior chamber; and   cooking the food item while on the food receiving portion of the fiber base and within the interior chamber.   
     
     
         24 . The method of  claim 23  wherein the cooking is performed in an oven. 
     
     
         25 . The method of  claim 24  wherein the cooking is performed at a temperature higher than 500 degrees Fahrenheit. 
     
     
         26 . The method of  claim 23  wherein the cooking is performed in a commercial oven. 
     
     
         27 . The method of  claim 26  wherein the cooking is performed at a temperature of at least 900 degrees Fahrenheit. 
     
     
         28 . A molding system for molding a food container, the molding system comprising:
 a first mold configured to mold a compostable fiber base including an upwardly facing food receiving portion that receives a food product, the food receiving portion having an inner surface, a plurality of radial channels running radially in the inner surface, and a corresponding plurality of sector portions of the food receiving portion delineated by the plurality of radial channels; and   a second mold configured to mold a compostable fiber cover selectively engageable with the base, the cover including a substantially downward facing interior surface and a substantially upward facing exterior surface, the cover sized and shaped to provide an interior chamber which protects the food product, the cover including a peripheral sidewall having an inner surface, a smooth portion of the inner surface, and a rough portion of the inner surface.