Food Product Packaging and Method for Producing Food Product Packaging

Abstract

A food product packaging and method of producing the same is provided for containing rigid food products. The packaging includes a tray having at least one receptacle, rigid food products housed in the receptacle and a removable flexible film secured to the tray and enclosing the receptacle. The receptacle is shaped to enable the rigid food products to slide into and be positioned in the receptacle in an orientation that is generally parallel to the bottom wall thereby reducing the chances of the food products breaking in the receptacle and reducing the chances of the food products puncturing the flexible film.

1 . A method for manufacturing a tray containing mini crackers comprising the steps:
 providing the tray have a receptacle, the receptacle defined at least in part by a curved wall adjacent a bottom wall so as to define a shape of the receptacle;   dropping the mini crackers into the receptacle, the shape of the receptacle enables the mini crackers to slide in the receptacle toward the bottom wall and stop in an orientation generally parallel to the bottom wall; and   enclosing the receptacle with a flexible film wherein the occurrences of the mini crackers puncturing the flexible film is reduced due to the shape of the receptacle.   
     
     
         2 . The method of  claim 1  wherein the mini crackers are dropped into the receptacle using a funnel. 
     
     
         3 . The method of  claim 1  wherein the shape of the receptacle is defined by a curved wall having a radius of curvature of at least about 0.35 inches and wherein the shape of the receptacle accommodates the mini crackers having a width dimension and a length dimension of 1 inch or less and wherein the receptacle houses between 10 and 35 mini crackers. 
     
     
         4 . A method for manufacturing a tray containing mini rigid food products comprising the steps:
 providing the tray having a top surface and a receptacle, the receptacle having a bottom wall, having at least one side wall with a straight portion adjacent to and perpendicular to the top surface and integral with a curved portion adjacent to the bottom wall;   moving at least ten of the mini rigid food products into the tray such that the mini rigid food products enter the receptacle, slide toward the bottom wall and stop in an orientation that is generally parallel to the bottom wall and below the top surface; and   applying a flexible film removably securable to the top surface of the tray and enclosing the receptacle so that the flexible film is not punctured by the mini rigid food products when being secured to the top surface.   
     
     
         5 . The method of  claim 4  wherein the mini rigid food products have a width dimension and a length dimension of 1 inch or less. 
     
     
         6 . The method of  claim 4  wherein between 10 and 35 mini rigid food products are moved into the tray. 
     
     
         7 . The method of  claim 4  wherein the receptacle has a height and wherein the receptacle height is no more than 1.5 times the width dimension and the height dimension of the mini rigid food products. 
     
     
         8 . The method of  claim 4  wherein the tray is fabricated of a semi-rigid material. 
     
     
         9 . A method for manufacturing a tray containing food products comprising the steps:
 providing the tray having a receptacle, the receptacle having a shape defined at least in part by a bottom wall, a top surface, and a side wall having a straight portion adjacent to and perpendicular to the top surface and a curved portion integral with the straight portion and adjacent to the bottom wall;   moving a plurality of the food products into the receptacle, the food products having a sharp portion and having a width dimension and a length dimension of 1.0 inches or less, so that the shape of the receptacle enables the food products to enter the receptacle and move into a position in the receptacle in an orientation that is generally parallel to the bottom wall and below the top surface; and   removably securing a flexible film to the top surface of the tray to enclose the receptacle whereby the occurrences of the sharp portion of the food products puncturing the flexible film after the flexible film is secured to the top surface of the tray are reduced as compared to a tray not having the same shape.   
     
     
         10 . The method of  claim 9  wherein the receptacle has a height and wherein the receptacle height is no more than 1.5 times the width dimension or the height dimension of the food products. 
     
     
         11 . The method of  claim 9  wherein the shape of the receptacle includes a squared off end and a pointed end. 
     
     
         12 . The method of  claim 11  wherein the pointed end includes a wall having a draft angle. 
     
     
         13 . The method of  claim 9  wherein the tray is fabricated of a semi-rigid material and wherein the receptacle includes a step-down to provide rigidity to the tray. 
     
     
         14 . The method of  claim 9  wherein the tray includes a second receptacle containing cheese.