Systems and methods for creating a sealed pallet enclosure

Abstract

The present disclosure relates to creating a sealed enclosure around the cartons of packed goods using standard, commercially available equipment and materials selected for their compatible adhesive properties which also include providing gas barrier, stretch, adhesion, and sustainability. The system and methods are designed to be flexible, modular, and movable for easy relocation and use at small to medium size and seasonal harvest and cooling locations.

1 . A method for providing a sealed enclosure and modified atmosphere for a pallet of goods, the method comprising:
 providing a prefabricated or preformed bottom cap to a stack of cartons on a pallet;   providing a prefabricated or preformed top cap to the stack of cartons on the pallet;   wrapping a stretch film with compatible adhesive properties around sides of the stack of cartons, the bottom cap, and the top cap to create the sealed enclosure; and   creating a modified atmosphere within the sealed enclosure.   
     
     
         2 . The method of  claim 1 , wherein the modified atmosphere comprises:
 i) allowing natural respiration of a perishable product included within the cartons to create the modified atmosphere; or   ii) injecting one or more gases through one or more nozzles into the sealed enclosure; or   iii) containing one or more substance treatments within the enclosure prior to sealing; or   iv) a combination of i & ii; or   v) a combination of i, ii, & iii.   
     
     
         3 . The method of  claim 1 , further comprising forming the preformed bottom cap and the preformed top cap of a plastic material, polymer lined cardboard, or a substrate, or a combination thereof. 
     
     
         4 . The method of  claim 1 , wherein providing the preformed bottom cap comprises:
 providing a sheet of material with sections scored or cut for:   folding the sections to create one or more cap sides; and   sealing one or more corner flaps of the one or more cap sides together using sustainable adhesive materials.   
     
     
         5 . The method of  claim 1 , further comprising forming the preformed bottom cap or the preformed top cap of a biodegradable material, recyclable material, or both biodegradable material and recyclable material and forming the bottom cap or the top cap with gas and moisture barrier properties. 
     
     
         6 . The method of  claim 1 , where the preformed bottom cap or the preformed top cap have a cap base with perimeter dimensions that are configured to the dimensions of the pallet such that the cap base of the preformed bottom cap or the preformed top cap is slightly larger in plan view than the pallet. 
     
     
         7 . The method of  claim 1 , wherein a side component of the sealed enclosure is a sleeve which fits over the sides of the cartons and is then sealed to the top and bottom caps using an elastic band or stretch film with an adhesive laminated side. 
     
     
         8 . The method of  claim 1 , wherein side components of the sealed enclosure is a semi-rigid sheet that is placed along the sides of the cartons and is then sealed to the top and bottom caps using an elastic band or stretch film with an adhesive laminated side. 
     
     
         9 . The method of  claim 1 , wherein a material of the top cap or bottom cap is made of a durable material enabling it to be returned to source for re-use. 
     
     
         10 . The method of  claim 1 , wherein the top cap or bottom cap is constructed with tabs which are able to be tucked between layers of the cartons for improved stability and sealing of the sealed enclosure. 
     
     
         11 . The method of  claim 1 , wherein the preformed bottom cap and the preformed top cap comprise a cap base and a plurality of cap sides extending perpendicular to the cap base, and wherein the plurality of cap sides extend perpendicularly to the cap base by 1 inch or more, 3 inches to 6 inches, 4 inches to 8 inches, or a combination thereof. 
     
     
         12 . The method of  claim 1 , further comprising forming the stretch film, the preformed top cap, and the preformed bottom cap of materials that are compatible in design, texture, sealing and/or adhesion properties. 
     
     
         13 . The method of  claim 1 , wherein the sealed enclosure formed by the stretch film, the preformed top cap, and the preformed bottom cap is free from staples, filaments, tape, glue, or connection adhesives. 
     
     
         14 . The method of  claim 1 , further comprising forming the stretch film, the preformed top cap, and the preformed bottom cap of materials that have oxygen and carbon dioxide transmission properties selected based on the goods to provide a predetermined modified atmosphere environment. 
     
     
         15 . The method of  claim 1 , further comprising providing the preformed bottom cap between the pallet and the cartons during harvest and packing of the cartons in a field or during packing cartons in a packing facility with a product. 
     
     
         16 . The method of  claim 15 , further comprising providing the preformed top cap on top of the cartons in the field, or at the packing facility, or at a cooling warehouse. 
     
     
         17 . The method of  claim 16 , further comprising providing the stretch film after cooling of the product within the cartons. 
     
     
         18 . The method of  claim 1 , wherein creating the modified atmosphere comprises injecting gasses into the sealed enclosure before, during, or after the enclosure has been completed and sealed. 
     
     
         19 . The method of  claim 1 , further comprising pulling a vacuum through one or more nozzles to create a negative pressure before creating the modified atmosphere. 
     
     
         20 . The method of  claim 1 , further comprising pulling a vacuum through one or more nozzles to create negative pressure from one location on the sealed enclosure, while injecting gasses at a separate location on the sealed enclosure. 
     
     
         21 . The method of  claim 1 , where gasses for the modified atmosphere include one or more of carbon dioxide, nitrogen, ozone, hydrogen peroxide, or 1-MCP. 
     
     
         22 . The method of  claim 1 , where any of the preformed top cap, the preformed bottom cap, the stretch film, or any combination thereof, contains functional ingredients including one or more of potassium permanganate, cyclodextrin, potassium bicarbonate, citric acid, sodium percarbonate or 1-MCP. 
     
     
         23 . A flexible, modular, movable system for providing a sealed enclosure to a pallet of goods, the system comprising:
 a preformed top cap, a preformed bottom cap, and wrapping film;   a lifting system configured to elevate a stack of cartons from the pallet; and   a pick and place mechanism configured to move the preformed top cap and the preformed bottom cap to the pallet of goods.   
     
     
         24 . The system of  claim 23 , wherein the lifting system holds the stack of cartons while the pallet is lowered, and the pick and place mechanism moves the preformed bottom cap onto the pallet, and then the stack of cartons is lowered into the bottom cap. 
     
     
         25 . The system of  claim 23 , wherein the lifting system comprises a side lifting system or a top-down lifting system. 
     
     
         26 . The system of  claim 23 , further comprising a forklift configured to elevate the stack of cartons. 
     
     
         27 . The system of  claim 23 , wherein the pick and place mechanism is (i) configured to provide the preformed bottom cap between the pallet and the stack of goods and (ii) configured to provide the preformed top cap on a topmost surface of the stack of goods. 
     
     
         28 . The system of  claim 23 , further comprising a film stretch system configured to apply the wrapping film to sides of the pallet of stacked goods to complete the sealed enclosure. 
     
     
         29 . The system of  claim 23 , further comprising a robotic pallet mover configured to move the pallet of goods from one process station to a subsequent process station. 
     
     
         30 . The system of  claim 23 , wherein the pallet of goods comprises a plurality of cartons stacked on the pallet, with each carton filled with perishable product.