Top formed packaging

#The present invention relates generally to food packaging and in particular to food packaging relating to perishable foods.

#For many years, retailers have sold perishable food products such as fresh meats in “case ready” packaging. Generally, case ready packaging is based upon a central packaging location where animals are slaughtered and cut into retail cuts. Before distribution to the retail outlets, the meat is packaged in a modified atmosphere packaging. Thus, retail outlets benefit because they do not have to employ butchers for on-sight cutting and packaging of the perishable food products.

#One drawback to case ready packaging is a mismatch between the size of the food product and the dimensions of the tray that the food product is contained in. For example, a perishable food product may have an irregular shape with variable dimensions, such as a cut of beef or poultry. In contrast, the preformed trays used for packaging the irregularly shaped food products have a predetermined fixed regular shape. Thus, the food product is generally contained in a preformed tray that is larger than the food product. As a result, there is substantial headspace between the product and the clear lidding material when the food product is sealed in its final package.

#FIG. 1 is a sectional partial view of a package according to embodiments of the present invention;

#FIG. 2 is a sectional partial view of a heat-sealing platen and a female thermoforming mold that is housed within the platen according to embodiments of the present invention;

#FIG. 3 is a sectional view of a thermoforming assembly according to embodiments of the present invention; and

#Referring to FIG. 1, a completed food package 10 includes a food item 12 that is situated within a preformed tray 14 having a lidding material 16 thermoformed and heat-sealed 18 thereto. The tray 14 may include a base 20, a layer 22 and a flange 24. In embodiments of the present invention, the lidding material 16 may be hermetically heat-sealed 18 to the flange 24.

#The base 20 may be a conventional base made from material such as plastic or paperboard. Likewise, the layer 22 may be a conventional layer that is coated or laminated to the base 20. The food item 12 may be any food item including perishable foods such as meat and poultry. According to embodiments of the present invention, the lidding material 16 may be any flexible heat-sensitive film that is capable of being thermoformed.

#Generally, according to embodiments of the present invention, the lidding material 16 is positioned over the tray 14. Thereafter, the lidding material 16 is thermoformed to conform to the general shape of the food product 12 and is heat-sealed to the flange 24.