Vrijsen, Marc (Bremstraat 42, Zonhoven, B-3520, BE)
Dirksen, Johan (Kosmoslaan 25, AT Eindhoven, NL-5632, NL)
Vrijsen, Marc (Bremstraat 42, Zonhoven, B-3520, BE)
| 1. | A system, comprising : a container; a tubular food casing disposed in the container, wherein the tubular food casing is configured such that at least portions of a cross sectional area of the food casing are compressed and the food casing is configured to form a serpentine pattern having a plurality of folds; and fluid applied to the tubular food casing and operable to moisturize the tubular food casing. |
| 2. | The system of Claim 1, wherein each fold is a crease. |
| 3. | The system of Claim 1, wherein a length of a majority folds is at least 10 times longer than a width of the tubular food casing. |
| 4. | The system of Claim 1, wherein a length of the tubular food casing is 100 meters (m) up to 1,500 m. |
| 5. | The system of Claim 1, wherein the tubular food casing includes a plurality of transverse seams. |
| 6. | The system of Claim 5, wherein each fold coincides with a transverse seam. |
| 7. | The system of Claim 1, wherein the applied fluid is for shipping and the container is operable to receive additional fluid at a later time for stuffing. |
| 8. | The system of Claim 1, wherein the container is operable to receive an amount of fluid sufficient to permit stuffing of the food casing. |
| 9. | The system of Claim 1, wherein the container is waterproof. |
| 10. | The system of Claim 1, wherein the fluid comprises at least one of water, an antimycotic, or a plasticizer. |
| 11. | A system, comprising: a container; a tubular food casing disposed in the container and folded into a plurality of folds, wherein each fold is at least 10 times longer than a width of the tubular casing configured; and fluid applied to the tubular food casing and operable to moisturize the tubular food casing. |
| 12. | The system of Claim 11, wherein the folded tubular food casing forms a serpentine pattern. |
| 13. | The system of Claim 11, wherein the tubular food casing includes a plurality of transverse seams. |
| 14. | The system of Claim 11, wherein the container is operable to receive an amount of fluid sufficient to permit stuffing of the food casing. |
| 15. | A method, comprising: disposing a tubular food casing into a container, wherein the tubular food casing is configured such that at least portions of a cross sectional area of the food casing are compressed and the food casing is configured to form a serpentine pattern having a plurality of folds; and applying fluid to the tubular food casing, wherein the fluid is operable to moisturize the tubular food casing. |
| 16. | The system of Claim 15, wherein each fold is at least 10 times longer than a width of the tubular casing. |
| 17. | The system of Claim 15, wherein the tubular food casing includes a plurality of transverse seams. |
| 18. | The system of Claim 15, wherein the applied fluid is for shipping and the container is operable to receive additional fluid at a later time for stuffing. |
| 19. | The system of Claim 15, wherein the container is operable to receive an amount of fluid sufficient to permit stuffing of the food casing. |
| 20. | The system of Claim 15, wherein the container is waterproof. |
TECHNICAL FIELD This invention relates to food packaging, and more particularly to food casings for packaging emulsions of food products, such as processed cheeses and meats, for example.
BACKGROUND In the packaging of food emulsions, in particular meat emulsions, into sausage- like packages, it is desired by the industry to use continuous tubular casings in order to minimize the interruptions, e. g. , downtime, to what can generally be classified as automated food stuffing equipment. For small diameter casings (e. g. pure cellulose), the two is typically gathered into a sheared stick which can be loaded manually or semi-automatically into a stuffing machine. For large diameter casings (e. g. cellulose/paper reinforced casing or fibrous), the casing is originally supplied in cut pieces with each piece having a closed end (e. g., clipped, tied or sewn) and in open end for manually loading onto a stuffing machine such as a stuffing horn. Generally, continuous flattened tubular casings are available packaged on, for example, a roll, a coil, a wheel or a spool, or, alternatively, packaged in an accordion-folded or shirred manner. A roll or spool, as well as a coil or wheel, of course, normally, although not always, needs to be mounted for rotation as the casing is fed into the automated stuffing machines. The sheared material through involves placing the tube on a rod and compressing the tube into an accordion-folded shirred material, on the other hand, does not need to be removed from its package for use (e. g., wieniepak), but is simply fed from the opened shipping carton directly into the automated stuffing machinery.
In the case of larger diameter casing, the casing needs to be soaked before it is able to be loaded onto a stuffing machine. Typically, individual strands are loaded manually onto the stuffing machine The casings which are supplied today in a preset cut length and one end opened are also typically designed to that length because logos are printed on each piece. The combination of being closed on one end and having a unique property per cut piece have been the reason why it has been difficult to supply casings in a continuous tube.
Where non-shirred, flattened casing is to be used, one approach to increasing the amount of running time, between start-up of the automated packing equipment and shut-down to load in new casing material, is to increase the size of the roll, coil, spool or wheel (hereinafter collectively referred to as"rolls") on which the flattened casing is wound. This has limitations, in that the larger the size of the roll, the heavier it becomes and the more cumbersome it becomes to handle. As a consequence, heavier- duty feed equipment is required to mount such rolls, and relatively higher-powered drive equipment is required to overcome the greater static inertia of such packaging to feed out the casing material wound thereon. In addition, the mounting of enlarged rolls becomes more difficult, as such increased weight packaging is considerably less easily handled. Thus, the weight of the rolls of flattened casing becomes a significant factor in relation to the facility of their use.
Another approach that has been proposed is related to the packaging of flattened folds. Firstly, folding of the flattened casing enables complete filling of squared boxes. This is an improvement in terms of space economy in comparison to the packaging of cylindrically shaped rolls in squared boxes. However, weight of the package is still a factor. A variety of approaches have been proposed whereby the tail end of folded flattened casing in a given box (the last portion of the flattened casing remaining in the box as it is emptied) can be attached to the lead end of a casing extracted from a new and succeeding box. The most simple approach is to splice the two ends together, on-the-fly, with some form of adhesive, for example, tape.
However, with the high-speed machinery that is used for automated packing, splicing on-the-fly is a difficult task and not all operators are capable of splicing on-the-fly routinely and rapidly without error, as is required.
Another approach is described in West German Laid Open Patent Application (Offenlegungsschrift) 33 18 373.2. In this patent application, arrangements are described in which the tail end of the flattened casing is left to extend out of the packaging carton so that it may be spliced to the lead end of the next package of flattened casing. This splicing can be done while the automated stuffing equipment is in full operation, during the period in which the initial packaging carton is being emptied. Thus, there is more time to complete the splicing, thereby making the task less difficult and more likely to result in an acceptable splice. Also, no down time is required for the splice.
There is a basic problem, however, inherent in any splicing technique. That is, the splice, if it holds, ultimately will encompass the food emulsion, which is packed into it. The area of the splice, even though it may be functionally acceptable, still creates an unsightly joint on the food product, which customers and users tend to find objectionable. Also, as previously suggested, the splicing does not always hold, causing even more downtime. Therefore, another approach is to enhance the ease of loading each package of flattened food casing, unspliced, into the automated equipment, and thus, enable the loading time to be shortened, as shown in U. S. Patent No. 5,127, 873. This approach does include downtime for changing the casing at the end of each packaging carton, but attempts to minimize its duration. Furthermore it eliminates the objectionable splice and the occasional extended downtime due to failed splices.
To load the casing into an automated stuffing machine, the flattened casing must be threaded through a system of guides, which may include rollers. This guide/roller system feeds the casing through the machine to the actual point where the food emulsion is to be stuffed into the casing. Included in this feed system is a cutting steps in which the piece is cut after the transverse seam, the piece is positioned on a stuffing horn, stuffed with food product, clipped or tied, and the sequence repeats as disclosed in German Application DE 101 11 136 Al. At about the point where the actual food stuffing occurs, the flattened tubular casing is opened up to form a tube, for example a cylindrical shape, which can be subsequently stuffed with food emulsion.
A further concern when loading casing material into an automated stuffing machine is the moisture content of the casing. Most casing especially cellulose casing materials must contain a certain level of moisture to be pliable enough for use in an automated stuffing machine. The moisture content allows the material to be fed through the machine and stuffed with the food emulsion without undue resistance or breakage and enable stuffing up to the required diameter while maintaining a firm shape. These same materials, such as cellulose-based casing materials, are typically transported and stored at low moisture levels which then requires fully soaking before stuffing. This reduced moisture level reduces the weight of the casing material and reduces the likelihood of microbial growth on casing material during transport and storage. Another form is to supply pre-moisturized casings where the casings are moisturized via conventional known technologies up to a moisture level which does not require soaking prior to stuffing. Prior to stuffing, the casing material is moisturized in a bath or in a dipping area from which the casing material is fed on rollers in and out of a bath. One example of a dipping area is shown in Figure 1 of German Application DE 101 11 136 Al.
SUMMARY A food stuffing system is provided having an automated stuffing machine, a food product, and a tubular casing material. The tubular casing material, which may have transverse seams, is folded in a container adapted for shipping the flattened tubular casing material. The container may further be waterproof and adapted for maintaining moisture of the pre-soaked casings and/or to enable additional moisture through adding moisture or including materials (like liners) which will gradually release moisture. In addition, the tubular casing material may be soaked prior to introduction of the tubular casing material into the automated stuffing machine and being stuffed with the food product.
A method for stuffing tubular casing material with food product may include creating multiple transverse seams in an elongated section of a tubular food casing material with an open end. The casing material is folded with transverse seams into a waterproof container adapted for transporting the folded tubular casing material. The waterproof container is transported to the vicinity of an automated stuffing machine.
Water is added to the waterproof container to increase the moisture content of the folded tubular casing material with transverse seams. After waiting for the tubular casing material to absorb the water and become moisturized tubular casing material with a transverse seam the casing material is introduced into the automated stuffing machine. The stuffing machine stuffs food product into the open end of the tubular casing material such that the tubular casing material contains food product from the open end to a first transverse seam and then seals the open end. Then, the automated stuffing machine cuts the tubular casing material near the first transverse seam to create a food product and an open end on the elongated section of the tubular casing material.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS FIG. 1 is a sectional view of a container holding a folded food casing with transverse seams.
FIG 2 is a schematic view of a food stuffing system using a folded food casing with transverse seams.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION FIGURE 1 illustrates a system 100 for packaging a food casing. In general, system 100 is operable to provide a moisturizing environment for folded casings.
Conventionally, casing is stored and sold in a shirred form or on a reel such that the casing does not contain a sufficient amount of moisture to permit stuffing with a food product without additional treatment. Pre-moisturized shirred or reels have been introduced in the market for products which do not involve pre-detennined cut lengths which also involve a closure or seam at one end and subsequently supplied in a continuous manner. In preparing the food casing for stuffing, the casing is often soaked in an aqueous solution to raise the moisture content to a level sufficient to permit stuffing. For example, the casing may be dipped, sprayed, immersed, or otherwise put in contact with an aqueous solution. In addressing this preparation step, the system 100 uses a container 102 for maintaining a moisture content of a stored food casing sufficient to permit stuffing. As a result, the system 100 minimizes, eliminates, or reduces the need to prepare a casing prior to stuffing a food product <BR> <BR> (e. g. , meat products, cheese products). In other words, a food casing stored in system 100 may immediately be ready to stuff with a food product without the preparation steps discussed above.
At a high level, the system 100 includes the container 102, a food casing 104, and fluid 106 applied to the food casing 104, but the system 100 may include other features not illustrated. The container 102 is operable to hold the food casing 104 including the fluid 106 such that a moisture level is substantially maintained in the container 102 for a period of time. The container 102 may have any suitable dimensions. The container 102 is often sized to accept a suitable length of casing material without being too heavy to load with standard equipment. For example, the container 102 may have a 115 centimeter (cm) length, a 11 cm width, and an 80 cm height. The width of the container 102 may be based on the width of the food casing 104 in a flattened state. In doing so, the amount of material used to manufacturer the container 102 and/or the amount of fluid 106 used to moisturize the food casing 102 may be less compared to other containers. The container 102 may be composed of any suitable material such as cardboard, plastic, resin, metal, a composite, a combination of the foregoing, or other materials. In some examples, the container 102 may include folding lines such that an empty box can be folded to reduce its volume when not in use.
The container 102 is frequently waterproof. A significant advantage of having a waterproof container 102 is that moisture may be added to the container 102 to increase the moisturization of the food casing 104. Typically, the container 102 will be filled with food casing 104 at a rather low moisture content. This reduces the weight of container 102 during shipping and storage. Once the container 102 is within the proximity of a stuffing machine, additional fluid 106 may be added to the container 102 to increase the moisture level of the food casing 104. This allows the operator to skip the typical soaking procedures described above. An advantage is that fresh fluid 106 is more likely to be used in each container 102, thereby preventing the spread of microbes that may cause disease or otherwise spoil the food product. A further advantage of container 102 being waterproof and having folded food casing 104 is that fluid 106 may be added incrementally. For example, some fluid 106 may be added as the food casing 104 is packed into container 102 and more added prior to stuffing.
Such a waterproof container 102 may be constructed in several ways. A waterproof container 102 may be composed entirely of waterproof materials, such as plastics, resins, metals, or composites. A waterproof container 102 may also be made up of a structural component and a separate waterproof component. Structural components used in such a combination may be wood or cardboard, among others.
Waterproof components could be waterproof bags (e. g. , plastic bags), liners, or waterproof coatings on the structural material. In some implementations, the sides of the container 102 are sealed using glue or welds. The lid 116 may be sealed using tape, glue, sealants, or other mechanisms that may be removed at a later point in time to provide access to the interior of the container 102. Depending on the expected use and the duration of soaking in the container 102, the container does not necessarily need to be completely waterproof. It may be satisfactory if the container has few leaks over a 12 hour period, an 8 hour period, or even a 4 hour period, especially if the expected use is for less time or the customer is willing to accept some leaking. The purpose of the waterproof container 102 is to substantially maintain the moisturize content of the food casing 104.
The food casing 104 is operable to store, retain, package, or otherwise receive a food product. In the illustrated embodiment, the food casing 104 is tubular, for example, having a circular, elliptical, square, or other cross sectional shape but suitable to hold a food product. hi some examples, the width of the food casing 104 is between approximately 2 cm and 25 cm. In some examples, the length of the food casing 104 is between approximately 100 meters (m) and 1500 m. The food casing 104 may be manufactured from any suitable material such as protein films, plastics, cellulose, collagen, fabrics (e. g. , linens or raw silk), paper, laminated paper products, and others.
In some examples, the food casing 104 is a tubular cellulose casing for packaging meat emulsions such as sausages (e. g. , liver sausage). The food casing 104 may be formed from a continuous piece of casing material such as a seamed or seamless tube of cellulose film or the food casing 104 may be formed by combining multiple pieces of casing material. In either case, the pattern for the food casing 104 may be stamped, punched, cut, or otherwise removed from a casing material. In the illustrated implementation, the food casing 104 is a continuous tube having a first end 108, a second end 110, a plurality of folds 112, and a plurality of seams 114. In some implementations, the first end 108 is open and the second end 110 is closed with a seam 114. A first open end 108 may be mounted on a stuffing horn up to the first seam 114, and the food casing 104 may then be stuffed with food product. The next segment of the food casing 102 may then be stuffed in the same manner once the initial segment is removed.
Each fold 112 lays a first portion of the food casing 104 over a second portion of the food casing 104. In the illustrated implementation, each fold 112 includes a compressed portion 118, a second compressed portion 120, and an intermediate portion 122. Compressed could be flattened, twisted, or otherwise reduce the cross sectional area of the food casing 104. A portion of the food casing 104 is disposed within the container 102 and collapsed to form the first compressed portion 118. The portion may collapse due to the force of gravity or the application of pressure. The first flat portion 118 may span the entire length of the container 102. The intermediate portion 122 bends the food casing 104 transverse to its longitudinal axis. The intermediate portion 122 may be curved, angled, or otherwise shaped such that the second flat portion 120 overlays the first flat portion 120. The second flat portion 120 may overlay the entire first flat portion 120 or a segment of the first flat portion 120.
The folds 118 are distinguished in the art from shirring, which forms a tubular strand of material. In the illustrated implementation, the successive folds 112 form a serpentine pattern with the food casing 104. The length of each fold 112 may be any length suitable for transporting. For example, each fold may be 5,10, 20, or 30 times the width of the food casing. The number of seams 114 included in first and second flat portions 118 and 120, respectively, may depend on the length of the container 102 and the distance between seams 114.
Each seam 114 generally provides a barrier preventing the transmission of food product across the seam 114. For example, the seam 114 may substantially prevent meat emulsions from seeping through the sealed portions of the food casing 104 during stuffing and/or storage. The seam 114 may be continuous along the portion of the body casing 104 being sealed. The barrier may be formed using any suitable sealing <BR> <BR> agent or sealing process. Suitable sealing agents may include glues (e. g. , acrylic glues), sewn seams, staples, clips, ties, hot melts, ribbons, or a combination of the foregoing. For a cellulose food casing, a sewn seam may be desirable. For a thermoplastic food casing, a thermal seal may be desirable. The seam 114 may be formed by coating portions of the food casing 104 with a sealing agent and then activating the sealing agent to form the seal. For example, the portions may be coated <BR> <BR> with a primed material (e. g. , polyvinylidene chloride) and then heat sealed. In some implementations, a sealing agent is applied via a transport carrier such as tapes. The width of the seam 114 needed to substantially prevent the loss of food product will vary depending on the sealing process. In one example, the width ranges from less than. 5 millimeters (mm) to 3 centimeters (cm). The distance between seams 114 may depend on the type of food product used to stuff the food casing 104. The distance between seams 114 is typically between approximately 5 cm and 45 cm. In some examples, the distance is up to 150 cm.
The fluid 106 is primarily used for maintaining the moisture content of the food casing 104. As a result, the food casing 104 may become flexible and provide sufficient elasticity for stuffing. The fluid 106 may include water, plasticizer (e. g., glycerol or propylene glycol), water soluble antimycotic, water insoluble antimycotic, a combination of the foregoing, or other additives. For example antimycotic additives may reduce the growth of microbes in the casing material, while flavor and color additives may change the appearance or flavor of the food product. The fluid 106 may be added to the container prior to the food casing 104, after the food casing 104, or the fluid 106 may be directly applied to the food casing 104. The fluid 106 may be delivered by spray, bubble, diptank, or pouring into the container 102, added through moisture liners 107 (e. g. , wet paper or tissue), or a combination of the foregoing. In some examples, a sufficient amount of fluid 106 is added to raise the moisture content of the food casing 104 resulting in increasing the weight of the food casing 104 by 35% to 175% based on the weight of dry food casing 104. Moisture liners 107 may be added to preserve or maintain moisture levels in the case when the food casing 104 is presoaked. As mentioned above, the fluid 106 may be added to the container 102 after the food casing 104. Furthermore, the food casing 104 may be shipped in a dry state or semi-dry state in the container 102, and once the container 102 reaches a destination, the fluid 106, or additional fluid 106, may be added prior to stuffing the food casing 104. hi this case, the expense of shipping may be reduced due to the reduced weight of the container 102. Moisturizing may still be done at the time the food casing 104 is produced or packed and the packaging may retain the moisture level. An advantage of having moisture added shortly before processing is that antimycotics may be reduced and/or eliminated from the fluid 106. Once the fluid 106 is applied to a dry food casing 104, the food casing 104 may need to soak in the fluid 106 for a period of time (e. g. , 15 minutes (min) to 90 min) before the casing is sufficiently elastic for stuffing with food product.
FIGURE 2 illustrates a food stuffing system 200 for manufacturing an end product 202. The food stuffing system 200 is comprised of an automated food stuffing machine 204, a supply of food product 206, and food casing 104. The stuffing machine 204 stuffs the food casing 104 with the food product 206 to create an end product 202.
A method for providing food casing 104 to an automated stuffing machine 204 includes creating multiple transverse seams 114 in the food casing 104. The food casing 104 with transverse seams 114 is then placed into a container 102 with folds 112 in the food casing 104. The container 102 with food casing 104 is stored or transported to a location near the automated stuffing machine 204. Fluid 106 may be added to the container 102 either prior to placing the food casing 104 into the container 102, prior to storage, prior to shipping, and/or after the container 102 is near the stuffing machine 204. Once the fluid 106 has had time to soak into the food casing 104, the food casing 104 may be fed into the stuffing machine 204. The stuffing machine 204 pumps food product 206 into the open end 108 of the food casing 104 and then seals the open end 108 and removes that segment from the food casing 104.
For example, the stuffing machine 204 may cut the food casing 104 behind the first transverse seam 106 thereby releasing the segment from the stuffing machine 204.
The cutting generates another open end 108 to receive the food product 206.
A number of implementations of the invention have been described, and a number of other implementations have been mentioned or suggested. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other implementations are within the scope of the following claims.
Next Patent: METHOD AND DEVICE FOR REMOVING SPINAL CORD