Various forms of cheese packaging are known. The most common forms of package are sealed to prevent entry of airborne contaminants which might affect the quality or shelf-life of the cheese. Such packages typically comprise a top surface extending across a surface of the cheese and having a lip around the periphery of the surface which can be cut or torn to allow entry to the package, remaining surfaces being essentially shrink wrapped onto the cheese extend from the top surface across the surface of the packaged product. Such packages are typically displayed with the top surface presented towards a prospective customer, other orientations of the package appearing unattractive to a potential consumer. A label identifying the type of cheese, the supplier and other information of interest to the consumer is typically applied to the top surface. It will be appreciated that when the package is overturned, the information cannot be viewed.

The present invention aims to provide a packaging method for providing a sturdy package which allows high visibility of the packaged product, is simple to open and which provides a large surface area for displaying information without obscuring the product.

In accordance with the present invention, there is provided a method for packaging a perishable food item comprising; a) heating a first sheet of thermo-formable plastics material, b) indexing the first sheet into a forming station of a forming apparatus and forming a plurality of first cups, c) introducing the perishable food item into each of the first cups d) heating a second sheet of thermo-formable plastics material, e) indexing the second sheet into position over the first sheet so as to enclose the perishable food item f) enclosing the two sheets in a chamber, the chamber including a top plate positioned over the top sheet and having a profile shaped to provide a plurality of recesses similarly shaped to the desired cup shape for the package g) applying a vacuum to the chamber whereby to draw from the second sheet a plurality of second cups h) introducing one or more inert gases into the cups of step g) i) sealing an area around the cups of step h) j) stamping out individual packages each comprising an opposed pair of cups sealed together by a centrally arranged peripheral rim and enclosing a perishable food item.

The perishable food item is desirably, cheese. In addition to cheese, other food items may be enclosed in the package, for example, but without limitation, crackers or processed meats.

The cups may have any geometrical shape, including, without limitation, a dome, a prismatic triangle, a prismatic rectangle, a cylinder or a prismatic star. Desirably, the opposed pairs of cups are of substantially the same depth so as to provide a 3-dimensionally symmetrical package, though this is not essential.

The rim desirably has a similar shaped perimeter to the perimeter of the cups around their open ends. Optionally, the stamping step involves cutting the rim to include a tab extending outwardly from the seal, the tab comprising a piece of one or both of the first and second sheet. If the tab comprises pieces of both sheets, these are not sealed together. The tab serves as an aid for peeling the seal between the two opposed cups apart to reveal the enclosed food item.

The method may comprise the further step of applying printed matter to the surface of the rim. In addition or in the alternative, printed matter may be applied to the outer surface of one or both of the cups.

The thermo-formable plastic is preferably at least partly transparent or translucent so as to provide a window for viewing the food item when packaged. Suitable thermo-formable plastics include, without limitation, polyethylenes, PET, PVC, MAP and combinations of the aforementioned.

The first and second sheet may comprise the same material or different materials. Preferably, when formed, the package is inflexible so as to prevent damage to the package and/or its contents when in transit.

Optionally, the plastic is thermo-setting so that the shape of the packaging may be permanently retained after manufacture.

The seal may be welded. Alternatively, a non-toxic adhesive may be applied between the sheets to form the seal. The form of seal may be selected to render the package resealable.

The one or more inert gases may include, without limitations, carbon dioxide and/or nitrogen.

The method may further comprise collecting a plurality of the individual packages and enclosing them in a secondary package. The secondary package may, for example, but without limitation, comprise a box or a net.

In another aspect, the invention provides a cheese packaged according to the aforementioned method.

One example of the inventive method will now be further described with reference to the following figures in which: Figure 1 illustrates a base web and a top web having been indexed into a pair of forming plates Figure 2 illustrates the vacuum formed packages of the invention prior to the stamping out step Figure 3 illustrates an individual pack as results from the stamping out step.

In accordance with the example method, a base film 1 of approximately 325 mm wide 250/50 micron PVC/PE is fed into a packaging apparatus. The film is held in position by grippers and is indexed to a pre-heater station where the film is heated to a temperature sufficient to render it pliable. The pliable film is then indexed to a forming station 2 where 15 pockets (cups) 3 of dimensions about 38 mm round and 7.5 mm deep are prepared. The pocketed film 1, 3 is further indexed through a second heater and is filled with a cheese portion 4. The filled cups are then indexed into position beneath a sealing head.

A top film 5 of 100 micron Cryovac Darfresh (comprising high and low density polyethylene with an EVOH barrier) is fed into the apparatus and is picked up by a second set of grippers. The top film is passed through 2 stages of pre-heating, similar to the base film. The pliable top film is then positioned over the base film in the sealing head. A pair of plates, the top of which has an internal profile shaped to provide a plurality of recesses similarly shaped to the desired cup shape for the package, close together enclosing the top and bottom films and cheese portions. A vacuum is then drawn into the space surrounding the two films causing the top film to be drawn into the cup shaped recesses of the top plate. Subsequently, the space is de-vacuumed and a rim around each cupped cheese portion is welded. The remaining area where the two films meet is left unsealed.

The welded web comprising 15 individually packaged cheese portions is then indexed to a cutter or stamping station. The cutting/stamping apparatus is configured to cut a shape around the sealed rim and including a lip 6 which is not welded.