Background of the Invention Most products must be shipped from one point to another prior to their sale to consumers, and are usually stored for a period of time at one or both locations.

During shipping and storing, ventilation, heating, and/or cooling must often be provided to the products for various reasons. Perishable products such as fruit, for example, may require ventilation and cooling in order to maintain their freshness.

Without such ventilation or temperature control, these products might arrive at their final destination in a spoiled or damaged condition. Accordingly, it is usually not sufficient to merely package and/or palletize these perishable products in closed or unventilated containers.

In addition, many products that are shipped in bulk are containerized and placed onto standardized pallets for ease of handling during shipment. Various types of containers are employed depending upon the products being shipped. Fruit and vegetables, for example, are most often shipped in rectangular corrugated containers which are stacked in ordered arrangements on wooden pallets. More often than not these containers are only intended for a single use, and are discarded by the retailer after the product has been unpacked and sold to consumers. Thus, any reduction in the amount of the material used in containerizing produce would result in significant cost savings. Further, even greater efficiency and cost savings could be realized if all or a portion of the containers were reusable or readily recyclable.

Another important consideration that must be taken into account in the shipment of goods is that the methods employed must ensure that the product arrives at its destination undamaged. Often the containers are merely stacked upon the pallet in a convenient arrangement, and shipped in that manner. When the product is in transit, however, the containers may shift and become dislodged from the pallet thereby resulting in damage to items being shipped. In order to correct this problem, various means have been employed in the past, including the securing the containers to one another by means of plastic sheeting wrapped around the parameter of the palletized stack of containers. In addition numerous configurations of stabilizing separators, or tier sheets, have been employed to separate and secure the various layers of containers disposed and stacked on a particular palletized load. One such tier sheet is disclosed in U.S. Patent 5,547,081, by Mullock et al. (August 20, 1996), which is incorporated herein by reference.

Another factor which often must be taken into account, especially with produce, is the necessity for adequate ventilation within the containers. For example, many perishable goods have ventilation and temperature parameters which must be varied or controlled during shipping and storing. Thus, at certain points during the shipping and/or storing periods it may be necessary to increase ventilation, or raise or lower the temperature of the products in order to ensure optimal freshness and ripeness. One product for which this is particularly true is bananas. Bananas are typically packed in the form of banana clusters (or hands) into corrugated containers or boxes at the plantation where they are harvested in a very green, unripened state.

These cardboard boxes are then placed within large shipping containers, which are

in turn placed in refrigerated ships. During shipment, the pulp temperature of the bananas is kept at a temperature between 560 and 590 Fahrenheit. Once the ship has docked, the bananas are transferred to refrigerated trucks or rail cars, and transported to a warehouse. Once again, the pulp temperature is maintained between 560 and 590 Fahrenheit in order to retard the ripening of the bananas, thereby prolonging their shelf life. In order to maintain this temperature range, it is necessary to provide ventilation means within the cardboard or corrugated boxes, as well as within any inner containers such as plastic bags or tunnel pads. Ventilation is typically achieved by providing a plurality of ventilation openings about the surfaces of the boxes.

These openings allow for cooled air to be circulated within the boxes, thereby maintaining the proper pulp temperature.

Once the bananas have reached the warehouse, the boxes are placed in ripening rooms where the pulp temperature is permitted to rise to about 600 to 620 Fahrenheit. Ethylene gas is also circulated about and within the containers by means of the ventilation openings. A combination of increased temperature and ethylene gas will hasten the ripening process, thereby reducing the time necessary for the bananas to fully ripen. Once this process has been completed, however, it is desirable to remove ethylene gas and decrease the temperature of the bananas in order to decelerate ripening. Since the ripening process within the bananas releases ethylene gas and large quantities of heat, and since the ripening process will continue even at temperatures below 600 Fahrenheit, it is critical that sufficient ventilation be provided within the stacked containers in order to reduce the pulp temperature and remove ethylene. Thus, once the bananas are removed from the ripening rooms and

transported to the retailer, it is usually necessary to take steps to ensure that increased ventilation can be provided to the bananas. If the ethylene gas is not removed from the bananas or the temperature is not sufficiently decreased, the bananas will continue to ripen at an accelerated rate, thereby shortening their shelf life.

Thus, the containers and packaging employed for bananas must be able to account for the varying ventilation and temperature control needs during the shipping and storing steps. Nonetheless, when cardboard containers are used to form a palletized load of bananas, temperature pull down rates are not as efficient as is desired. Because cardboard containers are good insulators, even when they are provided with ventilation apertures, rapid, predictable, and efficient temperature pull down of palletized boxes of bananas is difficult if not impossible to achieve. As a result, palletized cardboard containers of bananas often yield unevenly ripened fruit.

Further, while many of the containers and methods employed have generally met the needs of producers and retailers, many containers, such as cardboard boxes, usually require a considerable amount of extra handling.

Accordingly, there is a need for an improved system for providing a stable, unitized, multi-tiered palletized stack of product containers, as well as a method for packing, shipping and readying such products for retail, that will ensure proper shipping and storing conditions. Such a system would allow for produce to be packed, shipped, and readied for retail use without requiring excess materials or handling. Additionally, there is always a need for containers, and palletizing systems, and packing methods which improve the shelf life, appearance, and freshness

of perishable products such as fruits and vegetables. Further, there is always a need for packing and transporting such products in as compact a space as possible that still allows for adequate and efficient ventilation and temperature control in order to more efficiently store, protect and transport the product for retail use.

Summary of the Invention Accordingly, it is a primary object of the present invention to provide an improved and more efficient stable stacking system for packaging, transferring and readying produce for retail use.

Additional objects, advantages and other novel features of the invention will be set forth in the description that follows, and will also be apparent to those skilled in the art upon examination of the following or may be learned with the practice of the invention.

To achieve the foregoing and other objects, and in accordance with one aspect of the present invention, an improved tier sheet for stabilizing a plurality of containers of product is provided. The tier sheet comprises a top surface that includes an outer perimeter and a support area for supporting a plurality of containers. The top surface of the tier sheet also includes a plurality of upwardly projecting protuberances that are located so as to define a plurality of upper product cells. These protuberances further engage the containers aligned thereon so as to stabilize them and to prevent substantial movement relative to one other.

The tier sheet also includes a bottom surface that comprises a plurality of underlying product cells. The underlying product cells are disposed substantially underneath the upper product cells of the top surface of the tier sheet. The tier sheet also includes a plurality of ventilation apertures. Preferably, each upper product cell includes one or more of these ventilation apertures.

The tier sheet may also include one or more longitudinally or transversely disposed stiffening ribs. Preferably, at least one of the stiffening ribs comprises one or more of the upstanding protuberances. Preferably, each upper product cell includes a substantially convex support area of substantially uniform inverted-U- shaped lateral cross-section along its length. The tier sheet may also include a peripheral retaining lip depending downwardly from its perimeter.

Additionally, the tier sheet may include a plurality of elongated slits for holding one or more removable support walls. Preferably, a portion of these slits is disposed near the outer perimeter of the tier sheet and a portion of the slits is disposed adjacent a centerline that divides the tier sheet into two halves of approximately equivalent area.

One or more center support walls may be disposed in the slits, each of the center support walls comprising first and second end portions separated by and hingedly connected with a middle portion. Preferably, each of the first and second end portions include one or more downwardly depending tabs capable of being disposed in corresponding slits disposed near the outer perimeter of the tier sheet.

Additionally, each middle portion of the center support walls include one or more downwardly depending tabs capable of being disposed in corresponding slits disposed substantially adjacent the centerline so that each of the first and second end portions are substantially parallel with a first pair of opposing tier sheet sides and so that the middle portion is substantially parallel with a second opposing pair of tier sheet sides and the centerline.

Additionally, one or more end support walls may be disposed in the slits, each of the end support walls comprising first and second end portions separated by and hingedly connected with a middle portion. Preferably, each of the first and second end portions and middle portion include one or more downwardly depending tabs capable of being disposed in corresponding slits disposed near the outer perimeter of the tier sheet so that each of the first and second end portions are substantially parallel with a first pair of opposing tier sheet sides and so that the middle portion is substantially parallel with a second opposing pair of tier sheet sides.

Preferably, each of the center support walls and each of the side support walls include a plurality of ventilation holes. Further, the center portion of each support wall may include first and second domed surfaces that are substantially convex on a first side of the center portion and substantially concave on a second side of the center portion.

The foregoing and other objects may also be accomplished by providing a method of stacking a plurality of loaded flexible containers of produce in a unitized, stable multi-tiered arrangement, comprising the steps of: (a) providing a plurality of loaded flexible containers; (b) providing a first tier sheet constructed in accordance with the present invention as discussed in detail hereinabove; (c) placing first and second center support walls, constructed in accordance with the present invention as discussed in detail hereinabove, on the first tier sheet; (d) placing one of the containers in each upper product cell of the first tier sheet; (e) placing first and second end support walls, constructed in accordance with the present invention as discussed in detail hereinabove, on the first tier sheet; (f) placing a second tier sheet, that is of substantially identical configuration as the first tier sheet on top of the plurality of containers; and (g) arranging a second tier of containers on the top surface of the second tier sheet; so that a unitized, stable stack of containers is formed.

Steps (f) and (g) in the above method may be repeated in order to provide additional tiers of containers, as desired. The flexible containers may each comprise a plastic bag that have a top portion and a sealed bottom portion. Preferably each of the bags further include a perforation connecting the top and bottom portions.

The produce in the bags is preferably a plurality of banana clusters, each of which comprise a plurality of bananas. Each banana cluster further has a tip portion and a crown and the bananas of each cluster are connected to one another at the crown. The bananas may be positioned in each bag in three rows in a "crowns down" configuration.

To achieve the previously recited and other objects, and in accordance with another aspect of the present invention, a reusable, stackable shipping receptacle for transporting produce is provided. The shipping receptacle is of a substantially rigid, rectangular construction and has a bottom wall and four side walls. Preferably, each side wall is hingedly connected at a bottom edge with the bottom wall. The bottom wall comprises one or more upper product cells defined by two or more of the side walls. Each upper product cell further comprises a substantially convex produce support area of substantially uniform inverted-U-shaped lateral cross-section along substantially its entire length.

Preferably, the bottom wall of the shipping receptacle further comprises one or more underlying product cells, each of which further includes a substantially concave produce support area. Each substantially concave produce support area is preferably of substantially uniform inverted-U-shaped lateral cross-section along its length. Preferably, each receptacle comprises 2 upper product cells and 2 underlying product cells that are substantially rectangular and of approximately equivalent size.

The foregoing and other objects may also be accomplished by providing a method of stacking a plurality of reusable, stackable shipping receptacles for transporting produce comprising the steps of: (a) providing a plurality of open-topped receptacles, each of said receptacles comprising a reusable, stackable shipping receptacle constructed in accordance with the present invention as discussed hereinabove; (b) arranging a first tier of the stackable receptacles in a substantially rectangular pattern in such a manner so that each receptacle is substantially adjacent at least two other receptacles; and (c) arranging a second tier of stackable receptacles atop the first tier of receptacles so that the substantially concave produce support areas of the second tier of receptacles are positioned substantially above the convex produce support areas of the first tier of the receptacles; so that a unitized, stable stack of containers is formed.

Step (c) in the above method may be repeated in order to provide additional tiers of receptacles, as desired. Further, each tier of stackable receptacles preferably comprises four receptacles.

To achieve the previously recited and other objects, and in accordance with another aspect of the present invention, a method of packing, shipping, and transferring a load of bananas and readying the bananas for retail use is provided comprising: (a) loading a plurality of flexible bags with a plurality of banana clusters comprising a plurality of bananas in a first location. Each banana cluster has a tip portion and a crown and the bananas of each cluster are connected to one another at the crown. Each bag has a neck portion, a top portion, a sealed bottom portion, an interior bottom and an opening adjacent the neck portion. Each bag is manufactured from a plastic having sufficient strength to permit one to grasp the sealed neck and lift the bag containing all of the bananas for transfer. Each of the bags further includes at least one perforation connecting the top and bottom portions of each bag and one or more ventilation apertures; (b) arranging the plurality of flexible bags in a unitized, stable multi-tiered arrangement; (c) shipping the bananas to a second location; (d) removing a bag from the unitized arrangement by grasping the neck of the bag and lifting the bag containing the bananas;

(e) placing the bag containing the bananas within an open-topped reusable container, thereby transferring the bananas into the reusable container without removing said bananas from said bag; (f) transferring the reusable container to a third location; (g) rotating the bag approximately 1800 about its longitudinal axis within the reusable container; and (h) tearing the bag at the perforation and tucking separated portions of the bag beneath and around the bananas so that at least one row of the bananas is exposed and in position for retail use.

Steps (e) - (h) may be repeated in order to unload, ship, and position for retail use additional bags of bananas, as desired. Preferably, the step of loading a plurality of flexible bags with a plurality of banana clusters comprises the following steps: (a) providing a tunnel pad comprised of flexible plastic material; (b) placing the tunnel pad on the interior bottom of the bag; (c) placing a first row of banana clusters in the flexible container atop the tunnel pad and the interior bottom;

(d) positioning a portion of the tunnel pad atop and in direct contact with at least a portion of the bananas in the first row; (e) placing a second row of banana clusters in the bag such that a portion of each banana cluster of the second row is positioned atop a portion of the tunnel pad and a portion of the bananas of the first row; (f) positioning a portion of the tunnel pad atop and in direct contact with at least a portion of the bananas in the second row; (g) placing a third row of banana clusters in the bag such that a portion of each banana cluster of the third row is positioned atop a portion of the tunnel pad and a portion of the bananas of the second row; and (h) sealing the bag at the neck.

The step of arranging the plurality of flexible bags in a unitized, stable multi- tiered arrangement may comprise the above-described method of stacking a plurality of loaded flexible containers of produce in a unitized, stable multi-tiered arrangement using the tier sheet constructed in accordance with the present invention as discussed in detail hereinabove. Further, the step of arranging the plurality of flexible bags in a unitized, stable multi-tiered arrangement may comprise the above-described method of stacking a plurality of reusable, stackable shipping receptacles for transporting

produce using the stackable shipping receptacle constructed in accordance with the present invention as discussed in detail hereinabove.

Preferably, the tunnel pad includes one or more perforations across either its width or length. Further, the first and second rows of bananas are preferably positioned in a "crowns down" configuration within the bag. More preferably, the crowns of the third row of bananas are positioned substantially adjacent the tip portion of the second row of bananas. The tip portions of the third row of bananas are preferably positioned substantially adjacent the tip portions of the first row of bananas.

Brief Description of the Drawings While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed the same will be better understood from the following description taken in conjunction with the accompanying drawings in which: Figure 1 is a perspective view of the tier sheet according to the present invention; Figure 2 is a top plan view of the tier sheet of Figure 1;

Figure 3 is a perspective view of the removable product support wall used with the tier sheet of the present invention; Figure 4 is a cross-sectional view of a tier sheet according to the present invention taken along line 4-4 of Figure 2; Figure 5 is a rear plan view showing the center portion of the product support wall of Figure 3; Figure 6 is a cross-sectional view of the product support wall of the present invention taken along line 6-6 of Figure 5; Figure 7 is a cross-sectional view of the product support wall of the present invention taken along line 7-7 of Figure 5; Figure 8 is a cross-sectional view of the product support wall of the present invention taken along line 8-8 of Figure 5; Figure 9 is a cross-sectional view of the product support wall of the present invention taken along line 9-9 of Figure 5; Figure 10 is a perspective view of a partial palletized load showing 4 layers of product in place;

Figure 11 is a perspective view showing two center support walls installed on a tier sheet layer; Figure 12 is a perspective view of a pallet partially loaded with containers and showing containers disposed on the various product cells of the top tier sheet; Figure 13 is a perspective view of a partial palletized load of containers showing the top tier of containers, and top support walls in place; Figure 14 is a perspective view of a partial palletized load showing 5 layers of product in place; Figure 15 is a perspective view of a pallet loaded with containers incorporating the tier sheet and support walls of the present invention; Figure 16 is a perspective view showing a worker loading a container of produce onto a product cell of a tier sheet of the present invention; Figure 17 is a side plan view of the flexible bag of the present invention; Figure 18 is atop plan view of the tunnel pad of the present invention; Figure 19 is a cut-away view of the packing procedure of the present invention;

Figure 20 is a cut-away view of the packing procedure of the present invention; Figure 21 is a cut-away view of the packing procedure of the present invention; Figure 22 is a perspective view of the stackable dome-bottomed shipping receptacle of the present invention; Figure 23 is a top plan view of the stackable dome-bottomed shipping receptacle of the present invention in a collapsed state; Figure 24 is a side plan view of 2 layers of stacked dome-bottomed shipping receptacles of the present invention showing the contour of the product support area dashed lines; Figure 25 is a perspective view of a partially loaded pallet of stackable dome- bottomed shipping receptacles of the present invention; Figure 26 is a perspective view of a partially loaded pallet of stackable dome bottomed shipping receptacles showing 4 containers of bananas in position in the top tier;

Figure 27 is a perspective view of a pallet loaded with stackable dome- bottomed shipping receptacles of the present invention; Figure 28 is a perspective view of the transfer procedure of the present invention showing a load of bananas being transferred from a partially loaded pallet incorporating the tier sheet system of the present invention; Figure 29 is a perspective view of the transfer procedure of the present invention showing a load of bananas being transferred from a partially loaded pallet incorporating the dome-bottomed stackable shipping receptacles of the present invention; and Figure 30 is a perspective view of a reusable box showing a load of bananas ready for retail use after the perforations of the flexible bag and tunnel pad have been torn and pulled away.

Detailed Description of the Preferred Embodiment Referring now to the drawings in detail, wherein like numerals indicate the same elements throughout the views, Figures 1 and 2 show the preferred embodiment of the improved tier sheet for stabilizing a plurality of containers of product of the present invention, generally designated by the numeral 10. Although essentially any standard container, such as corrugated boxes, may be employed with the tier sheet of the present invention, a flexible container, such as a plastic bag, is particularly

preferred to be used with the present invention when produce, such as bananas, are being shipped. The tier sheet 10 is generally rectangular in shape, since the vast majority of pallets and resultant palletized loads of stacked shipping containers are of a similar shape. Preferably, tier sheet 10 is approximately 48 inches by approximately 41 inches. Obviously, other shapes could be employed for tier sheet 10 depending upon the shape of the pallets and containers being used.

The tier sheet 10 of the present invention comprises a top surface 14 that includes an outer perimeter and a support area upon which a layer of containers may rest. The top surface 14 of the tier sheet 10 also comprises a plurality of upwardly projecting protuberances 20 that are located so as to define a plurality of upper product cells 22. The spacing between the projecting protuberances 20 obviously may be varied depending upon the specific dimensions of the containers to be disposed on the upper product cells 22. Preferably, each product cell 22 is approximately 9 inches by approximately 19 inches. The protuberances 20 advantageously engage the containers aligned thereon so as to stabilize them and to prevent substantial movement relative to one other. Protuberances 20 do not have to completely surround each product cell 22 in order to effectively engage the containers disposed within each cell.

Preferably, each side of each product cell 22 is provided with at least one such protuberance 20 in order to effect adequate container stability. Preferably, each of the protuberances 20 is substantially elongated and of a length of between about 3 inches and about 36 inches. Additionally, the upstanding protuberances may be substantially hollow which advantageously allows the tier sheet 10 to be injection molded which will be described in greater detail hereinafter. In order to facilitate

ease of loading the tier sheet 10 with containers, it is preferred that the protuberances 20 are of a relatively short height as compared with the height of the containers to be stacked thereon. This will allow workers to load the tier sheet in a more ergonomic fashion in that they are not required to lift the containers being loaded up and over any significant obstruction. Preferably, each of the protuberances are of a height between about 0.5 inch and about 6 inches.

The tier sheet also includes a bottom surface that comprises a plurality of underlying product cells disposed substantially underneath the upper product cells 22 of the top surface 14 of the tier sheet 10. When multiple tier sheets are used to form a multi-layered stacked load of containers, each underlying product cell of a tier sheet 10 may engage or contact a top portion of a corresponding container disposed on an upper product cell 22 of a lower tier sheet.

As described previously, many products, such as produce, require ventilation, heating, and/or cooling during shipping and storing for various reasons. Perishable products such as produce, for example, requires ventilation and cooling in order to maintain freshness and/or to control ripening. Such ventilation and temperature control means are necessary so that such perishable products might arrive at their final destination in an unspoiled and undamaged condition. Accordingly, in order to provide means for ventilating and circulating air among containers disposed thereon and thereunder, each tier sheet 10 also includes a plurality of ventilation apertures 32 so that adequate ventilation is insured for each such cell 22. This slot shaped ventilation means allows for adequate ventilation without requiring significant removal

of material from the top surface 14. As a result, adequate ventilation can be provided with the containers disposed on the tier sheet without affecting the structural integrity of the tier sheet. More preferably, each upper product cell 22 includes from about 1 to about 12 ventilation apertures 32. Each of the ventilation apertures may comprise a substantially elongated slot that is preferably substantially parallel with one or more of the upstanding protuberances 20. Preferably, each upper product cell 22 includes one or more of these ventilation apertures 32.

The tier sheet of the present invention may be manufactured of any materials using a number of different methods. It is preferred, however, that the tier sheet be singularly molded and that, for considerations of weight and strength, the tier sheet of the present invention be manufactured of an engineering thermoplastic, and preferably thermoformed. Preferably, the tier sheet is made from high density polyethylene. This results not only in a strong and light weight tier sheet, but also one that is relatively inexpensive to manufacture and is durable and reusable.

As one skilled in the manufacturing of plastic articles will understand, when an item is injection molded, a linear grain structure will be present in the article.

While this grain structure will resist rotation and flexing in a direction perpendicular to the grain, such will not be the case in a direction parallel to that of the grain.

Accordingly, and as best shown in Figures 1 and 4, the tier sheet 10 may also include one or more longitudinally disposed stiffening ribs 34 or transversely disposed stiffening ribs 36. These ribs 34, 36, especially when disposed in a direction perpendicular to that of the grain structure, provide additional stiffening and strength

for the tier sheet. This in turn results in a more stable load of containers when the tier sheet is fully loaded. Preferably, at least one of the stiffening ribs 34, 36 comprises one or more of the upstanding protuberances 20. This configuration simultaneously provides additional strengthening of the tier sheet while providing advantageous definition of product cells 22.

Preferably, each upper product cell 22 includes a substantially convex support area 38 of substantially uniform inverted-U-shaped lateral cross-section along its length. As will become apparent and as explained in greater detail hereinafter in the descriptions of the methods of the present invention, this convex support area is especially advantageous for supporting contoured product loads. For example, when a flexible container (i.e., a plastic bag) holding rows of bananas is disposed on the convex support area, the curvature of the rows of bananas may snugly engage the convex support area. Such a configuration not only provides additional product support as is especially desired when transporting easily damaged and perishable goods such as bananas, but it also allows for stacking contoured products such as bananas in a more compact and efficient manner. For example, if a row of bananas was disposed on a flat bottomed box, as is customary in the industry, additional pressure is imparted to the fruit at its contact points. In contrast, when essentially all, or at least a significant portion, of each banana in a row of bananas is able to lie flush against a support surface, the weight load is advantageously distributed more evenly.

Further, when a palletized load of containers of irregularly shaped, curved products, such as rows of bananas, is stacked in a unitized arrangement, additional layers of such containers may be added to each palletized load when the tier sheet incorporating

the convex support areas of the present invention is employed. Accordingly, and as will be described in greater detail, additional product may be shipped within a given volume of a standard palletized load as compared with a palletized load incorporating standard substantially planar tier sheets.

Depending on the size of the containers to be stacked thereon, the tier sheet 10 may include from about 2 to about 16 upper product cells 22 and from about 2 to about 16 underlying product cells. Preferably the tier sheet includes 8 upper product cells and 8 underlying product cells, both arranged in two rows of four cells.

Each upper product cell 22 and each underlying cell are preferably rectangular and of approximately equivalent size.

Additionally, the tier sheet 10 may include means for holding one or more removable support walls 50. Preferably, the means for holding one or more support walls comprises a plurality of elongated slits 48. A portion of these slits 48 is disposed near the outer perimeter of the tier sheet 10 and a portion of the slits 48 is disposed adjacent a centerline that divides the tier sheet into two halves of approximately equivalent area. Preferably, none of the slits 48 are disposed within any of the product cells 22.

One or more support walls 50 may be disposed in the slits 48. As best shown in Figures 3 and 5, each of the support walls 50 comprise first and second end portions 52a, 52b separated by and hingedly connected with a middle portion 54.

Preferably, each of the first and second end portions 52a, 52b include one or more

downwardly depending tabs 58 capable of being disposed in corresponding slits 48 disposed near the outer perimeter of the tier sheet 10. Additionally, each middle portion 54 of the support walls 50 include one or more downwardly depending tabs 58 capable of being disposed in corresponding slits 48 disposed either near the outer perimeter of the tier sheet or substantially adjacent a centerline that divides the tier sheet 10 into two halves of approximately equivalent area. When in position on the tier sheet 10, each of the first and second end portions 52a, 52b are substantially parallel with a first pair of opposing tier sheet sides and the middle portion 54 is substantially parallel with a second opposing pair of tier sheet sides and the centerline. Each of the first and second end portions 52a, 52b of each support wall 50 are preferably substantially perpendicular to the corresponding middle portion when in place on the tier sheet.

For each tier sheet, and as will be described in greater detail in the method descriptions of the present invention, it is preferred that two centrally disposed support walls and two side support walls be employed. In this manner, with all four walls disposed on the tier sheet 10, a substantially continuous support structure is formed about the periphery of the tier sheet. Similarly, when all four walls are in position, and as shown in Figure 13, the two middle portions 54 of the centrally disposed walls provide a double-walled transverse support structure adding additional stability to the tier sheet structure.

As should be appreciated, utilizing the tier sheet 10 with support walls 50 of the present invention results in several notable advantages over commonly used

stacking systems. For example, the inclusion of walls 50 in the system of the present invention eliminates the need for product containers disposed on the tier sheet to be sufficiently rigid to support above-disposed layers of product. Additionally, because support walls 50 include tabs 58 that are disposed in the tier sheet, additional stability is achieved as compared with boxes that are merely set on a standard sheet. Because support walls 50 provide the necessary support for above-disposed layers of product, non-rigid containers incorporating less material than traditional corrugated boxes, such as plastic bags, may be used to containerize the product being palletized.

Obviously, the elimination of excess packing materials advantageously reduces the amount of waste material that must be discarded or recycled when the product arrives at its destination.

The walls 50 are preferably injection molded and made from a sufficiently durable material, such as an engineering thermoplastic, so that like the tier sheet 10 of the present invention, they may be reused. Preferably, the walls 50 are made of high density polyethylene. Additionally, because the walls are preferably removable and hinged, they may be collapsed and returned in a compact space-efficient fashion for later use to ship additional goods. Although it is preferred that the support walls be removable from the tier sheet, it will be understood that they may be formed as an integral part of the tier sheet itself.

Preferably, each of the support walls 50 includes a plurality of ventilation holes 62 in order to facilitate ventilation of product disposed within the walls. More preferably, each of the first and second end portions 52a, 52b and each center portion

54 of the support walls 50 include four ventilation holes 62. Further, each side support wall and each center support wall may include a plurality of detents 74 located substantially above the tabs 58 depending from the lower edge of the support wall 50. Advantageously, each detent 74 of a wall 50 of a lower tier sheet may receive a corresponding tab 58 of an above-disposed wall 50 of an adjacent tier sheet.

As shown in Figure 1, the tier sheet may also include a peripheral retaining lip 42 depending downwardly from its perimeter. Each lip 42 is capable of fitting about the support walls 50 of the adjacent lower tier of product. This arrangement adds additional stability to the palletized load.

As best shown in Figures 6-9, the center portion 54 of each support wall 50 may include one or more domed surfaces 76 that are substantially convex on a first side 78 of the center portion 54 and substantially concave on a second side 80 of the center portion. Preferably, the second substantially concave side 80 of each center portion is adjacent with one or more of the upper product cells 22 when walls 50 are installed on the tier sheet 10. This "bowed-out" arrangement effectively increases the volume enclosed by the support walls 50 on a tier layer. Accordingly, more product may be disposed within each cell 22 than if the walls 50 were planar. Further, curved containers may be fitted snugly against each concave side 80 so as to provide additional support and to prevent sliding.

As best depicted in Figures 10-16, a method of stacking a plurality of loaded flexible containers of produce in a unitized, stable multi-tiered arrangement that

utilizes the tier sheet 10 and support walls 50 of the present invention, as described previously, is provided. In order to form a secure base for the load of stacked containers of produce, a standard pallet 64 may be provided. While pallet 64 may be of any design and of any of a variety of materials, it is preferred that pallet 64 be of a plastic construction such as the type now often employed for shipping purposes.

After the pallet 64 has been provided, several layers of containerized product, supported by tier sheets 10 and support walls 50, may be placed thereon as described below. For example, Figure 10 shows a partial palletized load having 4 layers of product in place. As seen in Figure 10, each layer is formed by first providing a tier sheet 10 of the present invention. Retaining lip 42 of the tier sheet may be placed around the support walls 50 of the adjacent lower tier of containers in order to provide additional support to the palletized load.

Next, and as shown in Figure 11, two centrally disposed support walls 50 are positioned in the holding means of the tier sheet. As described previously, each of the support walls 50 comprise first and second end portions 52a, 52b separated by and hingedly connected with a middle portion 54. Each of the first and second end portions 52a, 52b and the middle portions 54 include a bottom edge having one or more tabs 58 depending downwardly therefrom. The tabs 58 of each middle portion of the two centrally disposed support walls 50 are disposed in corresponding slits 48 substantially adjacent a centerline that divides the tier sheet 10 into two halves of approximately equivalent area. Preferably, as shown in Figure 11, the middle portions 54 of the two centrally disposed support walls are sufficiently spaced apart

to accommodate the aforementioned domed surfaces 78 of the middle portions 54.

Preferably, the convex sides 78 of the middle portions 54 of the two centrally disposed support walls are facing each other so that product storage area is maximized.

The tabs 58 of each first and second end portions 52a, 52b of the centrally disposed support walls 50 are disposed in one or more of the slits 48 disposed near the outer perimeter of the top surface 14 of the tier sheet so that each of the first and second end portions of the centrally disposed support walls 50 are substantially parallel with a first pair of opposing tier sheet sides and so that the middle portions 54 are substantially parallel with a second opposing pair of tier sheet sides and the centerline. Preferably, each of the first and second end portions 52a, 52b of each centrally disposed support wall 50 substantially perpendicular to the middle portions 54.

After the centrally disposed support walls 50 are in place on the tier sheet 10, loaded flexible containers of produce 82 are positioned on each of the upper product cells 22 of the tier sheet, as shown in Figure 12. Protrusions 20 advantageously help align and secure the flexible containers 82 of produce in place. Preferably, as shown in Figure 17, each loaded flexible container comprises a gussetted plastic bag 82 having a top portion and a sealed bottom portion 86. Preferably, each bag 82 further includes one or more ventilation openings 88 and an open end 90 adjacent the top portion.

Preferably each of the bags 82 further includes a perforation 100 connecting the top and bottom portions. More preferably, the perforation 100 extends down the length of bag 82 from a first side of open end 90, across the sealed bottom portion 86, and up the length of bag 82 to a second side of open end 90. Advantageously, this preferred arrangement of perforation 100 divides the bag 82 into two halves.

Accordingly, if a sealed bag 82 having such a perforation is inverted 1800, the perforation may be readily accessed and torn, and the sides of the bag may be pulled back to reveal the contents of the bag. The produce in the bags 82 is preferably a plurality of banana clusters, each of which comprises a plurality of bananas. More preferably, the banana clusters are arranged within the bags 82 in accordance with the preferred packing method of the present invention to be described in detail hereinafter.

As should be appreciated, because the upstanding protuberances 20 are of relatively short height, loaded containers 82 of produce do not have to be raised over any significant obstructions in order to be positioned in a product cell 22.

Accordingly, as shown in Figure 16, the bags 82 of produce may be put in position on the tier sheet 10 in an ergonomic fashion that does not require excessive lifting or maneuvering by a worker 68. Further, because there are no significant obstructions, produce that is easily damaged is less susceptible to bumping or bruising while being positioned. Although the containers of produce may be loaded manually by one or more workers without any additional equipment other than the various components of the tier sheet system, it is preferred that hydraulic packing stations be used to load the containers. Specifically, the palletized load may be built on a hydraulic platform

that can be raised or lowered as the palletized load is assembled in order to keep the layer being assembled in an ergonomically efficient position for the workers loading the produce.

Next, and as shown in Figure 13, two peripherally disposed, or side, support walls 50 are positioned in the holding means of the tier sheet. The tabs 58 of each middle portion 54 and each end portion 52a, 52b of the two peripherally disposed, or side, support walls 50 are disposed in corresponding slits 48 substantially adjacent the outer perimeter of the tier sheet. When in position on the tier sheet 10, each of the first and second end portions 52a, 52b of the side support walls 50 are substantially parallel with a first pair of opposing tier sheet sides. Each middle portion of the side support walls is substantially parallel with a second opposing pair of tier sheet sides in such a manner so that each of the first and second end portions 52a, 52b of each side support wall 50 further is substantially perpendicular to the middle portions 54.

Next, as shown in Figure 14, an additional tier sheet 10 is placed on top of the exposed layer thus completing the fifth tier layer. Again, the retaining lip 42 of the tier sheet may be placed around the support walls 50 of the adjacent lower tier of containers in order to provide additional support to the palletized load. Multiple tiers may be built according to the present method in order to provide additional tiers of containers as desired. Preferably, from about 3 to about 12 layers of produce are produced with the present system. More preferably, nine tiers or layers of produce are included with the tier sheet system, as shown in Figure 15. Additionally, a rigid

top cap 66 may be provided and may be disposed about the periphery of the top most support walls of a palletized load. Preferably, cap 66 is comprised of rigid plastic similar to the other components of the tier sheet system. Further, additional securing means, such as strapping tape may be used in order to provide additional security to the palletized load.

The tier sheet 10, the support walls 50, the top cap 66 and the pallets 64 are durable and designed for a repeat return and reuse. Advantageously, because support walls 50 are preferably hinged, they are collapsible into a substantially flat state and may be compactly stored when being returned for later use. The volume occupied by the various components of the tier sheet system, when compacted and stacked for return, is only roughly 25% of the volume of a complete nine-layered erected palletized load incorporating the components of the present invention. Significantly, the additional cost and environmental impact associated with disposing of and/or recycling currently used corrugated packaging is substantially eliminated. For example, the tier sheet system of the present invention, when used to build a palletized layer of produce, replaces the need of using heavy and expensive disposable corrugated boxes, normally using about 3.2 lbs. of paper each.

As discussed previously, when the tier sheet system of the present invention is used to transport flexible containers of bananas, additional fruit may be stored in a given volume. Specifically, because the contoured tier sheet is capable of approximating the curvature of the rows of bananas, and because the tier sheet system of the present invention utilizes relatively less packing material than conventional

shipping systems, there is less wasted space within a palletized load. Additionally, because the surfaces of the tier sheet approximate the curvature of bananas, there are fewer pressure points in discreet areas of the banana rows. Accordingly, there is less resultant bruising and damage to the fruit during shipping. This is especially important for bananas which are susceptible to bruising, neck damage and latex seepage if mishandled.

As mentioned previously, the necessity for adequate ventilation within the various layers of a palletized load is especially important when transporting produce.

Bananas, and many other perishable goods, have ventilation and temperature parameters which must be varied or controlled during shipment and storage.

Accordingly, it is necessary at certain points during the shipping and/or storing periods to increase ventilation or adjust the temperature in order to insure optimal freshness and ripeness.

The tier sheet system of the present invention allows for more effective ventilation and more predictable temperature control as compared with standard palletized loads incorporating cardboard or corrugated containers. Because cardboard is a good insulator and frequently absorbs water, it is often difficult to increase or decrease the temperature in a controlled, uniform fashion throughout a palletized load using corrugated containers. In contrast, the plastic components of the tier sheet system of the present invention are not water absorbent, and they do not have corrugation channels that could trap insulating air. Accordingly, greater control of temperature pull down can be achieved thus resulting in more uniform fruit quality.

This ability to more readily control and adjust temperature results in better customer control of preparing and ripening the fruit for retail use and greater stability while the fruit is in retail display. This results in less spoilage and higher yields of fruit and advantageously eliminates the relatively high rate of spoiled or damaged fruit associated with shipping perishables in cardboard containers.

In an alternate embodiment of the present invention, and as best shown in Figures 22-24, a reusable, stackable shipping receptacle, generally indicated by the reference numeral 114, may be used for stabilizing a plurality of containers of produce. The stackable shipping receptacle 114 is of a substantially rigid, rectangular construction and has a bottom wall 116 and four side walls 118a-d. Preferably, stackable shipping receptacle 114 is molded from an engineering thermoplastic.

Further, each side wall 118 is preferably hingedly connected at a bottom edge with the bottom wall 116. Advantageously, this hinged arrangement allows for the shipping receptacle 114 to be selectively erected and collapsed.

The bottom wall 116 comprises one or more upper product cells 120 defined by two or more of the side walls 118. Similar to the convex support area 38 of the previously described tier sheet of the present invention, each upper product cell 120 of the receptacle 114 further also comprises a substantially convex produce support area 122 of substantially uniform inverted-U-shaped lateral cross-section along substantially its entire length. More preferably, each side wall 118 is provided with one or more engaging tabs 127 capable of securely engaging an adjacent sidewall 118 in order to selectively maintain the stackable receptacle 114 in an assembled state.

Preferably, each side wall 118 includes one or more ventilation apertures 119.

Further, one or more apertures 119 may further serve as handles 121 in order to provide a means for readily lifting the receptacle 114. Additionally, each convex support portion 122 includes from about 1 to about 12 ventilation holes 123.

Preferably, each of the ventilation holes comprises a substantially elongated slot that is preferably substantially parallel with one or more of the side walls 118.

Preferably, the bottom wall of the shipping receptacle further comprises one or more underlying product cells 124, each of which further includes a substantially concave produce support area. Each substantially concave produce support area is preferably of substantially uniform inverted-U-shaped lateral cross-section along its length. Each convex produce support area is further preferably disposed substantially above a corresponding concave produce support area. Preferably, each receptacle 114 comprises 2 upper product cells and 2 underlying product cells that are substantially rectangular and of approximately equivalent size.

As shown in Figure 24, each stackable receptacle 114 may include a downwardly depending retainer 117 disposed near an edge of the bottom perimeter of the box 114. The retainers 117 provide an extra measure of stability when receptacles 114 are stacked in multiple layers. Similar to the tier sheet 10 of the present invention, the stackable receptacle 114 exhibits improvement over prior art container systems. Specifically, the convex support portions 122 of the receptacles allow for additional product to be stored in a given volume, especially when a product such as bananas is being shipped because the convex portions 122 are capable of

approximating the curvature of banana rows. Additionally, stacked layers of produce incorporating the stackable receptacle 114 of the present invention exhibit all of the improved temperature pull down and ventilation advantages associated with the tier sheet of the present invention over standard corrugated shipping containers. Further, because stackable receptacles 114 are collapsible, they similarly might be returned for subsequent use and in a space efficient manner.

As best depicted in Figures 25-27, a method of stacking a plurality of reusable, stackable shipping receptacles of produce in a unitized, stable multi-tiered arrangement that utilizes the stackable receptacles 114 of the present invention as described previously, is disclosed. In order to form a secure base for the load of stacked receptacles of produce, a standard pallet 64 may be provided. While pallet 64 may be of any design and of any of a variety of materials, it is preferred that pallet 64 be of a plastic construction such as the type now often employed for shipping purposes.

After the pallet 64 has been provided, several layers of containerized product, supported in the stackable receptacles 114, may be placed thereon. For example, Figure 25 shows a partial palletized load showing 4 complete layers of product in place. As shown in the figure, it is preferred that each layer of product comprise four stackable receptacles arranged in a substantially rectangular configuration in such a manner so that each receptacle 114 is adjacent with at least two other stackable receptacles. More preferably, and as discussed in greater detail previously, each receptacle 114 comprises two convex support surfaces 122.

Although Figure 25 shows the top tier of receptacles empty, it is preferred that each receptacle 114 is packed prior to being placed on the pallet layer. Preferably, flexible containers of produce are packed and assembled within the stackable receptacles themselves 114 prior to being palletized. Because each stackable receptacle 114 preferably includes two convex support areas 122, two flexible containers of product are preferably placed and packed in each stackable receptacle before being palletized. One or more removable separators may be employed while packing the first flexible container of product in the stackable receptacle 114 in order to provide additional product support while packing the flexible containers.

As shown in Figures 17 and 26, each flexible container preferably comprises a gussetted plastic bag 82 having a top portion and a sealed bottom portion 86.

Preferably, each bag 82 further includes one or more ventilation openings 88 and an open end 90 adjacent the top portion. Preferably each of the bags 82 further includes a perforation 100 connecting the top and bottom portions. The produce in the bags 82 is preferably a plurality of banana clusters, each of which comprise a plurality of bananas. More preferably, the banana clusters are arranged within the bags 82 in accordance with the preferred packing method of the present invention to be described in detail hereinafter.

Multiple layers may be built according to the present method in order to provide additional tiers of stackable receptacles as desired. Preferably, from about 3 to about 12 layers of produce are built. More preferably, nine tiers or layers of produce are included with the stackable receptacle system, as shown in Figure 27.

Additionally, a rigid top cap 126 may be provided to cover the top layer of stacked receptacles of a palletized load. Although it is preferred that the cap 126 cover the entire top layer, individual caps may be provided for each stackable receptacle 114 of the top layer. Preferably, cap 126 is comprised of rigid plastic similar to the components of the tier sheet system and the stackable receptacles 114. Further, additional securing means, such as strapping tape may be used in order to provide additional security to the palletized load.

The stackable receptacles 114, caps 126 and the pallets 64 are durable and designed for a repeat return and reuse. Advantageously, because stackable receptacles 114 are preferably hinged, they are collapsible into a substantially flat state and may be compactly stored when being returned for later use. Significantly, similar to the tier sheet system of the present invention, the additional cost and environmental impact associated with disposing of and/or recycling currently used corrugated packaging is substantially eliminated with the present stackable receptacle method. For example, the stackable receptacles 114, when used to build a palletized layer of produce, replace the need of using heavy and expensive disposable corrugated boxes, normally using about 3.2 lbs. of paper each.

Similar to the tier sheet system, when the stackable receptacle system of the present invention is used to transport flexible containers of bananas, additional fruit may be stored in a given volume. Specifically, because the contoured surfaces of the stackable receptacles are capable of approximating the curvature of the rows of bananas, there is less wasted space within a palletized load. Additionally, because

the surfaces of the stackable receptacles approximate the curvature of bananas, there are a fewer number of pressure points in discreet areas of the banana rows.

Accordingly, there is less resultant bruising and damage to the fruit during shipping.

This is especially important for bananas which are susceptible to bruising, neck damage and latex seepage if mishandled.

As mentioned previously, the necessity for adequate ventilation within the various layers of a palletized load is especially important when transporting produce.

Bananas, and many other perishable goods, have ventilation and temperature parameters which must be varied or controlled during shipment and storage.

Accordingly, it is necessary at certain points during the shipping and/or storing periods to increase ventilation or adjust the temperature in order to insure optimal freshness and ripeness.

Similar to the tier sheet system of the present invention, the stackable receptacle system allows for more effective ventilation and more predictable temperature control as compared with standard palletized loads incorporating cardboard or corrugated containers. Because cardboard is a good insulator and frequently absorbs water, it is often difficult to increase or decrease the temperature in a controlled, uniform fashion throughout a palletized load using corrugated containers. In contrast, the plastic components of the stackable receptacle system of the present invention are not water absorbent, and do not have corrugation channels that could trap insulating air. Accordingly, greater control of temperature pull down is achieved thus resulting in more uniform fruit quality. This ability to more readily

control and adjust temperature results in better customer control of preparing and ripening the fruit for retail use and greater stability while the fruit is in retail display.

This results in less spoilage and higher yields of fruit and advantageously eliminates the relatively high rate of spoiled or damaged fruit associated with shipping perishables in cardboard containers.

Based on the foregoing improvements associated with using the tier sheet system and stackable receptacle system of the present invention, a new method for packing, shipping, and transferring a load of bananas and readying the bananas for retail display and sale has been developed. Although this method is preferably used with the tier sheet system or the stackable receptacle system of the present invention, the present method may also be used with most any standard prior art shipping system. As mentioned previously, while many of the various containers and methods employed in the past have met the needs of producers and retailers, these containers and methods have usually required a considerable amount of product handling. The present method substantially reduces the amount of handling of the bananas from the time they are packed at the plantation right up to the time they are delivered and readied for retail use, display or sale.

The first step of the present method comprises loading a plurality of flexible bags 82 with a plurality of banana clusters. It should be noted that each banana cluster can be defined as comprising a crown portion 98 and a tip portion 96 as shown in Figure 19. Before being loaded, the flexible bags 82 are first preferably disposed in a reusable packing box 99. The packing box 99 may be manufactured of

any suitable and sufficiently strong material. Before being inserted within the reusable packing box 99, the bag 82 is opened in any typical manner used to open a plastic bag (i.e., by forcing air into open end 90). Bag 82 is then inserted into packing box 99 with open end 90 of the bag 82 extending out of the top of packing box 99. Open end 90 is then draped about the outside of the side walls of box 99, thereby completely exposing the interior of the bag which is now in place in the packing box 99. Preferably, at least a portion of perforation 100 of bag 82 is oriented and disposed on or near the bottom of the bag 82 and packing box 99.

Preferably, an optional tunnel pad 104 may then be inserted into and placed on the interior bottom of the bag as shown in Figure 19. As further shown in Figure 19, a first row of banana clusters 132 may be positioned atop the tunnel pad 98, preferably in a "crowns down" configuration. Next, as shown in Figure 20, a portion of tunnel pad 104 is folded over the first row of banana clusters 132. The second row 134 of banana clusters is then inserted in a crowns down configuration so that a portion of each of these banana clusters is positioned atop a portion of banana clusters of the first row 132. Further, the first and second rows of banana clusters are separated by a portion of the tunnel pad 104 so as to minimize contact and friction between the banana rows, reducing the amount of scarring on the bananas.

Next, and as shown in Figure 21, a portion of the tunnel pad 104 is folded up and over the tip portions of the first and second rows of banana clusters 132, 134.

Next, and as further shown in Figure 21, a third row of banana clusters 136 is placed within the bag 82 in such a manner so that the tip portions 96 of the third row of

bananas 136 are substantially adjacent the tip portions 96 of the first row of bananas 132. Further, the third row of bananas 136 is positioned such that the crown portions 98 of the third row of banana clusters are substantially adjacent to the tip portions of the second row of banana clusters 134. As can be seen in Figure 21, this packing arrangement results in a tight fit of three rows of banana clusters that are separated from each other by the tunnel pad 104.

Based on the size of bag 82 typically employed in the shipment of bananas, each row will typically comprise between about 3 and about 4 banana clusters.

Preferably, the total weight of the three rows of bananas is approximately 31 lbs. of bananas. As discussed in greater detail in U.S. Pat No. 5,617,711, by Rodriguez et al. (April 8, 1997), and incorporated herein by reference, the ability of the present packaging method to reduce the amount of moisture lost is significant for the shipment of bananas, because significant moisture losses usually take place when conventional packaging systems are used. Accordingly, by incorporating the present packaging method, the weight of the bananas packaged according to the present method may be reduced as compared with conventional packing systems because less water weight is lost prior to delivery to retail.

Once the bananas have been loaded within the bag 82, the open end of the bag 90 is cinched together by hand in any manner typically employed for closing plastic bags, such as a consumer might do with a plastic garbage bag. After the open end 90 of the bag 82 has been cinched together, the cinched top portion of the bag is

then sealed in any conventional manner such as securing the cinched end with strapping tape, a length of cord, or any other appropriate fashion.

Preferably, as shown in Figure 17, each flexible container comprises a gussetted plastic bag 82 having a top portion and a sealed bottom portion 86.

Preferably, each bag 82 further includes one or more ventilation openings 88 and an open end 90 adjacent to the top portion. Preferably each of the bags 82 further includes a perforation 100 connecting the top and bottom portions. More preferably, the perforation 100 extends down the length of bag 82 from a first side of open end 90, across the sealed bottom portion 86, and up the length of bag 82 to a second side of open end 90. Advantageously, this preferred arrangement of perforation 100 divides the bag 82 into two halves. Accordingly, if a sealed bag 82 having such a perforation is inverted 1800, the perforation may be readily accessed and torn, and the sides of the bag may be pulled back to reveal the contents of the bag.

The bag 82 can be constructed of any of a number of materials, and is preferably made of a substantially clear, flexible plastic such as that typically used for plastic bags, however, bag 82 can also be manufactured of opaque material. The presently preferred material for the bag is linear low density polyethylene, having small amounts of additional additives to insure that bag 82 may be easily opened and be of adequate strength, while maintaining its inexpensiveness. The exact formula for the material of the bag 82 is not critical, and the various combinations of materials well known to those skilled in the art can be readily employed.

As will be understood, perforation 100 can be replaced by any type of area of weakness which would permit the bag to be opened easily. For example, bag 82 could be scored at the location where perforation 100 is now positioned.

Alternatively, bag 82 could even be molded so that the area of weakness corresponds to a thin area in bag 82.

Preferably, the ventilation apertures 88 of the bag are arranged in a series of rows in order to provide ventilation for the bananas therein. Preferably, bag 82 has about 20 round ventilation apertures 88 located adjacent each of the lower corners of the bag, or a total of about 80 such apertures. The preferred positioning of ventilation apertures 88, as shown in Figure 17, will help insure that the apertures provide proper ventilation of the bananas therein. Preferably, apertures 88 are of a size that would not permit substantially any portion of the bananas to extend therethrough.

As best shown in Figure 18, the tunnel pad 104 comprises a sheet of flexible plastic. Although the tunnel pad 104 is preferably made from polyethylene, the tunnel pad may comprise any suitable material that similarly advantageously reduces friction and resultant scarring between the banana clusters as they settle and shift during shipment. Preferably, the tunnel pad 104 is rectangular and is preferably approximately about 31 inches by about 21 inches. In fact, tunnel pad 104 may be manufactured from recycled polyethylene, since it is rather simple to produce sheets of recycled polyethylene. In order to produce a strong tunnel pad, however, it is preferred that the recycled material be sandwiched between two layers of virgin

plastic. It is even possible that the polyethylene bags typically employed for covering banana bunches while the bunches are still growing on banana plants may be recycled for this use, particularly since there is a large supply of such used bags readily available.

Ventilation holes 108 are preferably provided across the length of the tunnel pad 104, more preferably in the form of 5 spaced rows of holes 108. This spacing of the holes 108, permits more even ventilation when the various ends of the tunnel pad are disposed about rows of bananas.

In order to prevent excessive friction in rubbing between banana clusters, tunnel pad 104 must be of sufficient thickness. It is preferred that the tunnel pad 104 have the thickness of between about 5 and about 10 mils, most preferably about 7 mils. Preferably, tunnel pad 104 includes a perforation 106, or any other appropriate area of weakness, that extends across the width of the tunnel pad.

After each bag 82 of bananas has been packed and sealed in packing box 99, it may be arranged with a plurality of other packed bags of bananas in a unitized, stable multi-tiered arrangement. This step of arranging the plurality of flexible bags 82 in a stable multi-tiered arrangement may comprise the above-described method of stacking a plurality of loaded flexible containers of produce using the tier sheet and support wall system constructed in accordance with the present invention and as discussed in detail hereinabove. Alternatively, the step of arranging the plurality of flexible bags in a stable multi-tiered arrangement may comprise the above-described

method of stacking a plurality of reusable, stackable shipping receptacles constructed in accordance with the present invention and as also discussed in detail hereinabove.

After the bananas have been loaded and secured in the multi-tiered arrangement, they are then ready for shipment. When the packaged bananas arrive at either a port or distribution warehouse, a worker may remove each loaded bag from the unitized arrangement by grasping the neck of the bag and lifting the bag therefrom. Because the bananas are packed in a tight configuration within the bag 82, it is possible to lift the bag without any significant resultant shifting of the bananas as is described in detail in U.S. Patent 5,617,711, by Rodriguez et al. (Apr.

8, 1997). As shown in Figures 28 and 29, each loaded bag 82 is preferably placed in an open-topped reusable container 130. Preferably, container 130 should be at least as large, and preferably slightly larger in dimension, than the loaded bag 82 in order to facilitate shifting of the bananas without causing damage. Preferably, container 130 comprises a light-weight, reusable container such as that typically employed in Europe for the transfer of fruits and vegetables to retailers. One particularly advantageous type of container which can be employed in the process of the present invention is that manufactured by Schoeller International GmbH, of Munich, Germany (distributed through its IFCO subsidiary in Dusseldorf), and described in U.S. Patent 5,398,834, by Umiker (Mar. 21, 1995), incorporated herein by reference. These containers are made from plastic, and may be folded down flat for return transit. Such containers are readily reusable, and may even be employed for various types of fruits and vegetables. These containers are also stackable with one another, and readily fit upon standard pallets.

Figure 28 shows a worker 68 removing one load of bananas 82 from a partial pallet using the tier sheet system of the present invention. Figure 29 similarly shows a worker 68 removing one load of bananas 82 from a partial pallet of the stackable dome bottomed receptacles 114 of the present invention. Before being shipped to the retailer, each bag 82 may either be placed in the reusable container 130 oriented in much the same fashion as it was on the palletized load, or it may be inverted at this time, rotated 1800 and placed in the container 130 (as shown in Figures 28 and 29).

Alternatively, the bag 82 may be rotated in container 130 after being shipped to the retailer.

After the bag of bananas has been rotated 1800 from its position during transport, thus exposing the perforation 100 of the bag 82, the perforation of the bag 100 and the perforation of the tunnel pad 106 may be torn. As shown in Figure 30, the various portions of the tunnel pad 104 and the bag 82 may be tucked away from the top row of bananas 136 in order to expose them to consumers. The above- described method greatly minimizes excessive manipulation and handling of fruit during all phases of transport and while being displayed in the market. Specifically, excess manipulation of the fruit while on display in the market is avoided because lower layers of bananas are not exposed until top layers have been removed.

The foregoing description of a preferred embodiment is by no means exhaustive of the variations of the present invention that are possible, and has been presented only for purposes of illustration and description. Obvious modifications and variations will be apparent to those skilled in the art in light of the teachings of the foregoing description. Accordingly, it is intended that the scope of the present invention be defined by the claims appended hereto.