DE102010021838A1 - Method and device for the portioned packaging of a food mass - Google Patents

Abstract

A method is shown for portioned packaging of an at least substantially incompressible food mass, in particular processed cheese, which is poured as a flowable mass into a tubular casing, comprising a thermoplastic plastic film, the thermoplastic plastic film of the casing surrounding the food mass, with displacement of the food mass from sealing areas is formed into individual units defining a portion in each case in such a way that the units arranged one behind the other are delimited from one another by sealing in the sealing area and then separated from one another.

Description

The invention relates to a method for the portioned packaging of an at least substantially incompressible food mass, in particular of processed cheese, which is filled as a flowable mass in a tubular casing having a thermoplastic plastic film. Furthermore, the invention relates to a device for carrying out the method.

For portioned packaging of such food mass various methods are known. In some processes, the food mass is poured into trays preformed from a stable film, especially plastic. The filled with the food mass individual shells are subsequently closed and separated. The disadvantage of this solution is that a separate tool or even a separate machine is required for each work step, in particular preforming, filling, closing and separating. In addition, the portioned filling of already preformed packages with such a food mass relative to the adjustment is relatively complex.

For the packaging of processed cheese, in principle, three procedures are known: Firstly, it is known to bring the processed cheese into disc shape and stack these individual slices "slice on slice" on each other. On the other hand, it is known to make individually wrapped slices (IWS). For this purpose, a film tube is filled with processed cheese and smoothed into a tape before it is divided by dislodging, sealing and cutting into individual slices. Another way to wrap processed cheese is to surround individual portions with an aluminum foil. Such portions are known as triangular shapes, which are grouped into several in a circle in a common outer packaging. The individual portions can be provided with a thread cutting the film as Aufreißlhilfe. Such portioned packaging in aluminum foil is relatively expensive.

The object of the present application is therefore to propose a process for the portioned packaging of a food mass, in particular of processed cheese, in which the individual packs of the food mass can be produced in a simple and cost-effective manner in various forms and easy for the consumer to handle. It is also an object of the invention to propose a device for implementing the method.

These objects are achieved by a method having the features of claim 1 and an apparatus having the features of claim 7. Advantageous embodiments are mentioned in the subclaims.

The essential basic idea of the invention is first of all to fill the food mass into a film tube and subsequently to deform it by thermoforming while retaining the food mass. In principle, the mass of food from areas of the completely filled tube is displaced into areas in which a deep-drawing takes place virtually at the same time. A separate thermoforming stamp is not required. The food mass acts like a stamp and pushes the foil into the shape of the tool. The mass, which is too much in the areas of displacement, finds space in the newly formed areas. According to the invention, the thermoplastic film of the surrounding surrounding the food mass envelope is transformed under displacement of the food mass from seal areas to each one unit defining units in a mold. These units arranged one behind the other in a chain are delimited from one another by a seal in the sealing area and then separated from one another.

Such a unit is also referred to below as filled with the food mass cavity. The one portion of the food mass defining cavity is thus formed according to the invention in the already filled film web. The flowable food mass enveloped by the film web completes the shape of the film layer and assumes the shape of the cavity. The shape of the film web is thus accompanied by a portioning of the food mass.

The method according to the invention makes it possible to automatically produce individual packages that are easy to handle. The method can replace the subsequent filling of already preformed trays. This significantly simplifies the production of single-pack food packages and significantly increases product output. With the simultaneous deformation of the film tube and the food mass, the method is particularly suitable for the portioned packaging of processed cheese, since processed cheese with its temperature-adjustable viscosity is particularly easy to handle. The process enables continuous production. At the same time it offers a high variability in terms of the possible packaging forms. The cavities can be formed in almost any form in the filled film web and offer in particular by their three-dimensional orientation a great deal of scope for product design.

It is particularly advantageous that the reshaping of the filled film web according to the invention can be integrated into existing production plants for packaging food masses. A conversion or an extension of previously used machine lines to the new method is thus possible.

In a preferred embodiment, both film layers of a double-layer, filled with food mass film tube are formed. By molding opposing cavities in the two-ply film web, the total available volume of the individual packaging can be increased. The two-sided deformation of the two-ply film web also allows a symmetrical design of the upper and lower part of the single pack. For example, in the case of asymmetric shaping, an upper part of the forming means is made smooth while the lower part has forming cavities.

Preferably, a negative pressure in a forming agent is applied to support the formation of the cavities in the film layer. The negative pressure causes a kind of thermoforming effect in the film layer. It is applied while the forming segment of the forming agent closes in the sealing region of the double-layered film web. Before opening the forming agent, the vacuum is deactivated again. The film layer is not only pressed into the mold segment, but also sucked. She lies down on its walls and takes on its shape. The negative pressure causes a precise molding of the given shape by the thermoplastic film.

The food mass is not only displaced from the seal areas, but also sucked into the mold segments. It follows the shape of the film layer and fills the mold segment. In the sealed area, due to the combined suction and displacement effect acting on the food mass, only a small residue of food mass remains, whereby the subsequent sealing of the film layers in the sealing area is simplified. It is particularly advantageous if the negative pressure in height and duration of the food mass is adjusted.

A temporary and local heating of the thermoplastic plastic film helps to mold the cavities into the film web. For this purpose, the areas of the forming agent which come into contact with the film to be formed are heated.

Thermoplastic plastics of different types and film thickness can be processed with the method or the device. In particular, films of PE, PET and PP are suitable. The preferred film thickness is between 20 μm and 100 μm. The method also makes it possible to use film tubes made of film webs of different materials. For example, film webs of thermoplastic and aluminum foil can be combined.

Preferably, a separating segment of the forming agent is first retracted into the food mass enveloped by the film web. This separating segment designed in the manner of a hold-down device moves into the production line before the individual packages are formed. This delimits the part to be formed from the rest of the film tube. This subdivision of the product strand defines the area of the filled film tube available for the forming process. The segment prevents food mass from flowing during the formation of the cavities from the rest of the production line into the part of the film web to be formed. Fluctuations in the volume of the individual packs produced can thereby be minimized.

To ensure the release of the product strand from the forming means, the cavities of the shaping means are preferably subjected to overpressure. For this purpose, it is advisable to use the vacuum connection also for supply with overpressure.

Preferably, the forming means comprises a means for sealing the sealing area located between the successive hollow bodies. By not only forming the cavities in the filled film web, but also sealing the seal area, this working step can be combined in one tool. This requires that a change in shape of the individual packaging is easier to perform. Such changes in shape usually go hand in hand with a change in the shape and position of the sealing area between the individual packages. When changing the packaging form, the set-up effort at the packaging installation is thus reduced.

In a particularly preferred embodiment, the sealing region separating the cavities is sealed by means of ultrasound. Sealing by means of ultrasound has the great advantage over sealing with heat that a seam sealed with ultrasound can be better opened again later, ie has an improved "Pealfähigkeit". In addition, the ultrasound displaces remaining amounts of food mass from the sealed area. A product inclusion in the sealed seam is avoided. This ensures a uniform strength of the sealed seam. In addition, a product inclusion in the seal area reduces the quality of the customer. The clean seal increases the quality impression of the finished product. In this case, the sealing by means of sonotrode and sealing anvil can take place in a separate working step. Preferably, the shaping means itself, in particular the lateral boundaries of its shaping cavity entering the sealing area, are designed as sonotrode. The sealing components are thus integrated into the forming agent.

At the end of the process, the film web is severed in the sealing area. The separate packs of food mass are then fed individually to the further packaging process. Preferably, the individual work steps of forming, sealing and separating the individual packages are combined in direct sequence. To convert the production plant to another form of packaging, only the forming agent and the separating device have to be exchanged. In a particularly preferred embodiment, the separating device is part of the forming agent.

In a further particularly preferred embodiment, the food mass is cooled before forming the filled film web. In contrast to the pouring of a liquid food mass into a preformed packaging mold, the food mass is pressed into the cavity according to the invention and preferably also sucked. For the filling of the molded into the film web cavities for the food mass thus no liquid, but only a still flowable consistency is required. When forming the cavities in the film layer, the food mass is already largely cooled. On a complex cooling of the molded individual packaging to prevent deformation in the further course of the manufacturing process and the placement of the secondary packaging can be omitted. For cooling in advance of the forming of the food mass is preferably performed in known manner via cooling belts along a cooling section or passed through a cooling water bath. This ensures a uniform cooling of the food mass. The film feed can be done before or after the cooling.

In a further particularly preferred embodiment, the edge regions of the two film layers protruding from a longitudinal sealing seam form an opening tab for opening the packaging. With the longitudinal sealing seam, the two film layers are joined together before molding the cavities. Depending on how the two-ply film web was laid, it has one or two longitudinal seal seams. If a single film is placed in a double-layered film web, it has on one side a longitudinal sealing seam which connects the lateral end regions of the two film layers to one another. The variant of a two-ply film web made of two film layers has longitudinal sealing seams on both sides. The film layers are dimensioned such that, after the sealing of the longitudinal sealing seam, film edge regions of the connected film layers survive. A pulling apart of the projecting edge areas of the film first opens the longitudinal sealing seam and, in the further course, the sealing areas of the individual packaging. The packaging portion can thereby be completely opened in a simple manner and remove its contents without residue from the packaging.

The projecting film edge regions are preferably cut off in such a way that the remaining film edge region of the two film webs has the shape of a tab projecting on the single package. The tab shape is intuitively recognized by the customer as an opening mechanism for the single pack, so that further instructions on the packaging are not required.

In a further preferred embodiment, the two-ply film web is in continuous forward motion. This creates an endless, constantly renewing product strand of the filled film web. An automatic tracking of the forming agent during the forming process allows continuous production of individual packages of food mass with a correspondingly high production output.

The method and the device according to the invention make it possible to produce packaging portions in a variety of forms. In addition to the known and popular with the consumer cheese corner shape and square or rectangular cavities can be formed in the film web. The indentation of the cavities can be made into a film web, indentations in both film webs can be symmetrical or asymmetrical with respect to one another. Another variable is the material choice of the slides. The possibilities of variation thus range from a symmetrical packaging with plastic film webs which have been identically formed on both sides and a sealing seam running around the middle of the package to a unilaterally formed package with an off-centered sealing seam whose unformed aluminum foil seals the packaging in the manner of a lid.

In contrast to the known aluminum foil packaging, the use of a transparent plastic film allows the consumer a direct view of the packaged product. Additives such as herbs or nuts do not have to are displayed on the label alone, but are visible to the consumer in the product itself. Preferably, the contents of the packaging can be made identifiable via a coloration of the packaging by means of a variety-specific coloring of a film web.

An embodiment of the invention is described below with reference to 1 to 11 described. It shows

1 an opened forming tool with a still undeformed production strand of the wrapped food mass;

2 : A section along the AA line 1 ;

3 : The closing forming tool at the beginning of retraction into the product strand;

4 : A section along the line BB the 3 ;

5 : The closing forming tool with a closed separating segment that has penetrated into the product strand;

6 : A section along the line CC the 5 ;

7 : The forming tool after completion of the forming process;

8th : A section along the line DD the 7 ;

9 : A hold-down of the forming tool;

10 : A base plate of the forming element with mold segments;

11 : A schematic representation of the various forming steps on the product line.

The 1 to 8th show an inventive shaping agent in the form of a forming tool 1 , The forming tool 1 is in a sequence of different phases of the forming process filled with food mass film web 2 shown.

In the 1 and 2 is that a shell 3 and a lower part 4 comprehensive forming tool 1 opened and has no contact with the production line of the film web 2 , top 3 or lower part 4 of the forming tool 1 are aligned towards the top and bottom of the production line and are mirror images of each other. The top 3 and the lower part 4 are essentially identical, so that information on features or movements of one part 3 . 4 of the forming tool 1 always mirror image on the other part 3 . 4 with refer.

Every part 3 . 4 of the forming tool 1 includes a base plate 5 and one on the production strand facing side of the base plate 5 arranged and releasably connected to her mold plate 6 , In the direction of the production line is on the part 3 . 4 a separation segment 7 in the manner of a hold-down. The base plate 5 and the hold down are over a guide 8th connected with each other. The leadership 8th is about springs 9 biased and allows a movement of the hold-down relative to the base plate 5 , The base plate 5 further comprises a vacuum or

Compressed air connection 10 that with one in the mold plate 6 inserted hollow chamber 11 connected is. About the hollow chamber 11 becomes a negative pressure on a mold segment of the forming tool 1 created.

The hollow chamber 11 is product strand side of a shelf 12 limited, by means of a spacer sleeve 13 from the base plate 5 is spaced. The shelf 12 forms together with laterally in the direction of the production line at the shelf 12 projecting webs 14 the mold plate 6 a to the filled film web 2 open mold segment 15 out, into which the foil web 2 is formed. The shape segment 15 thus forms a negative mold for those with the food mass 16 filled foil web 2 out.

The with food mass 16 filled foil web 2 has two foil layers 17 . 18 on, on both sides over longitudinal sealing seams 19 connected to each other. Along the longitudinal seal seams 19 standing foil edge areas 20 the double-layered film web 2 in front. For temporary and local heating of the thermoplastic film layer 17 . 18 has the mold plate 6 two temperature-controlled heating cartridges 21 on.

The 3 and 4 show the forming tool 1 at the beginning of the closing process. At this time, there is an outer surface of the hold-down 7 in the amount of the still undeformed product strand of the filled film web 2 , In order to heat the thermoplastic resin film to be formed, the hold-down device wiest 7 a heating element not shown here. The heated downholder 7 is offset on both sides of the enveloped food mass 16 and over the film edge areas 20 the double-layered film web 2 arranged. To warm the film edge area 20 through contact with the heated downholder 7 To avoid wearing, the hold-down 7 on both sides a longitudinally extending insulating 21 on the outside of a longitudinal web projecting in the direction of the production line 22 of the downholder attaches. The hold down 7 also has two transverse webs, not shown here, extending transversely to the production line, which in this position of the closing process, the two-ply film web 2 touch.

In the 5 and 6 are the hold downs 7 from top 3 and lower part 4 the forming tool 1 closed, leaving the film edge areas 20 between the longitudinal webs 22 and the insulating elements 21 is held. In this position of the forming tool, the transverse webs of the hold-down device 7 completely penetrated into the product strand. In terms of the production line at the beginning and at the end of the holddown 7 arranged transverse webs thus close the area of the production line, by the forming tool 1 is to be transformed.

The 7 and 8th show the forming tool 1 with completely closed upper and lower part 3 . 4 , With application of the negative pressure in the mold segments 15 moves in both parts 3 . 4 the pressure plate 5 together with the mold plate 6 in the direction of the production line. The heated bars penetrate 14 the mold plates 6 in opposite directions in the product strand, deform at this point the thermoplastic film layer 17 . 18 and displace the food mass located in this area of the product line 16 , The food stuff 16 presses the foil layers 17 . 18 into the mold segments 15 , The at least nearly incompressible food mass 16 acts like a thermoforming stamp, in the film layer 17 . 18 into the mold segments 15 suppressed. Here are in the film layers 17 . 18 one after the other, one portion each of the food mass 16 defining cavities 23 formed.

In addition, the film layer 17 . 18 through the in the mold segment 15 adjacent negative pressure against the heated shelf 12 drawn. The vacuum is applied after the hold down 7 has completely penetrated the product strand. The strength and duration of the vacuum is adjusted to the food mass. The still flowable, from the area of the closing webs 14 displaced food stuff 16 fills the forming cavity 23 completely off.

In the embodiment described here form two opposite cavities 23 a single serving of food stuff 16 out. The shape of the portion is determined by the shape segments 15 Of the parts 3 . 4 Are defined.

The clashing bridges 14 the mold plates 6 press the foil layers 17 . 18 together and define a seal area circulating the single packs 24 , For the permanent shaping of the single packs becomes the sealing area 24 sealed by means of a conventional ultrasonic sealing method. The webs work here 14 as sonotrode, so that the sealing components sonotrode and seal anvil are integrated into the forming tool. The two work steps can also be carried out by two tools that follow each other in the production process.

After the formation of the individual packs, the negative pressure in the mold segment 15 not maintained. The parts 3 . 4 of the forming tool move apart and give a strand of finished shaped, successive single packs of food mass 16 free.

While with the 1 to 8th described method steps, the forming tool moves at a speed v _wz , which corresponds to the speed v _{p of} the continuously moving production line. After opening, the forming tool moves 1 against the transport direction along the production line back to a starting position, from which a new cycle starts. From the starting position of the forming tool 1 moves the rear web in production direction 25 the hold-down 7 when closing the forming tool 1 in the boundary of the strand section, passing through the front web 25 was formed in the previous work cycle.

The 9 shows a hold-down 7 of the type described in axonometric representation. Clearly visible are the webs running parallel to the production line 22 , where the two-sided insulating 21 issue. The bridges 22 are over two total transverse, when closing the hold-down 7 in the production strand penetrating webs 25 connected with each other. The bridges 25 limit the portion of the producible in one cycle of the forming tool production line. Laterally on the hold-down 7 arranged are the feeders 26 for the heating element, not shown, and the associated sensors.

10 shows an axonometric view of a base plate 5 with attached mold plate 6 , At the mold plate 6 are the one form segment 15 sideways jambs 14 in front. The bottom of the mold segments forms the shelf 12 , The choice of mold segments 15 , here in the form of cheese corners, defines the shape of the individual packs.

The 11 shows a production line of the filled film web 2 to different, in the production line successively arranged times of the molding process. In the with food mass 16 filled and by two longitudinal sealing seams 19 sealed double-layered film web 2 become cavities 23 formed by a sealed area 24 in succession and the single pack 27 the food mass defining cavities 23 be separated. The single pack 27 circulating seal areas 24 is sealed by an ultrasonic sealant, which is not yet through the webs 14 displaced residues of the food mass 16 from the seal area 24 be removed. In a further process step, the successive individual packs 27 separated from each other. The foil border areas become thereby 20 so cut off that a remaining foil edge area of the two foil layers 17 . 18 an opening tab 28 for the single pack 27 ausformt.

Claims (10)

Process for the portioned packaging of an at least substantially incompressible food mass ( 16 ), in particular of processed cheese, which is filled as a flowable mass in a tubular casing, comprising a thermoplastic film, characterized in that the thermoplastic plastic film of the food mass ( 16 ) surrounding cladding ( 2 ) with displacement of the food mass from seal areas to individual units defining each one portion ( 23 ) is formed in a shape such that the units arranged one behind the other ( 23 ) by sealing in the sealing area ( 24 ) are separated against each other and then separated from each other. Method according to claim 1, characterized in that in order to support the forming of a unit ( 23 ) in the film layer ( 17 . 18 ) in a forming agent ( 1 ) a plastic film in the form of sucking vacuum is generated. A method according to claim 1 or 2, characterized in that the negative pressure is generated after a segment ( 7 ) of the forming agent ( 1 ) completely in the of the film web ( 2 ) coated food mass ( 16 ) is retracted Method according to one of the preceding claims, characterized in that the sealing is carried out by means of ultrasound, wherein in particular parts of the forming means are used as ultrasonic generator ("sonotrode"). A method according to claim 4, characterized in that the portions are separated from each other by cuts in the sealing area. Method according to one of the preceding claims, characterized in that the tubular sheath of a sealed on the longitudinal side of the film web ( 2 ) is formed, wherein opposing foil edge areas ( 20 ), the opening tabs ( 27 ) for the single pack ( 27 ) form. Device for portioned packaging of a flowable, at least substantially incompressible, food mass ( 16 ), in particular for carrying out the method according to one of the preceding claims, characterized by filling means for filling a hose-shaped envelope having a thermoplastic plastic film with the workable food mass ( 16 ), - Forming agent ( 1 ) for making a portion of defining units ( 23 ) from the envelope ( 2 ), wherein the forming agent ( 1 ) Shape segments ( 15 ) for forming successive units ( 23 ) specifiable shape in the film web ( 2 ), - sealing means for preparing the units forming a portion ( 23 ) delimiting seal areas ( 24 ), - Cutting means for separating portions. Apparatus according to claim 7, characterized in that the sealing means a sonotrode for ultrasonic sealing of the sealing area ( 24 ) having. Apparatus according to claim 7 or 8, characterized in that the forming means ( 1 ) means for generating a negative pressure in the mold segments ( 15 ) having. Packaging for an at least substantially incompressible food mass ( 16 ), in particular for processed cheese, produced by a process of claims 1 to 6.

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