SYSTEM AND METHOD FOR STORING, HEATING, AND PACKAGING FOOD PRODUCTS AT POINT OF CONSUMPTION
Background of the invention: This invention relates to snack delivery systems, and, more particularly, to self- service systems for storing chilled or frozen food product, and then delivering a heated product to a consumer at the point of consumption. The provision of separately packaged sandwiches and of other snack products for quick consumption is one of the most well-established growth markets in the global food industry. A product meeting some of the needs of such a market is the subject of US Patent No. 4,784,273, to the inventor, the content of which is incorporated by reference hereto. Desk-dining in the US as well as in Europe is becoming ever more popular. Nevertheless, 90% of all products sold in filling stations, kiosks, office-caterings or in sandwich shops are consumed in a cold state. The traditional products consumed in a warm state, strongly preferred by consumers, like for instance pizzas, paninis, ham- cheese toasts, quiches, apple strudels etc. are still not offered as separately packaged helpings which can be heated by the consumer himself without the intervention of service personnel in the diverse outlet and distribution channels as mentioned above. US Patent No. 5,997,924 to Olander, Jr. et al, US Patent No. 6,550,632 to Gubbini et al, and US Patent No. 5,772,072 to Prescott et al, the contents of which are incorporated by reference hereto, describe automated self-service processes and systems using a vending machine concept. None adequately address the need for individually packaged, single helping packages that can be automatically and quickly heated at the point of consumption. What is need therefore is a system for delivering single helping, packaged heated food products at the point of consumption. Further, what is needed is an automated system for the rapid delivery of packaged heated food products which requires little or no intervention on the part of its sales personnel.
Summary of the Invention A system is provided for storing, heating, and packaging food products. The
system includes a package for a food product and an oven for the food product. The system manipulates the package from storage, to heating in a heating step, to delivery to a consumer. During the heating step, the package is opened and closed thereafter, for delivery in a closed state. The oven of the system includes a schablone of insulating material, in order to focus heating. The system preferably includes a refrigerated storage container adjacent the oven, for storing multiple packages of food product in a cool, chilled or frozen state. In another aspect of the invention, a system is provided having a self-service oven equipped with a hybrid heating method, for the rapid heating of a frozen or chilled food product, in a manner which insures crispiness in the heated product. The hybrid heating method is made up of microwave mono-mode energy combined with hot air and optionally halogen to achieve crisp product quality in a shorted time period. It is an object of the invention to provide a system that conveniently stores and processes food product so as to deliver a heated product in a closed package, conveniently located at the point of consumption. It is another object of the invention to enable a consumer to heat a frozen or fresh pizza, or a portion of strudel within one to three minutes. It is another object of the invention to provide an oven which is easy for the consumer to operate. In an advantage, the system is located at the point of consumption, thereby enabling the convenience of the system to influence the purchase decision in order to increase product sales. In another advantage, the oven of the system is able to rapidly select an optimum combination from two heating systems, hygienically and conveniently heating hot snacks and sweet bakery products. In an advantage, the invention is useful for the baking and/or rapid re-heating of separately packaged helpings like for instance a slice of a pizza or quiche, panini sandwiches, ham/cheese toasts, or apple strudel portions etc. which can be prepared in a warm environment or by using heat or respectively consumed warm or hot, according to the desire of the consumer.
Brief Description of the Drawings FIG. 1 is a perspective view of the system of the invention. FIG. 2 is an exploded view of a package storing a food product, for use with the system of the invention. FIG. 3A is a cross sectional side view of the oven of the invention, having just received a package for heating. FIG. 3B is an enlarged detail view of the area A of FIG. 3A, showing a seal cutting step of the process of the invention. FIG. 4 is a top view of the oven of the invention (with a bar code reader/scanner removed, for clarity), having just received a package for heating. FIG. 5 is a cross sectional side view of the oven of the invention, having positioned the package for heating. FIG. 6 is a flow chart of a method of the invention. FIG. 7a and 7b are perspective views of an alternative embodiment of the invention. FIGs. 8a to 8c are top views of alternate forms of the schablones of the invention. FIG. 9 is a flow chart of the method of operation of the invention. FIG. 10a is a top view of an alternative package of the invention. FIG. 10b is a side view of the alternative package of FIG. 10a. FIG. 10c is a bottom, cut-away view of the alternative package of FIG. 10a.
Detailed Description of the Preferred Embodiments) Referring now to FIG. 1, a system 10 is provided for storing, heating, and packaging food products 12. The system 10 includes a package 14 in which the food product 12 is stored until consumption, and an oven 16 for heating the food product in a heating step. The system 10 preferably includes a refrigerated storage container 20 adjacent the oven 16, for storing multiple packages 14 of food product 12 in a cool state. The system 10 thus stores the food product 12, subjects the food product to a heating step performed by the oven 16, and delivers the heated product in the package 14. The package 14 is opened during the heating step and closed thereafter, for delivery in a closed state.
Referring now to FIG. 2, the package 14, enclosing the food product 12, is made up essentially of a transparent upper portion 22 and a translucent or opaque, reflective lower portion 24, hinged together via tabs 22a (which double as handling tabs) extending from a rearward wall 22b into slots 24b. The upper and lower portions 22 and 24 are formed to match the shape of the food product 12, and include ribs 22c and 24e, respectively, which allow enough space on all sides to avoid damage to the food product during transport, help in stacking, and help center the food product in the oven 16 during the heating step. A recess 22d in the upper portion 22 allows room for a napkin 26 and an eating utensil 30, which are held in place in the recess by an upper label 32 on which product identifying and marketing information is printed. Dimples 22e formed on a lateral side wall 22f, which flares outward at an edge 22g in order to center the upper portion 22 over the lower portion 24, snap into divots 24a when upper portion is properly positioned over the lower portion 24 (i.e., when the tabs 22a are inserted into slots 24b in a rearward flange 24c connected to a rearward wall 24d). Ribs 24e provide structural rigidity to the lower portion 24, as well as help evenly distribute heat during heating. A second label 34 bears the UPC code 35 and/or encoded cooking information (e.g., time and temperature, processing information such as crispiness desired, directing and coordinating hybrid heating, convective air flow volume and speed stored, optionally encoded in a 2-D color bar code) in computer readable fonn and applies across two opposed tabs 22h and 24f to seal the upper portion 22 to the lower portion 24. In order to facilitate the breaking of the seal (discussed in more detail below), when the package is closed, a significant gap exists between the upper tab 22h and the lower tab 24f. Note that this second label 34 can be printed integral with the label 32, or separately as shown. The lower portion 24, also known as a susceptor, may be made from any suitable, heat resistant material, including metal (e.g., aluminium), special heat resistant plastic, or paper (preferably having a reflective heat intensifier/susceptor layer formed thereon). A suitable susceptor is known under the trade name "MICRO-FLEX Q"™, or "MICRO- RITE"™, available from Graphic Packaging Corporation of Colorado, and is an active microwave packaging made up of paper and a metallic laminate. Referring now to FIG. 3A, a receiving/delivery mechanism 40 is a four bar linkage mechanism made up of the following linkages: (1) a grill 40a, pivotally
connected at one end at 40b to (2) an upper opening jaw 40c, and at an opposite end at 40d to (3) an actuating arm 40e, the opening jaw 40c being pivotally connected to (4) a housing 40f to which the actuating arm is also pivotally connected, at 40g. Actuating arm 40e is mechanically connected to a gear motor 41, controlled by a CPU 46, according to a processing program. The receiving/delivery mechanism 40 has an open end 42 into which the package 14 containing the food product 12 is inserted and positioned under a bar code reader or scanner 44 which reads a product code and/or processing instructions (in the form of a UPC code or a 2-D black and white or color bar code) as inputs for the CPU 46, which in turn controls handling, and cooking time and temperature for optimum heating, as well as the processing steps (by applying an optimum combination from heating elements including conventional, microwave and convective, hot air heating elements. The receiving/delivery mechanism 40 functions as a device which, in one operation, receives and opens the package 14, and, in another operation, after the bar code information is read, simultaneously opens and lowers the package into position in the oven 16 for heating. A display 48 is mounted on a front panel and is connected as an output device to the CPU 46. The display 48 displays marketing information (such as special prices, product advertising), use instructions, and warning and/or error messages to consumers and or technicians. Referring now to FIG. 3B, a close up view of opposed cutting and retaining fingers 50 and 52 is shown. When the mechanism 40 is in its upper most position, these fingers 50 and 52 are adjacent to each other. When the package 14 is inserted into the open end 42 and positioned under the bar code reader 44, the fingers 50 and 52 cut the sealing label 34, creating cut edges 34a and 34b, so as to make separable the upper portion 22 from the lower portion 24, in a pivoting manner. The fingers 50 and 52 further grip the tabs 22h and 24f, respectively, so as to allow the mechanism 40 to open the package 14 when it is lowered into the oven 16. Referring now to FIG. 4, the upper opening jaw 40c preferably has a window 54 allowing a consumer to view, at least in part, the heating step. Further, the mechanism 40 is designed to receive and handle triangular as well as round (for pizzas and quiches etc.) and rectangular packages (like apple strudels and toasts), or other corresponding
shapes. The schablone (or template) 13 of a shape which corresponds to the food product to be heated (including its thickness which corresponds to the thickness of the food product 12 and susceptor 24' subassembly) fits on the grill 40a and thus must be selected accordingly. The schablone 13 is therefore interchangeable and is made of insulating material such as a ceramic. For example, heat resistant, compressed quartz available from St. Goblain, France, is a suitable material, resistant to 1000 degrees Celcius. In the embodiment shown, the schablone 13 has an open lower end, permitting the package to enter into a corresponding triangular recess 13a into which air flow channels 13b are formed. However, it is foreseen that the differing shapes of the schablone 13 may be presented in the proper position by a turret device (not shown) which would index to the position over the grill 40a, depending on the cooking instructions read from the bar code 35, much like a multi-disk changer in a CD player. In this case, there would be one schablone 13 with multiple forms therein, in the form of a disk. Referring now to FIG. 5, the receiving/delivery mechanism 40 is shown in the lowered position, in which the package's lower portion 24 is pivotally separated from the upper portion 22 by the fingers 50 and 52. Further, a heat insulating barrier 60 raises and lowers along track guides 62 so as to separate and protect the upper portion 22 containing the napkin 26 and plastic utensil 30 from the heat generated during the heating step in the oven 16. The inner surface 64 of the barrier is optionally provided with a reflective coating. The barrier 60 is activated by a motor 66 which rolls the barrier up and down according to the control signals sent by the CPU 46. The barrier 60 essentially has three positions, one being fully closed, preventing access into the oven when the receiving/delivery mechanism 40 is in the receiving position, two, being partially closed so as to protect the upper portion 22 from the heat of the oven 16, and three, fully open, where the barrier is fully rolled up on a mandrel 68. Optionally, a second barrier (not shown) can be placed in the lower portion of the oven 16, almost a mirror image of the barrier 60, which helps ensure that the opening to the oven remains essentially closed at all times to maximize safety. Convective heating methods known as the RJMM methods are envisioned as suitable heating methods for implementation in the oven 16 in combination with
conventional heating elements 70' of the invention. Further information about such methods are available in EP application no 0136453, US 4,775,770, US 4,866,233, US 4,952,763, and PCT/IB00/00025, the contents of which are incorporated herein by reference thereto. Heating elements 70, 70' of conventional form are disposed in the oven 16 and controlled by the CPU 46 to heat according to the instructions provided on the bar code label 34. However, heating elements 70 of unconventional form, fonned to correspond to the shape of the food product 12 are likely to provide more rapid, even heating of the food product. Heating elements 70' based on traditional microwave technology or mono mode microwave heating such as RIMM can be combined and used together with conventional heating bars, where appropriate, as well as convective, hot air heating systems which helps ensure the crispiness of the heated food product. For example, the mechanism 40 may be programmed to rock back and forth a certain amount adjacent to a mono mode microwave heating device, in order for more even heating to take place. This helps ensure the crispiness of the heated food product 12. In addition, reflector panels (not shown) may move above the package 14 in the oven 14 hinged from the sides of the oven and then move out of the way, once heating is completed. Thus, the heat may be provided from above, sides, and/or underneath and can be separately heated up according to a unique heating profile. The most appropriate combination will be determined by further experimentation. Because the oven 16 is special purpose, meaning it operates only when the proper package 14 is inserted and the appropriate bar code information 35 is read, it can being small in size, measuring potentially no more than 30 cm broad, 20 cm high and 30 cm deep. It also avoids being misused by for example, making difficult or impossible the insertion of packaging of poor quality or which is unsuitable for use in heating, thus avoiding damage or soiling due to use with improper packaging. Further, because the lower portion 24 remains in place during heating, catching any scrap that might fall during heating, and because the hot air heating passes air over the food product 12 from above, the oven remains clean even after many uses. In addition, opening of the package 14 during heating enables more natural, crispy heating of the food product 12, unlike microwaving closed product, which retains
moisture and essentially steams the food product. The delivery of the heated food product 12 in a closed package allows the consumer to easily handle the heated product for consumption at the place of his choosing. Referring now to FIG. 6, in a method 80 of the invention, a package 14 of food product 12 is processed according to the following steps. In a first step 82, the system 10 is turned on and initialized, including activating a bar code reader 44 which continuously scans for the presence of a bar code. In a second step 84, only after the bar code reader 44 senses that a package 14 is in position, and thus, that the seal 34 has been cut by the fingers 50 and 52, the motor 66 is activated to raise the barrier 60 to its fully open position and, optionally, a grip (not shown) is actuated to retain the package 14 against the grill 40a in a proper orientation for heating. In a third step 86, the motor 41 is actuated, moving the receiving/delivery mechanism 40 from the upper receiving position, to a lower heating position, wherein the grill 40a is properly located in relation to heating elements 70 and the package 14 is held open by the fingers 50 and 52. In a fourth step 90, the barrier 60 is lowered to an intermediate position, just protecting the upper portion 22 of the package 14 from the heat generated during the heating step. In a fifth heating step 92, the heating elements 70, as well as any convection elements and air circulation devices (not shown) are activated according to a heating protocol specific to the food product 12 being heated. In a sixth step 94, the barrier 60 is raised. In a seventh step 96, the motor 41 is activated to raise (and simultaneously close) the package 14, for delivery to the consumer. The consumer may, using the tabs 22a if necessary, retrieve the now closed package 14, having the heated product therein, for consumption at the time and place or their choosing. Referring now to FIGs. 7a and 7b, in an alternate embodiment of the oven of the invention, an oven 100 has an enclosure 102 enclosing a heating space 104 which is accessible via a door 108 that is attached to the enclosure via a hinge 110. A retractable drawer 112 is connected to the enclosure 102 in a manner so as to be able to eject to receive a food product positioned on a susceptor 24' of the package 14' (shown in FIG. 9) in a schoblone 13' and to retract the food product 12 and susceptor 24' subassembly into the heating space 104. Referring now to FIGs. 8a to 8c, the schablone 13', 13", or 13'" optionally
includes hot air channels 13b' formed on the inner surfaces 13b' of the triangular, round, and circular pattern (respectively) into which the food product 12 and susceptor 24' subassembly is placed, in order to concentrate hot air or convective heat transfer into the food product and to reduce energy consumption. Referring again to FIG. 7b, in a hot air heating system, super heated air flows against the food product 12 from above (and thereby, as mentioned, helps minunize soiling from spatter or sizzling on heating), under the motive force of a blower 130, through a thermally insulated air path 132 into an upper manifold 134 through the air channels 13b' around the food product 12, into a lower manifold 136, back into the blower. Heating elements 131 (traditional resistive, microwave, RIMM, or halogen) are disposed in the air path to super heat the air that is forced around the food product 12 through the channels 13b' to rapidly heat the food product. Referring now to FIGs. 9 and 10a to 10c, in operation, after the consumer has removed a transparent upper portion 22' as well as a napkin 26', thereby uncovering a bar code 35', located under the susceptor 24', and has removed any eating utensils and/or seasoning, the package 14' is ready for processing by the oven 100. The oven 100 processes the packaged food product 12 held in a package 14' accord to a processing method 200, as follows. In a first step 202, a button 106 is activated, which opens the door 108, unlocks and egresses a retractable drawer 110 including the schablone 13'. In a second step 204, the oven 100 scans for a product code 35 repeatedly a predetermined amount of time and either detects and reads the product code, and if read, passing on to the next step where cooking instructions encoded on the product are executed, otherwise, the drawer 112 is closed. In a third step 206, if the product code 35' was detected and scanned, then the package 14 is processed according to the cooking instructions associated with the bar code 35'. In a fourth step 208, after execution of the cooking instructions, the door 108 opens, the schablone 13' egresses from the heating space 104 via the retractable drawer 110, and the scanner 44' reinitiates a repeated scanning sequence, scanning intermittently as long as it detects the presence of the product code 35'. In a fifth step 210, when the scanner 44' no longer detects the product code 35', indicating that the susceptor 24' and food product 12 have been removed from the schablone 13, the schablone retracts into the oven 100 and the door 106 is closed.
The method 200 is implemented on software routines which correspond to the food product 12 to be heated. The code 35, 35' on the package includes at least an indentifying product code 35, 35' which corresponds to instructions saved in memory on an internal computer in the oven 16, 16'. In this manner, the amount of data that must be stored in the code 35, 35' is minimized. Alternatively, the code 35, 35' is a 2-D color bar code having sufficient storage capacity to store detailed cooking instructions. Depending on the code read, the software executes a corresponding command file which performs the following steps of method 200. In the first step 202, an initiation signal is received when the button 106 is activated, which activates a latch (not shown) to open the door 108 and a gear motor (not shown) which drives the drawer 110 including the schablone 13' out of the oven 16, 16'. In the second step 204, a scanning subroutine is initiated which repeatedly scans for a product code 35 for a predetermined amount of time, or until a code is detected, and if detected, the code is scanned into memory, passing on to the next step. In the third step 206, if the product code 35, 35' was detected and scanned, then the package 14 is processed according to the cooking instructions associated with code of the food product 12. In the fourth step 208, after execution of the cooking instructions, the latch is actuated so as to open the door 108, whereafter the gear motor is actuated so as to egress the schablone 13, 13' from the heating space 104 via the retractable drawer 112, and a scanning sequence is initiated on the scanner 44', scanning intermittently as long as it detects the presence of the product code 35, 35'. In the fifth step 210, when the scanner 44' no longer detects the product code 35', indicating that the susceptor 24' and food product 12 have been removed from the schablone 13, the gear motor is reversed to retract the schablone 13, 13' into the oven 100 and closes the door 106. Optionally, during the heating step 92', the schablone 13 is moved back and forth a certain amount, in order to allow the magnetrons to scan the food product 12 being cooked. In an embodiment with a multi-form changer disk (mentioned above), the disk may oscillate back and forth a certain amount (using, for example, a link connected to a smaller, rotating driving wheel) in order to mimic the function of scanning or rocking. In each case, the result is more even heating of the food product and consequently, shorter cooking time with an improved result.
Referring in particular to FIGs. 10a to 10c, the package 14' differs from the package 14, already described in that the bar code 35' is located on the lower side 24g' of the susceptor 24', the upper portion 22 need not be formed to hinge on the lower portion 24' (due to the fact that the upper portion does not enter the heating space 104 because it may be manually removed from the lower portion prior to placement of the food product 12 and susceptor 24' subassembly in the schablone 13). Therefore, the upper portion 22' can be substituted with a suffite baking wrap 22". Further, tabs 24h' are formed on the susceptor 24' so as to enable easy removal of the heated food product 12 and susceptor 24' subassembly from the schablone 13. Preferably, the napkin 26' is positioned so as to cover the bar code 35', and to be of a size such that the food product 12 and susceptor 24' subassembly is too wide to fit in the schablone 13 unless the upper portion 22' and napkin 26' are removed before insertion into the schablone. Optionally, the ribs 24e' in the lower portion 24' correspond in spacing to the spacing between bars in the grill 40a', so as to sit lower in the schablone 13' then when covered by the napkin 26', further ensuring that a package having the napkin still wrapped about it will not fit in the schablone. Of course, in the case of paninis for example, the shape of the package 14' is rectangular and not triangular. A schablone 13' corresponding to the rectangular shape of the panini is required. Further, the cooking instructions preferably include an additional processing step involving the application of pressure to squeeze the panini (wrapped in suffite paper with aereation holes to minimize spatter) during cooking. Referring again to FIG. 7b, this pressure is applied by an optional cooking press which can either be applied via a metal form which compresses the panini from above, or as a metal heated roller 120 having ribs 122 which moves into position onto the panini from above and compresses the heated panini as it egresses the heated space 104' in the oven 100, the drawer 112 and schablone 13' being supported by a support roller 123. The door 106 includes seals that protect against the inadvertent leakage of microwaves into the environment surrounding the oven 100. In an advantage of the invention, a consumer is able to heat a frozen or fresh pizza or a portion of strudel within a short period. In another advantage, an oven 16, 100 is provided which is easy for the consumer to operate.
In another advantage, the system 10 can be located at the point of consumption, thereby enabling the convenience of the system to influence the purchase decision in order to increase product sales. In another advantage, the system 10 repackages the food product after heating. In another advantage, the oven of the system is able to rapidly, hygienically and conveniently heat hot snacks and sweet bakery products. In an advantage, the invention is useful for the baking and rapid re-heating of separately packaged helpings like for instance a slice of a pizza or quiche, panini sandwiches, ham/cheese toasts, apple strudel portions etc. which can stored in single serving portions and heated and consumed warm or hot. In another advantage, the combination of the oven 16, 100 described above and of the designed package 14, 14' enables the consumer to heat hot snacks. In another advantage, because the system is automated, and is only actuated when a properly positioned package 14 is detected, misuse is minimized. In another advantage, the oven 16, 100 is designed so as only to operate with the packages of the invention, in order that it not be used for general purpose re-heating where unpredictable packaging quality and properties may unduly soil the oven. Multiple variations and modifications are possible in the embodiments of the invention described here. Although certain illustrative embodiments of the invention have been shown and described here, a wide range of modifications, changes, and substitutions is contemplated in the foregoing disclosure. The embodiment described herein represents the prototype. For example, instead of using a bar code, an edge of the package 14 could be key cut or formed with a profile that is read by cams which then control the time and/or temperature of heating. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the foregoing description be construed broadly and understood as being given by way of illustration and example only, the spirit and scope of the invention being limited only by the appended claims.