Systems and methods for packaging trays of plantlets

Abstract

Packaging systems, apparatuses, and methods are provided for improving handling and shipment of plantlets. A carton carrier for transporting trays of plantlets may be provided. The carton carrier may include a bottom panel for receiving plantlet trays having first and second ends and first and second sides. The carton carrier may also include supporting side walls extending upwardly from the first and second sides of the bottom panel. The supporting side walls each define a support surface or shoulder at the top thereof. The carton carrier may also include end wall panels extending outwardly from the first and second ends of the bottom panel. The end wall panels may be configured to be foldable upwardly from the bottom panel to form end walls.

1 . A packaging system for transporting plantlet trays, the system comprising:
 (a) a carton carrier comprising:
 (i) a bottom panel having first and second ends and first and second sides, the bottom panel being configured to receive plantlet trays, 
 (ii) supporting side walls extending upwardly from the first and second sides of the bottom panel, the supporting side walls defining an upper support surfaces or shoulders, and 
 (iii) end wall panels extending outwardly from the first and second ends of the bottom panel, the end wall panels configured to be foldable upwardly from the bottom panel to form end walls; and 
   (b) a transport box having box side walls and box end walls, the transport box being configured to receive one or more carton carriers within an interior of the transport box such that the supporting walls and the end walls of each carton carrier inserted therein are supported by the box side walls and the box end walls.   
   
   
       2 . The packaging system as in  claim 1 , wherein each supporting side wall of the carton carrier comprises an inner side wall panel, an outer side wall panel, and a top shelf panel. 
   
   
       3 . The packaging system as in  claim 2 , wherein each supporting side wall of the carton carrier has a triangular cross-section. 
   
   
       4 . The packaging system as in  claim 3 , wherein each top shelf panel of the carton carrier is disposed between the corresponding inner side wall panel and the corresponding outer side wall panel. 
   
   
       5 . The packaging system as in  claim 4 , wherein the triangular cross-section of each supporting side wall comprises the top shelf panel forming the upper support surface of the respective supporting side wall and the corresponding inner side wall panel and corresponding outer side wall panel converging at a respective side of the bottom panel. 
   
   
       6 . The packaging system as in  claim 5 , wherein sides of the plantlet tray abut the inner side wall panels of the carton carrier about a top surface of the tray. 
   
   
       7 . The packaging system as in  claim 2 , wherein the carton carrier is formed from a blank. 
   
   
       8 . The packaging system as in  claim 2 , wherein the supporting side walls of the carton carrier have a specific height to provide space for the plantlets disposed within the plantlet tray. 
   
   
       9 . The packaging system as in  claim 1 , wherein the carton carrier is fiberboard. 
   
   
       10 . The packaging system as in  claim 9 , wherein the fiberboard is a corrugated cardboard. 
   
   
       11 . The packaging system as in  claim 10 , wherein ribs are defined by the corrugated cardboard and strengthen the carton carrier in at least one of a width direction or a height direction. 
   
   
       12 . The packaging system as in  claim 1 , wherein the end walls of the carton carrier contact the supporting side walls when both the ends walls and the supporting side walls extend upright. 
   
   
       13 . The packaging system as in  claim 1 , wherein the end walls of the carton carrier contact the ends of the tray of plantlets when the ends walls extend upright. 
   
   
       14 . The packaging system as in  claim 1 , wherein the upper support surface of the supporting side walls of the carton carrier provides a stackable surface on which another carton carrier may be placed. 
   
   
       15 . The packaging system as in  claim 14 , wherein multiple carton carriers are stackable within the transport box. 
   
   
       16 . The packaging system as in  claim 15 , wherein the transport box has a height that permits multiple carton carriers to be stacked on top of one another within the transport box. 
   
   
       17 . The packaging system as in  claim 16 , wherein the height of the transport box corresponds to a height of a specified number of carton carriers such that the upper support surface of the top carton carrier is flush with the top of the transport box once the transport box is closed. 
   
   
       18 . The packaging system as in  claim 1 , wherein the transport box includes inner lids and outer lids that form at least one of a top wall or a bottom wall of the transport box when the inner and outer lids are in closed positions. 
   
   
       19 . The packaging system as in  claim 18 , wherein the inner lids of the transport box comprise edges that abut one another when the inner lids are in a closed position and the outer lids comprise edges that abut one another when the outer lids are in a closed position. 
   
   
       20 . A carton carrier for transporting trays of plantlets, the carton carrier comprising:
 (a) a bottom panel having first and second ends and first and second sides, the bottom panel being configured to receive plantlet trays,   (b) supporting side walls extending upwardly from the first and second sides of the bottom panel, the supporting side walls defining an upper support surface or shoulder, and   (c) end wall panels extending outwardly from the first and second ends of the bottom panel, the end wall panels configured to be foldable upwardly from the bottom panel to form end walls.   
   
   
       21 . The carton carrier as in  claim 20 , wherein each supporting side wall of the carton carrier comprises an inner side wall panel, an outer side wall panel, and a top shelf panel. 
   
   
       22 . The carton carrier as in  claim 21 , wherein each supporting side wall of the carton carrier has a triangular cross-section. 
   
   
       23 . The carton carrier as in  claim 22 , wherein each top shelf panel of the carton carrier is disposed between the corresponding inner side wall panel and the corresponding outer side wall panel. 
   
   
       24 . The carton carrier as in  claim 23 , wherein the triangular cross-section of each supporting side wall comprises the top shelf panel forming the upper support surface of the respective supporting side wall and the corresponding inner side wall panel and corresponding outer side wall panel converging at a respective side of the bottom panel. 
   
   
       25 . The carton carrier as in  claim 24 , wherein sides of the plantlet tray abut the inner side wall panels of the carton carrier about a top surface of the tray. 
   
   
       26 . The carton carrier as in  claim 21 , wherein the carton carrier is formed from a blank. 
   
   
       27 . The carton carrier as in  claim 21 , wherein the supporting side walls of the carton carrier have a specific height to provide space for the plantlets disposed within the plantlet tray. 
   
   
       28 . The carton carrier as in  claim 20 , wherein the carton carrier is fiberboard. 
   
   
       29 . The carton carrier as in  claim 28 , wherein the fiberboard is a corrugated cardboard. 
   
   
       30 . The carton carrier as in  claim 29 , wherein ribs are defined by the corrugated cardboard and strengthen the carton carrier in at least one of a width direction or a height direction. 
   
   
       31 . The carton carrier as in  claim 20 , wherein the end walls of the carton carrier contact the supporting side walls when both the ends walls and the supporting side walls extend upright. 
   
   
       32 . The carton carrier as in  claim 20 , wherein the end walls of the carton carrier contact the ends of the tray of plantlets when the ends walls extend upright. 
   
   
       33 . The carton carrier as in  claim 20 , wherein the upper support surface of the supporting side walls of the carton carrier provides a stackable surface on which another carton carrier may be placed. 
   
   
       34 . A method of preparing trays of plantlets for shipping, the method comprising:
 (a) placing a tray of plantlets on a bottom panel of a carton carrier;   (b) folding the carton carrier along supporting wall creases to form supporting side walls along first and second sides of bottom panel;   (c) folding the carton carrier along first and second end wall creases to form end walls about first and second ends of the bottom panel; and   (d) placing the carton carrier in a box having box side walls and box end walls, such that the box side walls and box end walls support the supporting side walls and the end walls in an upright position.   
   
   
       35 . The method as in  claim 34 , further comprising stacking multiple carton carriers atop one another within the transport box. 
   
   
       36 . The method as in  claim 35 , wherein the supporting side walls define upper support surfaces or shoulders on which another carton carrier may rest. 
   
   
       37 . The method as in  claim 35 , wherein the transport box securely holds a specified number of carton carriers. 
   
   
       38 . The method as in  claim 34 , wherein the step of folding the carton carrier along first and second end wall creases to form end walls is performed by the step of placing the carton carrier in a transport box. 
   
   
       39 . A method as in  claim 34 , wherein the supporting side walls have an inverted triangular cross-section.