Packaging tray and method of use

Abstract

A packaging system for packaging food on a plurality of trays is provided. The packaging system has a main conveyor configured to move each of the plurality of trays about the packaging system and a tray unloader for unloading one tray from a tray stack onto the main conveyor. The packaging system has a food loader configured to place the food into each of the trays and a food accessory loader configured to place a food accessory into a storage compartment of each of the trays.

1 . A packaging system for packaging food on a plurality of trays, the packaging system comprising:
 a main conveyor configured to move each of the plurality of trays about the packaging system;   a tray unloader for unloading one tray from a tray stack onto the main conveyor;   a food loader configured to place the food into each of the trays; and   a food accessory loader configured to place a food accessory into a storage compartment of each of the trays.   
     
     
         2 . The packaging system of  claim 1 , wherein the tray unloader further comprises at least one tray engager configured to engage the tray at an end of the tray. 
     
     
         3 . The packaging system of  claim 2 , further comprising a drive system configured to move the tray engager and thereby drop the lowermost tray from the tray stack. 
     
     
         4 . The packaging system of  claim 3 , wherein the at least one tray engager has a curved shoulder and end configured to mirror the contours of the ends of the tray. 
     
     
         5 . The packaging system of  claim 4 , wherein the at least one tray engager further comprises two tray engagers one having a convex shoulder and convex end and the other having a concave shoulder and concave end. 
     
     
         6 . The packaging system of  claim 4 , wherein the at least one tray engager further comprises two tray engagers one having a convex shoulder and convex end and the other having a concave end with a straight shoulder. 
     
     
         7 . The packaging system of  claim 2 , wherein the tray engagers are interchangeable in order to mirror the contours of the types of packaging trays used in the packaging system. 
     
     
         8 . The packaging system of  claim 1 , wherein the food accessory is a thermometer. 
     
     
         9 . A system for unloading a tray onto a main conveyor in a food packaging facility, the system comprising:
 a stack conveyor configured to convey a tray stack toward a tray feed area;   a tray unloader located proximate the tray feed area and configured to remove a lowermost tray of the tray stack and place the tray onto the main conveyor wherein the tray unloader comprises:
 a tray engager for engaging an removing the lowermost tray; 
 a drive system configured to move the tray engager; and 
   wherein each of the trays has a tray bottom wherein the tray bottom is substantially flat and has two substantially straight sides on opposite sides of a perimeter of the tray bottom and two curved ends wherein a first end is curved away from the tray bottom and a second end is curved into the tray bottom and two side walls each extending above the straight sides of the tray bottom and located on opposite sides of the tray bottom and two curved end walls each extending above the curved ends of the tray bottom and wherein each end of each of the end walls is coupled to an end of the side wall thereby forming walls extending from the perimeter of the tray bottom;   
     
     
         10 . The system of  claim 9 , wherein the each of the trays further comprise a storage area for a food accessory and a food storage area for storing a food. 
     
     
         11 . The system of  claim 9 , wherein the at least one tray engager has a curved shoulder and curved end configured to mirror the contours of the curved ends of the tray. 
     
     
         12 . The system of  claim 9 , wherein the at least one tray engager further comprises two tray engagers one having a convex shoulder and convex end and the other having a concave shoulder and concave end. 
     
     
         13 . The system of  claim 9 , wherein the at least one tray engager further comprises two tray engagers one having a convex shoulder and convex end and the other having a concave end with a straight shoulder. 
     
     
         14 . The system of  claim 9 , wherein the tray engagers are interchangeable in order to mirror the contours of the types of trays used in the packaging system. 
     
     
         15 . A method of packaging food comprising:
 placing a tray stack onto a stack conveyor;   moving the tray stack toward a tray feed area;   dropping the tray stack into the tray feed area;   engaging a lowermost tray with a tray dispenser system;   using the tray dispenser system to lower the lowermost tray onto a main conveyor;   moving the tray toward a food loader and loading a food into the tray; and   moving the tray toward a food accessory loader and loading the food accessory into a storage area on a border of the tray.   
     
     
         16 . The method of  claim 15 , wherein using the tray dispenser further comprises:
 engaging the lowermost tray with a plurality of tray engagers;   rotating the tray engagers with a drive system and thereby releasing the lowermost tray;   
     
     
         17 . The method of  claim 15 , further comprising engaging a convex end wall of the tray with a concave shoulder and concave end of the of the tray engager. 
     
     
         18 . The method of  claim 17 , further comprising engaging a concave end wall of the tray with a convex shoulder and convex end of the of the tray engager. 
     
     
         19 . The method of  claim 15 , wherein moving the tray toward the tray feed area further comprises moving the tray stack on a conveyor.