Heat-able On-the-Go Food Products Apparatus and Method

Abstract

A molded pulp base container sprayed with a barrier and a sealant layer, used as a heatable package for on-the-go (OTG) food products is disclosed. The container by itself, in one embodiment, is used for microwave/oven heating the food contents in the container, eliminating the need for a separate susceptor or an additional package for heating. The inside surface of the container is spray coated with a food safe poly layer to create a moisture/oxygen barrier for shelf life stability. A sealant layer is directly applied on top of the barrier layer to provide hermesicity for the container. Adding a brine solution and a percentage of sodium to the finished package formulation, selectively heats the food contents of the package while keeping the package itself cool enough to handle. In another system embodiment, a condiment package is fitted to a formed top of the container.

What is claimed is: 
     
         1 . A heat-able container for storing and heating food therein, said container comprising a paper pulp material shaped shell to hold said food, a barrier layer and a sealant layer applied to an inside surface of said shell; wherein said barrier layer is sandwiched between said sealant layer and said inside surface of said shell; and said sealant layer is food safe. 
     
     
         2 . The heat-able container of  claim 1 , wherein said paper pulp material comprises salt. 
     
     
         3 . The heat-able container of  claim 1 , wherein said barrier layer moisture vapor transmission rate (MVTR) is less than 0.5 gm/package/day. 
     
     
         4 . The heat-able container of  claim 1 , wherein said barrier layer oxygen transmission rate (OTR) is less than 2 cc/package/day. 
     
     
         5 . The heat-able container of  claim 1 , wherein said sealant layer hermetically seals said container. 
     
     
         6 . The heat-able container of  claim 1 , wherein said barrier layer is food safe up to 500° C. 
     
     
         7 . The heat-able container of  claim 1 , wherein said sealant layer is food safe up to 500° C. 
     
     
         8 . The heat-able container of  claim 1  further comprises a condiment package that is shaped to fit outside a formed top of said container. 
     
     
         9 . The heat-able container of  claim 1  further comprises a condiment package that is shaped to fit inside said container. 
     
     
         10 . The heat-able container of  claim 9 , wherein said condiment package is made from plastic. 
     
     
         11 . The heat-able container of  claim 9 , wherein said condiment package is made from thermal formed pulp. 
     
     
         12 . The heat-able container of  claim 9 , wherein said formed top is configured to warm said condiment package contents. 
     
     
         13 . The heat-able container of  claim 9 , wherein said condiment package comprises at least one partition. 
     
     
         14 . The heat-able container of  claim 1  further comprises plural sealant layers and plural barrier layers. 
     
     
         15 . The heat-able container of  claim 1  wherein said container weight is less than 30 grams. 
     
     
         16 . The heat-able container of  claim 1  wherein the combined weight of said container, said sealant layer, and said barrier layer is less than 40 grams. 
     
     
         17 . The heat-able container of  claim 1  wherein said container wall thickness is less than 35 mils. 
     
     
         18 . The heat-able container of  claim 1  wherein the combined thickness of one layer of said sealant layer and said barrier layer is less than 6 mils. 
     
     
         19 . A method of making a heat-able container for storing and heating food, said method comprises the steps of:
 (1) mixing a pulp slurry;   (2) molding a container comprising a formed top from said pulp slurry;   (3) drying said molded container;   (4) spraying a barrier layer directly to an inside surface of said container;   (5) drying said container;   (6) spraying a sealant layer directly on top of said barrier layer;   (7) drying said container;   (8) curing said container;   (9) adding food products into said container; and   (10) sealing said container with said formed top.   
     
     
         20 . The method of  claim 19  wherein said process steps 4-6 are at least repeated twice to apply plural barrier and sealant layers. 
     
     
         21 . The method of  claim 19  further comprises the steps of:
 (11) positioning a condiment package on an outside surface of said formed top; and 
 (12) affixing a packaging label around said container and said condiment package. 
 
     
     
         22 . The method of  claim 19  further comprises the steps of:
 (11) positioning a condiment package inside of said container; and 
 (12) affixing a packaging label around said container and said formed top. 
 
     
     
         23 . The method of  claim 19  wherein said process steps do generate no waste water.