ARRANGEMENT OF EXPANDED POLYSTYRENE BOXES AND EXPANDED POLYSTYRENE BOX FOR FOOD TRANSPORT AND STORAGE

Description

FIELD OF THE INVENTION

The present invention has application in the transportation and storage industry, in particular in the transport and storage of food such as fresh fish in Expanded Polystyrene containers.

BACKGROUND OF THE INVENTION

In the food transport and packaging industry, specifically fresh products such as fish, containers or boxes made from Expanded Polystyrene (EPS) are used since the formulation of its resins is free of brominated compounds and contaminating additives.

For example, in countries like Brazil there is a logistics chain created for the sale of salmon, in which the unit of sale to end customers is a 70-lb box.

When this type of product is transported to its final destination or point of sale, the boxes are generally loaded in refrigerated trucks that maintain the cold chain or optimum temperature of the product to avoid its decomposition. However, to achieve this, the flow of cold air inside the container must be distributed in such a way as to ensure the necessary temperature required by the products stored in the boxes to avoid thawing.

In this context and as an example. it has been studied that the respiration heat of fresh salmon is 0 kcal/kg. 24 h. This means that the salmon does not release thermal energy once packed; thus, it is important to prevent heat from entering the box from outside to maintain optimal storage conditions.

Currently, to achieve these conditions, the boxes are distributed on the transport deck of the truck in a stacked but independent configuration and interspersed with each other, in order to leave spaces or channels between them that allow the air flow to pass through them.

A first disadvantage of this configuration relates to the problems associated with the stowage of the boxes, since when they are loose and separated from each other, they are susceptible to displacement due to movements of the truck and therefore to be damaged or even open during transport.

A second disadvantage is that the current dimensions of the boxes do not allow them to be moved on standard 1.2 m×0.8 m pallets, since they would not be fully supported on the pallet, with the risk of damage. This is due to the fact that the length of the traditional boxes exceeds 80 cm and their width exceeds 40 cm, so that the fish transported inside them is fully stretched. This problem is generated especially in the boxes for transporting Chilean salmon, which due to its size (80% of the sizes are in the range of 75-85 cm) requires boxes with sufficient volumes.

As a result of the aforementioned characteristics, said boxes must be loaded and ordered manually, an operation that entails a high logistical cost, since the pallets must be assembled in the warehouse and then have to be disassembled, with boxes being entered into the truck in units, thus considering a great use of time and human resources.

A third disadvantage of the current box configuration is that the horizontal channels formed between boxes do not conduct the cooling air optimally. In particular, the lower boxes resting on the (generally metallic) surface of the truck are exposed to heat from the outside, such as radiation from the pavement and that generated by the truck's axles themselves. The above causes an undesirable increase in the temperature of the content inside the boxes and therefore the risk that it deteriorates.

It is therefore the objective of the present invention to overcome the advantages described above, by means of a box and configuration that allows the transport and storage of fresh food in a more efficient way, facilitating the task of loading and stowing boxes, and at the same time improving their refrigeration conditions.

Another objective of the present invention is to improve the transport capacity of products inside the boxes, respecting the traditional sales unit of the market that is, maintaining the cubic capacity of the boxes so as not to affect the processes and logistics of the marketers.

DESCRIPTION OF THE INVENTION

In order to overcome the above-described drawbacks, an arrangement of Expanded Polystyrene (EPS) boxes grouped in a tower on a pallet is first proposed, where said boxes are distributed in at least 7 rows each consisting of three boxes separated from each other by a separation and ordered so that two boxes are arranged next to each other in parallel in the longitudinal direction of the pallet and the third is arranged perpendicular to the first, the box being arranged perpendicularly at one end of the tower which is opposite the end of the top and/or bottom row.

Second, a box made of Expanded Polystyrene (EPS) is proposed for the transport and storage of food, configured to be stacked on a pallet in an arrangement as described above. The box is composed of a rectangular body having an upper opening and a lid, where the body has a base with stacking grooves and the lid comprises stacking projections.

It is proposed that the boxes have a length in the range between 700 and 800 mm. a width in the range between 300 and 400 mm; and a height comprised in the range between 280 and 350 mm.

The specific characteristics of the box according to a preferred embodiment of the invention are detailed below:

Dimensions and Volume

		Length	Width	Height	Volume
	TYPE	(mm)	(mm)	(mm)	(l)
	Outside	797	397	300	95
	Inside	741	341	243	81

	Attribute	Value	Measure unit	Tolerance
	Density	19	g/l	±20%
	Weight	780	Grams	±20%
	Tolerance of dimensions length, width and height ± 1%. Thickness ± 2%

Mechanical Properties

Compression strength (external load for stacking)

Maximum load	Maximum suggested load	Design stress
(Kg)	(Kg)	(Kg)
8122	406	295

Maximum suggested load from the Maximum Load with Safety

factor = 2

Bending strength (internal load for product)

Maximum load	Maximum suggested load	Design stress
(Kg)	(Kg)	(Kg)
5974	298.7	32.5

Maximum suggested load from the Maximum Load with Safety

factor = 2

Thermal Properties

	Attribute	Value	Measure unit

	Thermal conductivity coefficient	0.033	W/(mK)at 0° C.
	Maximum thermal conductivity	35	mW/MK

From these specifications, a shorter and less wide box is obtained than those used in the state of the art but higher, maintaining the volume and therefore not affecting the storage capacity. This means that the sales unit is kept so as not to affect the processes and the existing logistics chain.

The change in the dimensions of the proposed box does not affect the product transported inside. For example, in the case of Chilean salmon, the reduction in length is offset by the gain in height of the box, allowing the fish to fit in the interior volume with the end of its tail bent. In this sense, the main advantage associated with a reduction in the length and width of the box allows them to be distributed on standard 1.2 m×0.8 m pallets, ensuring that the boxes are supported on 100% of their base and allowing an optimal distribution of weight loads. The goal is to completely eliminate case breaking, today a serious problem in the industry.

The table below shows a comparison between the attributes of the current box design and the one proposed here.

Attribute	Current design	New design

Length (mm)	890	797
Width (mm)	420	397
Height (mm)	257	300
Cubic capacity of the product (pounds)	70	70
Interior volume (liters)	61	61
Units by shipping (units)	680	735
Maximum net load by shipping (kilos)	19,800	20,800
Palletisable in 1.2 m × 0.8 m	No	Yes
Compact load	No	Yes
Air flow favored through lower section	No	Yes
Ramp loading time (minutes)	60	10

The design of boxes proposed allows them to be loaded and unloaded from trucks directly on a pallet and by means of conventional pallet trucks. With this, optimizing the times and resources for loading and unloading trucks is possible.

For stacking the boxes, the use of EPS pallets is proposed due to hygiene and thermal insulation issues. On this the boxes are distributed using a Cross Stocking to give the tower rigidity and stability.

Another advantage of the configuration proposed is that it allows the assembly of the tower of boxes by means of robots. For this, a space of 6 mm is preferably left between boxes so that the pallets can enter and exit the robot. This separation is considered in the design of the boxes, so that the dimensions of the tower fit exactly with those of the pallet and do not protrude from it.

Thanks to the use of the EPS pallet, the boxes of the lower level remain on a completely isolated surface from the truck floor, avoiding heating and melting of the product. The use of this element in combination with the ordering of boxes proposed optimizes the flow of cold air around the boxes, which moves up the tower, then goes down and is returned in its entirety under the EPS pallets, due to the grooves of the truck ramp and the channels formed by the same pallets.

In other words, with the proposed configuration, the load forms a true “product block” or “EPS block” enveloped by cold air, thus generating an enveloping circular flow much more efficient than that passing through the arrangement of boxes separated and supported on the surface of the truck, used today.

DESCRIPTION OF THE FIGURES

FIGS. 1 to 3 illustrate an arrangement of boxes according to the configuration used in the state of the art.

FIG. 2 illustrates the problems of state-of-the-art boxes when they are arranged on standard pallets.

FIG. 3 illustrates the problems of the state of the art box arrangement in terms of refrigeration.

FIGS. 4 and 5 illustrate the arrangement of boxes proposed by the present invention.

FIGS. 6a and 6b illustrate the flow of cooling air through and around the arrangement proposed by the present invention.

FIGS. 7a and 7b illustrate details of the body of the box proposed by the present invention.

FIGS. 8a and 8b illustrate details of the lid of the box proposed by the present invention.

FIG. 9 illustrates details of the pallet for transporting boxes of the present invention.

FIG. 10 illustrates a set of boxes stacked on a pallet according to the present invention.

DETAILED DESCRIPTION OF THE FIGURES

According to FIGS 1a and 1b, the ordering of EPS boxes 10 traditionally used inside refrigerated trucks comprises an arrangement in rows, each of said rows being composed of five boxes, with four of them located in the same longitudinal direction and one at the end in the opposite direction. The end at which the box is located in the opposite direction 11 alternates in each row as illustrated in FIG. 1b. Furthermore, a transverse space 12 is provided between the boxes that make up each row, which forms a space for air circulation and cooling of the boxes. The ordering of the pallet inside the truck is done manually.

Traditional boxes such as those illustrated in FIGS. 1 to 3 are 890 cm long, 420 cm wide and 257 cm high, which dimensions prevent them from being distributed on a standard EPS pallet 20, as illustrated in FIG. 2, which is why they must be placed manually on the floor of the truck, as shown in FIG. 3. Additionally and as seen in said Figure, there is the disadvantage that the boxes are located in the lower row and that are in contact with the truck's surface of the floor 30, they are subject to the heat radiated by the truck itself and/or the pavement. which affects the integrity of the products contained therein.

According to FIG. 4, the ordering proposed in the present invention is a cross stacking with three boxes 10 per row, so that two boxes are arranged-side by side in parallel in the longitudinal direction and the third is arranged perpendicular to the first. The box arranged perpendicularly alternates in each row between each end of the tower.

The tower of boxes formed has 7 rows preferably and the dimensions of the boxes allow them to be accommodated on a standard EPS pallet, as illustrated in FIG. 10. In addition, the assembly of the tower of boxes can be fully automated through the use of robots. To do this, a separation 13 is left between boxes (preferably less than 10 mm) so that the pallets of the robot building the tower can enter and exit. Also, said separation 13 is considered in the design of the boxes, so that the dimensions of the tower just match those of the standard pallet.

FIGS. 6a and 6b show an arrangement of 6 towers of boxes 10 each arranged on a pallet 20 on the inner surface 40 of a truck. The arrows shown represent the air flow that circulates around the boxes, especially that passing under the boxes, between pallet 20 and the interior surface 40 of the truck.

FIG. 7a shows the body 100 of a box according to a preferred embodiment of the invention comprising at least one wall reinforcing body 101 arranged on at least one face of at least one side wall, wherein said wall reinforcing body 101 comprises a wall supporting area 102 arranged towards the opening of the body 100 of the box. Furthermore, the body opening 100 comprises a perimeter edge 103, which corresponds to a connecting edge projecting upward from the opening. On the other hand, it can be seen that the body 100 comprises vertical holes 104 towards the four corners of the body, corner posts 105 arranged towards the upper corners of the body 100 and at least one lower recess arranged on the outer face of the body 100, towards the bottom of the same.

According to FIG. 7b, the base of the box 10 comprises a projected surface 110 having a configuration of stacking recesses and grooves, wherein said stacking grooves 111 are configured to receive stacking projections arranged on the outer face of the top. For their part, the stacking recesses 112 on the outer face of the bottom make it possible to substantially reduce the weight of the box and, at the same time, increase the resistance of the bottom of the box against impacts. Furthermore, the arrangement of the stacking recesses 112 is designed to avoid affecting the thermal insulation properties substantially. Additionally, the arrangement of stacking grooves 111 on the outer face of the bottom of the box and of stacking projections on the outer face of the lid, which fit in cooperative way while stacking, favors the cross stacking between boxes proposed in the present invention.

Finally, on the lower edges of the bottom of the box, there are lower recesses 113 providing a surface for the passage of straps that allow to securing the boxes on the pallet. Preferably a pair of lower recesses 113 is provided at each lower longitudinal edge of the box.

In FIG. 8a it is shown that the lid 200 of the box comprises upper recesses 213 aligned with the lower recesses of the body of the box and which also have the purpose of allowing the passage of straps. Furthermore, the spatial configuration of the stacking projections 211 of the lid 200 is seen, the latter being complementary with the stacking grooves of the outer face of the bottom of the body, illustrated in FIG. 7b.

In addition, FIG. 8b illustrates the details of the lower face of the lid 200, where it can be seen that it comprises a perimeter groove 203 to receive the perimeter edge of the body of the box. The lid 200 also comprises a centrally located arched cross beam 220 that seeks to increase the flexural strength of the cover.

FIG. 9 shows a preferred configuration of the pallet 20 used to stack the boxes of the present invention. It is preferably constructed of EPS in one single piece and is composed of a horizontal surface 21 and supporting members 22. The pallet preferably has industry standard dimensions, that is, a length of 1.2 m and a width of 0.8 m.

Each unit of pallet 20 allows boxes to be stacked in rows consisting of 3 boxes. For this, the upper face of the pallet has three supporting areas 23 circumscribed by a flange 24 with the shaped of the base of a box and that is configured so that the boxes can be deposited inside, preventing their movement in relation to the pallet. Furthermore, the supporting areas 23 have a slight separation between them to create the space that allows the entry of the robot pallets that builds the tower of boxes on the pallet.

Finally, FIG. 10 shows the tower of boxes 10 of the present invention stacked in a cross stacking manner on the pallet 20 and in a preferred 7-row configuration.