Biodegradable boards and methods of making the same
A biodegradable board having a high stiffness to weight ratio includes cocoa shell particles, cellulosic wood-based fibers, and no added binders. The cocoa shell particles may be sourced from a cocoa processing waste stream. The board has a grammage of at least about 2000 g/m 2 . The board may be assembled into a self-supporting point-of-sale display unit for displaying food products.
1 . A biodegradable board comprising:
from about 35% to about 50% cocoa shell particles;
cellulosic wood-based fibers; and
no added binders,
wherein the biodegradable board is formed of a single layer, and has a density from about 1000 kg/m 3 to about 1100 kg/m 3 .
2 . The biodegradable board of claim 1 , wherein the cocoa shell particles have a particle size of no more than about 1 mm.
3 . The biodegradable board of claim 1 , further comprising a thickness of about 0.75 mm to about 60 mm and a grammage of at least about 2000 g/m 2 .
4 . The biodegradable board of claim 1 , comprising about 35% to about 45% of the cocoa shell particles.
5 . The biodegradable board of claim 1 , further comprising a moisture content of less than about 4%.
6 . The biodegradable board of claim 1 , further comprising a rupture strength of at least about 350 psi.
7 . The biodegradable board of claim 1 , further comprising a modulus of elasticity of about 700,000 psi to about 1,000,000 psi and a tensile strength of about 4000 psi to about 7000 psi.
8 . The biodegradable board of claim 1 , further comprising an outer skin and an inner portion, wherein the outer skin is more dense than the inner portion.
9 . The biodegradable board of claim 1 , further comprising a dimpled first outer skin and a smoother second outer skin opposite the dimpled first dimpled outer skin.
10 . The biodegradable board of claim 1 , wherein the board has less than about 0.1% rub-off of the cocoa shell particles.
11 . The biodegradable board of claim 1 , wherein:
the cocoa shell particles are obtained from cocoa shells sourced from a cocoa processing waste stream, and
the biodegradable board is assembled into a point-of-sale display unit for displaying a cocoa-containing food product.
12 . A method of making a biodegradable board, the method comprising:
grinding cocoa shells sourced from a cocoa processing waste stream;
providing pulp from cellulosic wood-based waste material;
combining the ground cocoa shells with the pulp from cellulosic wood-based waste material to form a mixture;
compressing the mixture under heat to form a biodegradable board,
wherein the biodegradable board comprises from about 35% to about 50% cocoa shell particles, and
the biodegradable board is formed of a single layer, and has a density from about 1000 kg/m 3 to about 1100 kg/m 3 .
13 . The method of claim 12 , wherein the biodegradable board comprises about 35% to about 45% of the cocoa shell particles.
14 . The method of claim 12 , wherein the compressing is effective to form a biodegradable board having a rupture strength of at least about 350 psi.
15 . The method of claim 12 , wherein the compressing is effective to form a biodegradable board having a thickness of about 0.75 mm to about 60 mm and a grammage of at least about 2000 g/m 2 .
16 . The method of claim 12 , wherein the compressing is effective to form a biodegradable board having a modulus of elasticity of about 700,000 psi to about 1,000,000 psi and a tensile strength of about 4000 psi to about 7000 psi.
17 . The method of claim 12 , further comprising drying the biodegradable board to a moisture content of less than about 4% and wherein the cocoa shells are ground to a particle size of no more than about 1 mm.
18 . The method of claim 12 , wherein the biodegradable board contains no added binders.
19 . A self-supporting point-of-sale display unit comprising one or more biodegradable boards, each biodegradable board having a grammage of at least about 2000 g/m 2 and comprising:
from about 35% to about 50% cocoa shell particles;
cellulosic wood-based fibers; and
no added binders,
wherein the biodegradable board is formed of a single layer, and has a density from about 1000 kg/m 3 to about 1100 kg/m 3 .