Disposable cups made form recycled fiber
A paperboard, sidewall, and disposable cup made from about 70 wt % to about 100 wt % of recycled fiber. The paperboard can include about 70 wt % to about 100 wt % of recycled fiber, based on the total weight of the fiber. The paperboard can have a board thickness of about 14 mil to about 20 mil, an apparent density of less than about 11.5 lbs/3,000 ft 2 /mil, a CD Taber Stiffness of about 50 g*cm or more, and a MD/CD Taber Stiffness ratio of 1.0 to 3.0, and can be used to make recycled cups having sufficient strength and rigidity properties that rival cups made from virgin fibers.
1. A paperboard for making disposable consumer products, comprising:
about 70 wt % to about 100 wt % of recycled fiber, based on the total weight of the fiber;
a board thickness of about 14 mil to about 20 mil;
an apparent density of less than about 11.5 lbs/3,000 ft 2 /mil;
a CD Taber Stiffness of about 50 g*cm or more; and
a MD/CD Taber Stiffness ratio of 1.0 to 3.0.
2. The paperboard of claim 1 , wherein the recycled fiber is substantially derived from old corrugated containers.
3. The paperboard of claim 1 , wherein at least 25% of the recycled fiber is post-consumer recycled fiber.
4. The paperboard of claim 1 , wherein the paperboard comprises 75 wt % to 90 wt % of the recycled fiber and less than 25 wt % of virgin fiber.
5. The paperboard of claim 1 , wherein the apparent density is less than about 11.0 lbs/3,000 ft 2 /mil.
6. The paperboard of claim 1 , wherein the apparent density is less than about 10.5 lbs/3,000 ft 2 /mil.
7. The paperboard of claim 1 , wherein the cross direction (CD) Taber Stiffness is 75 g-cm or more.
8. The paperboard of claim 1 , wherein the MD/CD Taber Stiffness ratio is about 1.0 to about 2.5.
9. The paperboard of claim 1 , further comprising a surface coating at least partially disposed on a first side of the paperboard, wherein the surface coating comprises clay, starch, sizing, or a mixture thereof.
10. A sidewall for making a disposable cup made from recycled fibers, comprising:
a substrate comprising about 75 wt % to about 100 wt % of recycled fiber, based on the total weight of the fiber, wherein the substrate comprises:
a thickness of about 14 mil to about 20 mil;
an apparent density of less than about 11.5 lbs/3,000 ft 2 /mil;
a CD Taber Stiffness of about 50 g*cm or more; and
a MD/CD Taber Stiffness ratio of 1.0 to 3.0; and
a layer of low density polyethylene at least partially disposed on a first side of the substrate.
11. The sidewall of claim 10 , wherein the recycled fiber is substantially derived from old corrugated containers.
12. The sidewall of claim 10 , wherein at least 25% of the recycled fiber is post-consumer recycled fiber.
13. The sidewall of claim 10 , wherein the substrate comprises 75 wt % to 90 wt % of the recycled fiber and less than 25 wt % of virgin fiber.
14. The sidewall of claim 10 , wherein the apparent density is less than about 10.5 lbs/3,000 ft 2 /mil.
15. The sidewall of claim 10 , wherein the cross direction (CD) Taber Stiffness is 75 g-cm or more, and the MD/CD Taber Stiffness ratio is about 1.0 to about 2.5.
16. The sidewall of claim 10 , further comprising a layer of oil resistant material at least partially disposed on a second side of the substrate.
17. The sidewall of claim 16 , wherein the oil resistant material comprises low density polyethylene (LDPE) or an acrylic emulsion polymer.
18. A disposable cup, comprising:
a sidewall comprising:
a substrate layer comprising about 75 wt % to about 100 wt % of recycled fiber, based on the total weight of the fiber, wherein the substrate layer has a thickness of about 16 mil to about 20 mil; an apparent density of less than about 11.5 lbs/3,000 ft 2 /mil; a CD Taber Stiffness of about 50 g*cm or more; and a MD/CD Taber Stiffness ratio of 1.0 to 3.0; and
a layer of low density polyethylene at least partially disposed on a first side of the substrate; and
a bottom panel comprising about 75 wt % to about 100 wt % of recycled fiber, based on the total weight of the bottom panel, wherein the cup has a rigidity greater than about 0.6 lbf/0.25 inch deflection.
19. The disposable cup of claim 18 , wherein the rigidity is about 0.8 lbf/0.25 inch or more.
20. The disposable cup of claim 18 , wherein the rigidity is about 1.0 lbf/0.25 inch or more.
21. The disposable cup of claim 18 , wherein the substrate comprises 75 wt % to 90 wt % of the recycled fiber and less than 25 wt % of virgin fiber, the recycled fiber being substantially derived from old corrugated containers, and wherein the cross direction (CD) Taber Stiffness is 75 g-cm or more, the MD/CD Taber Stiffness ratio is about 1.0 to about 2.5, and the rigidity is about 1.0 lbf/0.25 inch or more.
22. The disposable cup of claim 18 , further comprising a layer of oil resistant material at least partially disposed on a second side of the substrate, wherein the oil resistant material comprises low density polyethylene (LDPE).
23. The disposable cup of claim 18 , further comprising a layer of oil resistant material at least partially disposed on a second side of the substrate, wherein the oil resistant material comprises an acrylic emulsion polymer.
24. A disposable cup, comprising:
a sidewall comprising:
a substrate layer comprising about 75 wt % to about 100 wt % of recycled fiber, based on the total weight of the fiber, wherein the substrate layer has a thickness of about 16 mil to about 20 mil; an apparent density of less than about 11.5 lbs/3,000 ft 2 /mil; a CD Taber Stiffness of about 50 g*cm or more; and a MD/CD Taber Stiffness ratio of 1.0 to 3.0; and
a layer of low density polyethylene at least partially disposed on a first side of the substrate;
a layer of oil resistant material at least partially disposed on a second side of the substrate, wherein the oil resistant material comprises low density polyethylene (LDPE) or an acrylic emulsion polymer; and
a bottom panel comprising about 75 wt % to about 100 wt % of recycled fiber, based on the total weight of the bottom panel, wherein the cup has a rigidity greater than about 0.6 lbf/0.25 inch deflection.
25. The disposable cup of claim 24 , wherein the rigidity is about 0.8 lbf/0.25 inch or more.
26. The disposable cup of claim 24 , wherein the rigidity is about 1.0 lbf/0.25 inch or more.
27. The disposable cup of claim 24 , wherein the substrate comprises 75 wt % to 90 wt % of the recycled fiber and less than 25 wt % of virgin fiber, the recycled fiber being substantially derived from old corrugated containers, and wherein the cross direction (CD) Taber Stiffness is 75 g-cm or more, the MD/CD Taber Stiffness ratio is about 1.0 to about 2.5, and the rigidity is about 1.0 lbf/0.25 inch or more.
28. The disposable cup of claim 24 , wherein the oil resistant material comprises low density polyethylene (LDPE).
29. The disposable cup of claim 24 , wherein the oil resistant material comprises an acrylic emulsion polymer.