Methods and apparatus for manufacturing fiber-based meat containers
Methods and apparatus for manufacturing a microwavable food container include: forming a wire mesh over a mold comprising a mirror image of the microwavable food container; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh including the accumulated fiber particles from the slurry bath; wherein the slurry comprises a moisture barrier, an oil barrier, and a vapor barrier.
1. A method of manufacturing a microwavable food container, comprising:
forming a wire mesh over a mold comprising a mirror image of the microwavable food container;
immersing a wire mesh in a fiber-based slurry bath;
drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and
removing the wire mesh including accumulated fiber particles from the fiber-based slurry bath;
wherein the fiber-based slurry bath comprises a moisture barrier, an oil barrier, and a vapor barrier.
2. The method of claim 1 , wherein the fiber-based slurry bath further comprises a retention aid.
3. The method of claim 1 , wherein:
the moisture barrier is in a range of 0.5%-10% of-a slurry weight; and
the oil barrier is in a range of 0.5%-10% of a slurry weight.
4. The method of claim 2 , wherein the moisture barrier is in a range of about 1.5%-4%, the oil barrier is in a range of about 1%-4%, and the retention aid is in range of about 0.1%-0.5%.
5. The method of claim 1 , wherein the moisture barrier comprises-alkylketene dimer (AKD).
6. The method of claim 1 , wherein the moisture barrier comprises-alkylketene dimer (AKD) in an amount of about 3.5%.
7. The method of claim 1 , wherein the oil barrier comprises a water based emulsion.
8. The method of claim 7 , wherein the water based emulsion comprises a long chain fluorine-containing polymer.
9. The method of claim 1 , wherein the fiber-based slurry bath further comprises a rigidity component in a range of 1%-5% by weight.
10. The method of claim 9 , wherein the rigidity component comprises an inorganic salt.
11. The method of claim 1 , wherein the fiber-based slurry bath is produced by grinding fibers to achieve a freeness in a range of 200-700.
12. The method of claim 1 , wherein the vapor barrier comprises a long chain fluorine-based polymer.
13. The method of claim 1 , wherein the vapor barrier is a spray coating in a-range of about 0.1-3% of a slurry weight.
14. The method of claim 2 , wherein the retention aid comprises an organic compound in a range of 0.1-1% of a slurry volume.
15. A microwavable container manufactured according to the method of claim 1 .