Acrylate and non-acrylate based chemical compositions for selectively coating fiber-based food containers

1. A method of manufacturing a meat tray, comprising the steps of:

providing a wire mesh mold approximating the shape of the meat tray;

preparing an aqueous fiber based slurry comprising at least one of old corrugated containers (OCC) and double-lined kraft (DLK) paper;

adding an embedded moisture barrier to the slurry;

immersing the mold in the slurry;

drawing a vacuum across the mold within the slurry until a desired thickness of fiber particles accumulates at a surface of the mold;

removing the accumulated particles from the mold;

drying and pressing the accumulated particles in a press to thereby form a bowl;

transferring the bowl from the press to a coating station; and

applying a non-acrylate moisture barrier layer comprising a non-acrylate based particulate solids in an aqueous solution to a surface of the bowl at the coating station, wherein the coating station comprises a spray system and a conveyor configured to move the bowl along a direction of travel into engagement with the spray system, the spray system comprising a first nozzle configured to discharge a first predetermined spray pattern onto a bottom of the bowl, and the first predetermined spray pattern comprises a substantially vertical curtain terminating in a line at the bowl.

2. The method of claim 1 , wherein the embedded moisture barrier comprises 2%-5% by weight alkyl ketene dimer (AKD).

3. The method of claim 1 , further comprising:

adding a dry strength additive to the slurry.

4. The method of claim 3 , wherein the dry strength additive comprises 0.5%-4.5% by weight starch.

5. The method of claim 1 , wherein the spray system further comprises a second nozzle configured to discharge a second predetermined spray pattern onto a sidewall of the bowl.

6. The method of claim 1 , wherein the moisture barrier layer comprises an approximately 1:3 solution of particulates and water.