Methods and apparatus for manufacturing fiber-based produce containers
Methods and apparatus for manufacturing vacuum forming a produce container using a fiber-based slurry. The slurry includes a moisture barrier comprising alkyl ketene dimer in the range of about 4% by weight, and a cationic liquid starch component in the range of 1%-7% by weight.
1. A method of using a slurry for vacuum forming a fiber-based produce container, comprising:
providing a slurry including: i) a moisture barrier comprising alkyl ketene dimer (AKD) in the amount of about 4% by weight; ii) a cationic liquid starch component in the range of 1%-7% by weight; and iii) a fiber base of at least one of softwood (SW), old corrugated containers (OCC), and newsprint (NP);
immersing a wire mesh mold in the slurry;
accumulating a layer of fiber particles around the wire mesh mold; and
drying and compressing the layer of fiber particles to form the produce container;
wherein the slurry further includes about 2% by weight of dry strength additive comprising a modified polyamine configured to form both hydrogen and ionic bonds with the fiber base.
2. The method of claim 1 , wherein the fiber base comprises OCC in an amount of about 70%, and newsprint in an amount of about 30%.
3. The method of claim 1 , wherein the slurry further comprises a coloring agent selected from the group consisting of a cationic dye and a fiber reactive dye.
4. The method of claim 1 , wherein the slurry further comprises a dye absorption agent selected from the group consisting of salt and soda ash.
5. The method of claim 1 , wherein the starch component comprises a polyamide epichlorohydrin (PAE) resin in an amount of 1%-4% by weight.
6. A method of using a slurry for vacuum forming a fiber-based produce container, comprising:
providing a slurry including: i) a moisture barrier comprising alkyl ketene dimer (AKD) in the amount of about 4% by weight; ii) a cationic liquid starch component in the range of 1%-7% by weight; iii) a fiber base of at least one of softwood (SW), old corrugated containers (OCC), and newsprint (NP); and (iv) a dry strength additive consisting of about 2% by weight of a modified polyamine configured to form both hydrogen and ionic bonds with the fiber base; (v) a coloring agent selected from the group consisting of a cationic dye and a fiber reactive dye; (vi) a dye absorption agent selected from the group consisting of salt and soda ash
immersing a wire mesh mold in the slurry;
accumulating a layer of fiber particles around the wire mesh mold; and
drying and compressing the layer of fiber particles to form the produce container.
7. The method of claim 6 , wherein the cationic liquid starch component comprises a polyamide epichlorohydrin (PAE) resin in an amount of 1%-4% by weight.