Poultry box
A repulpable moisture resistant poultry box having a composite structure with a fluted medium, a top backing board secured to one side of the fluted medium and a bottom backing board secured to the other side of the fluted medium. The backing boards and the fluted medium are impregnated with a hydrogenated triglyceride. The backing boards each have an outer surface coated with PET to provide moisture resistance repulpable and recyclable box.
1. A process for making a repulpable and recyclable poultry box comprising the steps of:
a). impregnating a corrugated paper medium with a hydrogenated triglyceride;
b). impregnating a first paper liner board with a hydrogenated triglyceride;
c). impregnating a second paper liner board with a hydrogenated triglyceride;
d). coating said impregnated first paper liner board with a coating of ethylene terephthalate on one side;
e). coating said impregnated second paper liner board with a coating of ethylene terephthalate on one side;
f). securing said first impregnated and coated liner board and said impregnated corrugated medium and said second impregnated and coated liner board together with an adhesive to form a composite sheet; and
g). curing said composite sheet with heat to cure said adhesive.
2. A process as claimed in claim 1 wherein said hydrogenated triglyceride is tallow.
3. A process for making a repulpable and recyclable poultry box comprising the steps of:
a). impregnating a first liner sheet of paper from an inline corrugator with tallow;
b). impregnating a fluted paper medium from an inline corrugator with tallow;
c). impregnating a second liner sheet of paper from an inline corrugator with tallow;
d). applying a biodegradable thermoplastic polyester to said impregnated first liner sheet of paper in line to coat said first liner sheet on one side;
e). applying a biodegradable thermoplastic polyester to said impregnated second liner sheet of paper in line to coat said first liner sheet on one side;
f). securing said first liner sheet, said medium and said second liner sheet together with an adhesive to from a composite corrugated structure with the first and second liner sheets polymer coating forming the outside surfaces of the composite corrugated structure; and
g). curing said composite corrugated structure with heat to cure said adhesive.
4. A process as claimed in claim 3 wherein said tallow liner sheets are impregnated with tallow at about 2.5 lbs./MSF.
5. A process as claimed in claim 3 wherein said fluted medium is impregnated with tallow at about 3.5 lbs./MSF.
6. A process as claimed in claim 3 wherein said biodegradable thermoplastic polyester coating is applied to said paper liner sheets at about 1 to about 2 lbs./MSF.
7. A process as claimed in claim 3 wherein said corrugated paper medium is impregnated with tallow at a greater weight than the tallow is applied to impregnate the liner boards.
8. A process as claimed in claim 3 wherein said tallow is a beef tallow.
9. A process as claimed in claim 3 wherein said polyester coating imparts improved moisture resistance.
10. A process as claimed in claim 1 wherein said hydrogenated triglyceride is a plurality of hydrogenated triglycerides.
11. A process as claimed in claim 3 wherein first and second liner sheets are Kraft paperboard liner.
12. A process as claimed in claim 1 wherein said adhesive is a starch based adhesive.
13. A process as claimed in claim 3 further including the additional step of placing said composite corrugated structure in a cutting station which cuts and scores the corrugated structure into a box blank.
14. A process as claimed in claim 1 further including the additional step:
h). placing said composite corrugated structure in a cutting station which cuts and scores the corrugated structure into a box blank.