Abstract: 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 one or more of a moisture barrier, an oil barrier, and a vapor barrier.

Abstract: 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 one or more of a moisture barrier, an oil barrier, and a vapor barrier.

Abstract: 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.

Abstract: Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes one or more of an embedded moisture barrier, vapor barrier, and oil barrier, and the topical coating comprises one or more of a vapor barrier, a moisture barrier, an oil barrier, and an oxygen barrier, for example polyvinyl alcohol, sugar alcohol, citric acid, and cellulose nanofibrils.

Abstract: Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes one or more of an embedded moisture barrier, vapor barrier, and oil barrier, and the topical coating comprises one or more of a vapor barrier, a moisture barrier, an oil barrier, and an oxygen barrier. For food containers having deep sidewalls, a spray coating system includes a first nozzle for applying a full cone spray pattern to the bottom surface of the container, and a second nozzle for applying a hollow cone spray pattern to the inside surfaces of the side walls.

Abstract: Methods and apparatus for vacuum forming a beverage carrier yoke are described. The yoke comprises a number (e.g., four or six) collars interconnected by a web, and each collar exhibits dimensions—including a nominal diameter and a substantially uniform thickness—selected to improve strength and increase comfort. The yoke is produced using a slurry comprising a moisture barrier and a fiber base.

Abstract: Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes one or more of an embedded moisture barrier, vapor barrier, and oil barrier, and the topical coating comprises one or more of a vapor barrier, a moisture barrier, an oil barrier, and an oxygen barrier. For food containers having deep sidewalls, a spray coating system includes a first nozzle for applying a full cone spray pattern to the bottom surface of the container, and a second nozzle for applying a hollow cone spray pattern to the inside surfaces of the side walls.

Abstract: Methods and apparatus for packaging and shipping wine. A shipping container includes: a vacuum molded base component having a plurality of cylindrical concave columns within which respective bottles are received; a substantially planar corrugated separator sheet having a plurality of receptors aligned with the axes of the columns and configured to slidably receive respective bottle necks associated with the bottles; a vacuum molded cap component for receiving the bottle necks therewithin; and an outer corrugated box within which the bottles, base component, separator, cap component components are securely disposed.

Abstract: Methods and apparatus for vacuum forming a meat tray using a slurry. The slurry comprises: a moisture barrier comprising AKD in the range of about 4% by weight; a fiber base comprising bagasse; and an oil barrier comprising a water-based emulsion in the range of about 1.5% by weight.

Abstract: 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.

Abstract: Methods and apparatus for vacuum forming a beverage carrier yoke using a slurry. The slurry comprises: a moisture barrier comprising AKD in the range of about 4% by weight; and a fiber base comprising OCC and NP.

Abstract: Methods and apparatus for fabricating a molded fiber part are described. A system for forming a molded fiber container includes a first plate configured to receive a molded fiber part having a moisture content, and a second plate configured to compress the part against the first plate, wherein at least one of the first and second plates includes a die cutting blade.

Abstract: Methods and apparatus for vacuum forming a meat tray using a slurry. The slurry comprises: a moisture barrier comprising AKD in the range of about 4% by weight; a fiber base comprising bagasse; and an oil barrier comprising a water-based emulsion in the range of about 1.5% by weight.

Abstract: Methods and apparatus for manufacturing a molded fiber part include: immersing a wire mesh mold in a slurry bath comprising water and fiber particles; drawing a vacuum across the wire mesh mold to cause fiber particles to accumulate at the wire mesh mold surface yielding a molded fiber part; transferring the molded part from the slurry bath to a die press assembly; and drying and die cutting the molded part in the die press assembly.

Abstract: Methods and apparatus for fabricating a molded fiber part. The die press assembly includes: a first plate having a first mold form and a first plurality of vent holes; and a second plate having a second mold form and a second plurality of vent holes; wherein: at least one of the first and second plates comprises a blade operable to cut the part; the die press assembly is configured to compress the molded fiber part between the first and second mold forms; and the first and second pluralities of vent holes are configured to remove moisture from the part.

Abstract: Methods and systems for shipping original design manufacturer (ODM) boxes. The system includes: a plurality of corner sets, each comprising at least two fiber cushions; a plurality of end cap sets, each comprising two opposing corrugated sleeves; and a graphical guide comprising and end cap selector and a corner selector. The graphical guide is configured to allow a user to: compare an ODM box to the end cap selector to thereby select one of the plurality of end cap sets; and compare the ODM box to the corner selector to thereby select one of the plurality of end corner sets. Each sleeve comprises a plurality of height score lines, a plurality of width score lines, and a support feature to stabilize the sleeve during folding.

Abstract: Methods and apparatus for manufacturing vacuum forming a produce container using a fiber-based slurry. The slurry includes a moisture barrier comprising alkylketene dimer in the range of about 4% by weight, and a cationic liquid starch component in the range of 1%-7% by weight.

Abstract: Methods and apparatus for vacuum forming a beverage lid using a fiber-based slurry. The slurry comprises a moisture barrier component in the range of 0.5%-10% by weight, a rigidity component in the range of 1%-4% by weight, and a polycationic component in the range of about 1%-4%.

Abstract: 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.