Abstract: An apparatus and method utilizes a forming machine which includes a mandrel and forming plate each shaped to conform the paperboard and/or corrugated material blank passing through the mandrel into the desired configuration for a leak-proof tray. The blank includes a layer of a suitable paperboard and/or corrugated material, and a layer of leak-proof plastic or paper material disposed over one side of the corrugated material. The corrugated material includes cutouts at each corner of the blank that enable the sides and ends of the blank to be folded relative to one another. The paper material continuously overlaps the surface of the corrugated layer and these cutouts to provide a continuous leak-proof barrier layer within the formed tray and at the corners of the blank when folded to form the tray, as the paper material is folded over itself to form a bellows corner in the tray.

Abstract: An apparatus and method utilizes a forming machine which includes a mandrel and forming plate each shaped to conform the paperboard and/or corrugated material blank passing through the mandrel into the desired configuration for a leak-proof tray. The blank includes a layer of a suitable paperboard and/or corrugated material, and a layer of leak-proof plastic or paper material disposed over one side of the corrugated material. The corrugated material includes cutouts at each corner of the blank that enable the sides and ends of the blank to be folded relative to one another. The paper material continuously overlaps the surface of the corrugated layer and these cutouts to provide a continuous leak-proof barrier layer within the formed tray and at the corners of the blank when folded to form the tray, as the paper material is folded over itself to form a bellows corner in the tray.

Abstract: A compostable food tray is provided including an upper layer formed of a flexible and compostable material that is secured to a lower layer formed of a foldable and compostable material. The lower layer can be folded to form a tray including an interior for holding a food item therein, while the upper layer extends beyond the periphery of the lower layer and can be wrapped over or around the food item in order to provide a package for the food item in conjunction with the lower layer.

Abstract: An apparatus and method for forming a tray is provided including a forming plate and the complementary aperture in the mandrel formed to define a space therebetween that deforms the blank into the desired shape of the tray. The space between or tolerance defined by the forming plate and the mandrel is less than the actual thickness of the tray at one or more sections and/or points on the tray, such as at the corners of the tray, in order to crush the foldable material forming the tray at the one or more sections. The crushing of the foldable material at these sections effectively removes any shape memory from the foldable material, such that the tray including the crushed sections retains the shape of the tray without the need for additional securing materials on the tray but without degrading any leak-proof functionality of the tray.

Abstract: A container or package for a food product is provided that includes a pedestal tray/support member formed of a material capable of supporting the weight of the food product to be positioned thereon and a cover engagable with the support member. The support member is formed with features to allow the cover to be readily engaged and disengaged from the support member and to enable the package to be easily grasped and moved in its entirety all without the need for a separate reinforcing corrugated pad disposed on the support member.

Abstract: A generally flat blank used to form an open-top container, the blank comprising a bottom panel bounded by end and side score lines, first and second side panels connected to the opposite sides of the bottom panel at the respective side score lines, each of the first and second side panels having a flap panel, each flap panel connected to each end panel by a hinged fold joint having a retaining slit, a first end panel connected to one end of the bottom panel at one score lines, a second end panel connected to the bottom panel opposite the first end panel and at least one locking extension connected to the second end panel having at least one locking member thereon that is releasably engageable with the retaining slit on the fold joint to selectively lock the second end panel with regard to the first and second side panels.

Abstract: The present invention is a container for use in baking and shipping food items. The container is formed of a paperboard material and includes a heat-resistant coating applied to all of the interior surfaces of the container. The coating enables a number of food items to be positioned within the container in contact with the coating such that the container and food items can be baked to properly prepare the food items therein. After baking, the container and food items can then be wrapped or otherwise packaged for shipment without transferring the food items to a separate shipping container. The container also includes a pair of end walls that are movable with respect to the container between retaining and dispensing positions to enable the container to be configured as serving tray for the items contained therein.

Abstract: The present invention is a container for use in baking and shipping food items. The container is formed of a paperboard material and includes a heat-resistant coating applied to all of the interior surfaces of the container. The coating enables a number of food items to be positioned within the container in contact with the coating such that the container and food items can be baked to properly prepare the food items therein. After baking, the container and food items can then be wrapped or otherwise packaged for shipment without transferring the food items to a separate shipping container. The container also includes a pair of end walls that are movable with respect to the container between retaining and dispensing positions to enable the container to be configured as serving tray for the items contained therein.

Abstract: The present invention is a method for forming a corrugated container having a double wall construction. A blank is formed of a pair of corrugated layers sandwiched between and adhered to adjacent flat layers and having a sufficient moisture content to enable the blank to be formed. The blank can include printed indicia, thermoresistant coatings, release coatings, and other coatings applied to the blank to enhance the utility of the container formed from the blank. The blank is then inserted into a thermoforming machine in which a pair of heated dies compress the blank into the desired container shape.