Abstract: Forming die assemblies for producing pressware are provided. In one or more embodiments, a forming die assembly can include an upper forming die, a lower forming die, and one or more lower forming springs coupled to the lower forming die, where the lower forming springs can be configured to spring load the lower forming die against the upper forming die when the forming die assembly is disposed in a closed position. The upper forming die can include an upper knockout, a forming punch, and a pressure ring aligned along a central axis of the forming die assembly, and the lower forming die can include a lower knockout and a contour rim aligned along the central axis of the forming die assembly. The lower surfaces of the upper forming die can form a punch profile and the upper surfaces of the lower forming die can form a forming profile.

Abstract: Systems and methods for producing pressware are provided. In one or more embodiments, a method for producing pressware can include producing a pressware product between an upper forming die and a lower forming die contained within a forming die assembly, retracting at least a portion of the upper forming die from the pressware product, and ejecting the pressware product from the lower forming die while feeding a web material between the upper forming die and the lower forming die. The method can also include cutting a segment of the web material to produce a substrate, and pressing the substrate between the upper forming die and the lower forming die to produce another pressware product.

Abstract: Systems for producing pressware are provided. In one or more embodiments, a system can include an upper moveable platen, a lower moveable platen, a stationary platen, a punch platen, and one or more forming die assemblies. The upper moveable platen and the punch platen can be disposed above the stationary platen and the lower moveable platen can be disposed below the stationary platen. The upper moveable platen, the punch platen, and the lower moveable platen can be configured to move toward and away from the stationary platen. Each forming die assembly can include a set of upper and lower forming dies. The upper and lower forming dies can be coupled to the upper and lower moveable platens, respectively, and configured to press substrates to form pressware products within passageways extending through the stationary platen.