Abstract: The present invention comprises a method for forming a biodegradable, thin-walled packing chip from an aqueous pulp of recycled newsprint by contacting the pulp with a mold comprising: (a) a solid core having substantially the shape of the article to be formed and having a minimal number of holes through which air may be evacuated and (b) an air permeable, stretchable fabric which covers the exterior of the core. After forming the chip on the fabric through application of a vacuum, the fabric is separated sufficiently from the solid surface to cause release of the chip from the fabric. The dried packing chip has enhanced packing qualities, is environmentally friendly and provides a significant new use for recycled newsprint.

Abstract: A method and apparatus for forming articles, used as dunnage material, from pulped paper products includes a paper shredder that forms the pulped paper and delivers it to a slurry tank. The slurry tank gravity feeds the slurry into a slurry reservoir where a pump pumps the slurry into molds. A plunger delivers compressed air to the slurry blobs contained within each molds to expand the slurry blobs to the shape of the molds and to force the water in the slurry through an outlet in the bottom of the molds to a vacuum chamber connected to the molds. The delivery of compressed air further forms a cavity within the expanded slurry blobs. During the next four steps, the molds again connect to the vacuum so that additional water is forced from the pulp into the vacuum chamber. Finally, an ejector supplies compressed air to the bottom of the molds such that the finished articles are propelled from the molds onto a conveyor which delivers the cubes to packaging machines.