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 vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes an embedded moisture barrier and/or vapor barrier, and the topical coating comprises an oil barrier comprising acrylate, rice bran wax, pectin, and pea protein.

Abstract: A fiber-based, plastic-free drinking cup is formed by providing a fiber-based slurry comprising a hydrophobic additive and a strength additive, then forming a drinking cup component by compressing and drying the fiber-based slurry in a form press assembly having an internal shape characterized by a conic frustum. The fiber-based slurry may include a dry pulp mixture of virgin fiber and recycled fiber, the hydrophobic additive is 1.0-10.0% of the dry pulp weight, and the strength additive is 1.0-10.0% of the dry pulp weight. In particular, the fiber-based slurry may include about 50% bleached hardwood, about 50% bleached softwood, about 2.5% strength additive, and about 3.5% hydrophobic additive by dry pulp weight.

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 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 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 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 a moisture barrier, an oil barrier, and a vapor barrier.

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 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 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 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 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 vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes an embedded moisture barrier and/or vapor barrier, and the topical coating comprises an oil barrier comprising acrylate, rice bran wax, pectin, and pea protein.

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 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 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 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 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.