MOLDED FIBER SEPARATOR

Abstract

Embodiments of the present disclosure provide plant-based separators for bottles or other cylindrical objects that require separation within a pack, for example for use in storage, transport, or display. In various embodiments, plant-based separators, dividers, and containers are disclosed that may include a tray-like cradling apparatus with a first active/engaging face and a second active/engaging face. In various embodiments, both engaging faces may be provided with functional shapes that include projections that may allow the separator to operate in laydown or upright dividing engagement with items such as bottles, candles, or other substantially cylindrical articles adjacent to the separator in order to provide impact and friction protection, while maintaining separation and location of the items in multi-item configurations.

Description

Cross Reference to Related Applications

The present application claims priority to U.S. Provisional Patent Application No. 61/381,898, filed Sep. 10, 2010, entitled “MOLDED PULP FIBER BOTTLE SEPARATOR,” the disclosure of which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

Embodiments of the present disclosure relate generally to the field of separators for bottles or other cylindrical objects that require separation and/or location within a pack, for example for use in storage, transport, or display, and more particularly to plant-based separators for bottles, such as wine bottles, for use in transport, storage, and/or display.

BACKGROUND

It is often desirable to transport and display fragile bottles or other vessels, typically containing liquids. For example, many beverage bottles are sold in six- or twelve-packs, which may include a molded fiber, chipboard, or corrugated cardboard divider to separate, locate, and protect the bottles. In the wine industry, it is common practice to ship wine on pallets containing packs of six (half case) or twelve (full case) bottles in either a horizontal (laydown) or vertical (standup) configuration, for instance. These arrays are typically packed in a corrugated carton with some type of protection layers positioned between adjacent bottles to prevent shifting, breakage, and capsule or label damage. Wine bottles also may be displayed in a store in this configuration, for instance arranged horizontally with three or four or six bottles resting on a separator.

Commonly, such protection layers are made from molded pulp fiber, and the bottles may generally be provided in groups of three, four or six bottles per horizontal layer. For example, a standard six bottle configuration typically has a first separator layer made of molded pulp fiber and positioned in the bottom of a transport container such as a box or carton. The separator layer includes a molded impression that generally matches that of the wine bottle and is adapted to receive the first layer of three bottles. A second separator layer may be placed on top of the first layer of bottles with molded functional projections facing upward to support and separate a second layer of three bottles, and a nonfunctional planar side facing or resting on the first layer of bottles. In some instances, another separator placed on top with the functional projections facing downward.

The molded pulp fiber separators are typically made from recycled paper or other natural or synthetic fiber and are easily biodegradable, recyclable, and/or compostable. Due to the fact that the molded pulp fiber manufacturing process traditionally used requires oven drying the molded separators on an extended flat conveyor/belt or on drying trays, it is difficult to design and produce molded pulp fiber separators that have two active/functional sides. Thus, a minimum of two or three separators are needed to protect two layers of bottles. This increases the cost, weight, and size of the overall packaging. Additionally, the traditional one-sided separators generally do not nest together well when stacked, and are difficult to separate for use.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings. Embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings.

FIGS. 1A, 1B, and 1C illustrate different views of an example of a plant-based separator, including a perspective view (FIG. 1A), a top view (FIG. 1B), and a side view (FIG. 1C), in accordance with various embodiments;

FIGS. 2A, 2B, and 2C illustrate different views of an example of a plant-based separator in use in a six-bottle laydown configuration. including a perspective view (FIG. 2A), a top view (FIG. 2B), and a side view (FIG. 2C), in accordance with various embodiments;

FIGS. 3A, 3B, and 3C illustrate different views of an example of a plant-based separator in use in a six-bottle stand-up configuration, including a perspective view (FIG. 3A), a side view (FIG. 3B), and a top view (FIG. 3C), in accordance with various embodiments; and

FIGS. 4A, 4B, and 4C illustrate different views of an example of a separator suited for a case configuration, including a perspective view of a plant-based separator (FIG. 4A), a perspective view of a plant-based separator in engagement with bottles (FIG. 4B), and a top view of a plant-based separator in engagement with bottles (FIG. 4C), in accordance with various embodiments.

DETAILED DESCRIPTION OF EMBODIMENTS

In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which are shown by way of illustration of embodiments in which the disclosure may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scopes of embodiments, in accordance with the present disclosure, are defined by the appended claims and their equivalents.

Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments of the present invention; however, the order of description should not be construed to imply that these operations are order-dependent.

The description may use perspective-based descriptions such as up/down, back/front, and top/bottom. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of embodiments of the present invention.

The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical contact with each other. “Coupled” may mean that two or more elements are in direct physical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.

For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” means (A), (B), or (A and B). For the purposes of the description, a phrase in the form “at least one of A, B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C). For the purposes of the description, a phrase in the form “(A)B” means (B) or (AB) that is, A is an optional element.

The description may use the phrases “in an embodiment,” or “in embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present invention, are synonymous.

Embodiments of the present disclosure are directed to plant-based separators, dividers, and containers that include a tray-like cradling apparatus with a first active/engaging face and a second active/engaging face. In various embodiments, both engaging faces may be provided with functional shapes that include molded projections that may allow the separator to operate in stacking, horizontal (“laydown”) or upright (“standup”) dividing engagement with items such as bottles, candles, or other substantially cylindrical articles adjacent to the separator in order to provide impact and friction protection, while maintaining separation and location of the items in multi-item configurations.

In various embodiments, multiple molded projections may functionally extend from the first and second engaging faces of the plant-based separator to form a series of receiving cradles that may engagingly receive multiple items, such as bottles. In some embodiments, a separator with two active/functional faces may include receiving cradles of different dimensions and/or configurations, for instance to accommodate bottles or other items of different sizes and shapes, such as tall Alsace or Hoch style bottles, Burgundy style bottles, champagne bottles, and Bordeaux style bottles. In various embodiments, such separators may be adapted to receive for instance 375, 750, or 1500 ml volume configurations, or any other size bottle.

In some embodiments, separators having two active faces may be made from plant-based materials, such as natural fibers, particles, and/or biopolymers, which may be formed, in some embodiments, in a molding process, such as a thermoforming molding process. In other embodiments, the separators may be formed by compression molding or any other forming process that may allow the separator to be formed into a desired configuration, as further described below.

In various embodiments, the plant-based separators may be made from any type of formable natural fibers, particles, biopolymers, or other types of plant-based (e.g., non-hydrocarbon-based) materials that allow the separator to be recyclable, compostable, and/or biodegradable. In various embodiments, such plant-based materials may include pulp fibers, such as paper, newsprint, cardboard, waxed cup stock, and/or non-waxed cup stock, and/or other plant-based fibers, such as bark, wood, miscanthus grass, hemp, bamboo, other grasses, and/or palm fiber. In various embodiments, other examples of plant-based materials may include cassava, tapioca, corn, paper foam, starches, and/or various other agricultural fibers and organic materials,. In various embodiments, the plant-based separators disclosed herein may be substantially formed from non-hydrocarbon-based materials. However, although the separators disclosed herein typically are made of plant-based materials, one of skill in the art will appreciate that they also may include small amounts of other formable and/or moldable materials, such as plastic, styrofoam, alloys, hydrocarbon-based materials, synthetic fibers, and other organic and inorganic materials.

In various embodiments, the plant-based separators having opposing active/functional faces as described herein may dramatically reduce the cost and energy consumption involved in shipping and using the separators as compared to the previously described bottle trays, which have only one active side. First, because the separator has two active sides, as few as half as many separators are needed to pack a given number of bottles (or other items) as compared to traditional, one-sided technologies. Second, because the separators described herein have improved nesting and de-nesting abilities (further described below) as compared to traditional separators, the same number of separators may be packed into a far smaller space for shipping and/or storage; e.g., about half the size. Thus, because approximately twice the number of two-sided separators will fit into the shipping space occupied by traditional dividers, and only half as many separators are needed to pack a unit of bottles, the cost of inbound freight, the space required for storage, the number required for packing bottles, and/or the overall carbon footprint may be reduced, for example, by a factor of about four in accordance with various embodiments.

FIGS. 1A, 1B, and 1C illustrate different views of an example of a plant-based separator 10, including a perspective view (FIG. 1A), a top view (FIG. 1B), and a side view (FIG. 1C), in accordance with various embodiments. In this specific, non-limiting example, bottles are shown positioned in a horizontal stacking (laydown) arrangement (see, e.g., FIG. 1C). In various embodiments, separator 100 may include a first engaging face 102 and a second engaging face 104 (see, e.g., FIG. 1A). In one specific, non-limiting example, separator 100 may be formed from a mat of pulp or other natural fiber, and may have a first series of functional projections 106 that extend from first engaging face 102 generally away from (e.g., above) a base 108 of the separator. A first series of receiving cradles 120 adapted to receive bottles or other generally cylindrical objects therein may thus be formed in various embodiments. In various embodiments, a second series of functional projections 122 also may extend from second engaging face 104 away from (e.g., below) base 108 to form a second series of receiving cradles 124 adapted to receive bottles or other generally cylindrical objects therein.

In various embodiments, the first and second functional projections 106, 122 may have any shape that allows them to form opposing receiving cradles 120, 124 such that they may protect and/or display bottles or other generally cylindrical objects in either a vertical (standup) or horizontal (laydown) configuration adjacent to both the first engaging face 102 and second engaging face 104 of separator 100. Thus, in various embodiments, first and second functional projections 106, 122 may include one or more curved and/or radiused surfaces 126 adapted to fit around at least a portion of the corresponding curved surface of a bottle or other generally cylindrical object. Although first and second functional projections 106, 122 are illustrated as generally pointed projections, one of skill in the art will appreciate that first and second functional projections 106, 122 may assume any of a variety of shapes, including, but not limited projections that include a slightly rounded or squared-off face on their distal tips.

In various embodiments, both first engaging face 102 and second engaging face 104 may be substantially smooth. Thus, in various embodiments when not it use, multiple separators 100 may be stacked such that first and second functional projections 106, 122 may nest together into a compact configuration for storage and/or shipping. In various embodiments, stacked separators 100 also may be easily separated from one another (e.g., de-nested) after storage and/or transport.

In some embodiments, first functional projections 106 may alternate with second functional projections 122 both in the length direction and the width direction of separator 100. For instance, in one specific, non-limiting example, a six-bottle separator may include two rows of first and second functional projections 106, 122 that form three first receiving cradles 120 and three second receiving cradles 124. Such a configuration may be suited for use as a half case shipper, using only a single divider in accordance with various embodiments. In another specific, non-limiting embodiment, an eight-bottle separator may include three rows of first and second functional projections 106, 122 that form four first receiving cradles 120 and four second receiving cradles 124.

One of skill in the art will appreciate that additional separators 100 may be used in series to add layers of bottles to an existing carton or stack. For instance, a second eight-bottle separator may be used with an existing eight-bottle array in order to accommodate an additional four bottle layer, thus forming a 12-pack or what is known as a typical case (see, e.g., FIGS. 4A, 4B and 4C). Alternately, a six- or eight-bottle separator 100 maybe used next to (or partially overlapping with) additional separators 100 in order to create additional rows. In some embodiments, the number of bottle-receiving cradles/cavities may be increased on each active side of separator 100 in order to increase the number of bottles each row may accommodate.

As described above, the double-sided separators 100 disclosed herein may allow bottles or other generally cylindrical objects to be packed for transport and/or display in much more compact packaging and with less waste in packing materials. Unlike traditional molded pulp fiber separators that have molded functional projections on only one side, the separators disclosed herein have functional projections on both sides, and each row of bottles does not require a separate separator. In various embodiments, forming processes that may be used to make the separators having two active/function faces of the present disclosure may provide more flexibility in the geometry of the projections formed in the separator design (e.g., forming projections on both sides of the base) as compared to traditional molded pulp fiber manufacturing processes.

The traditional pulp molding process uses a pulper that beats the waste paper or pulp bales to a uniform consistency with water. Various additives are then added to the pulp slurry, and the slurry is processed into shaped forms using a series of wet forming dies mounted on a molding drum or platen, and a mating set of transfer dies mounted on a transfer mechanism. The forming die is rotated or lowered and immersed in a vat containing the pulp slurry. A vacuum system attracts the fibers to deposit on the forming die screens as the suspending recycle water is drawn through the screen and drainage holes. The delicate, wet-formed products (about 70-75% water at this stage) are then transferred onto the transfer die and deposited on an oven belt or dryer conveyor trays and passed through a drying oven. Warping, shrinkage, and/or collapse of the molded part are risks during the drying process. At times, a post-press process may be utilized to achieve a desired shape and/or texture.

Because the wet product must be transferred onto a flat horizontal surface for subsequent drying, it has previously been difficult to create geometries that incorporate raised functional projections on both the top and bottom faces of the product. Generally, a sufficient weight-bearing surface, such as a predominantly flat-bottomed side, is needed in order for the not-yet-dried molded product to retain its shape. Hence, when being used in a carton pack which has layers of bottles, a molded part is needed to secure each layer. By contrast, the separators disclosed herein may actively engage and separate both an upper layer and a lower layer of bottles with a single component.

Thus, in specific, non-limiting embodiments, the separators of the present disclosure may be formed using a thermoforming method, in which the fibers deposited from the slurry solution may be subjected to curing by heat and pressure in situ to produce the final product. In some embodiments, the thermoforming machine may use a series of two or more transfer heads in which the formed part is progressively transferred forward until discharged on to a conveyor.

In various embodiments, the molded separators may be dried in the mold, and no oven curing may be needed. Thus, in various embodiments, the self-supporting molded separators disclosed herein do not need a flat side, and can assume any desired shape, texture and/or configuration. In other words, referring once again to FIG. 1A, in various embodiments, separator 100 may be made with molded functional projections 106, 122 on both sides, and separator 100 may “stand” on these “points” without collapsing downwards when transferred to a horizontal surface when it comes off of the mold because it has already been dried. In one, specific, non-limiting example, separator 100 may have pointed functional projections 106, 122 on both the first and second faces 102, 104, because there is no oven-drying step in which separator 100 or functional projections 106, 122 may warp or flatten.

Additionally, in various embodiments, the thermoforming method may produce molded products that have a greater strength and density, and greater uniformity and smoothness on all sides as compared to traditional technologies. In specific, non-limiting embodiments, because the molded articles may be passed through a series of pressing dies, the articles become may smooth on both faces 102, 104 as compared to traditional pulp manufactured articles, which have one smooth formed face and rougher opposing face. In various embodiments, this may allow the molded separators 100 to be less abrasive than traditional molded parts when in contact with labels on items being shipped or other delicate surfaces. In various embodiments, the two-sided smooth parts also may allow for more condensed stacking and precise nesting and de-nesting of the articles. Better nesting may reduce inbound freight (e.g., may reduce the carbon footprint) and storage costs, in accordance with various embodiments. Better de-nesting also may allow for more efficient packout at the user location because the articles separate far more easily. Although methods of producing the separators described herein are discussed with reference to thermoforming methods, one of skill in the art will appreciate that other methods may be used to form the separators, such as compression molding and the like in various embodiments.

Methods of using the separators disclosed herein are contemplated in accordance with various embodiments. As discussed above, the disclosed separators may be configured to store, transport, and/or display any number of bottles or other generally cylindrical items in either a horizontal (laydown) or vertical (standup) orientation. FIGS. 2A, 2B, and 2C illustrate a perspective view (FIG. 2A), a top view (FIG. 2B), and a side view (FIG. 2C) of an example of molded fiber separator in use in a six-bottle laydown configuration. FIGS. 3A, 3B, and 3C illustrate a perspective view (FIG. 3A), a side view (FIG. 3B), and a top view (FIG. 3C) of an example of molded fiber separator in use in a six-bottle stand-up configuration, in accordance with various embodiments.

As discussed, one common configuration is a six-bottle configuration. As illustrated in FIGS. 2A, 2B, and 2C, one method of using a separator 200 in a six bottle horizontal (laydown) pack, three bottles may be placed on their sides in an appropriately-sized container, such as a carton, and a six-cradle/cavity separator 200 as described above may be placed on top of the bottles such that second functional projections 222 project at least partially between the bottles and second receiving cradles 224 cradle each bottle (see, e.g., FIG. 2C). Three more bottles may then be placed on top of separator 200 such that first functional projections 206 project at least partially between the bottles and first bottle receiving cradles 220 cradle each bottle. One of skill in the art will appreciate that additional layers of separators and bottles may be stacked on top of these six bottles as needed, if additional bottles are to be packed in the same carton. Thus, in various embodiments, separator 200 may perform its separation/location function on both the lower and upper bottles from a single location between to the two layers, and thus may replace the 2-3 trays needed with traditional molded pulp fiber separators.

Another method of packing bottles (or other generally cylindrical items) is the vertical (standup) orientation. As illustrated FIGS. 3A, 3B, and 3C, this packing technique may require separators to be placed vertically to keep adjacent parts from moving out-of-position and provide assured separation/location between each part. In one specific, non-limiting method of packing a six-pack, three bottles may be inserted vertically in a row in a carton or other suitably-sized and shaped container. In various embodiments, a separator 300 may be placed adjacent to the bottles such that second functional projections 322 project at least partially between the bottles and second bottle receiving cradles 324 cradle each bottle. In various embodiments, three more bottles may then be placed on the other side of separator 300 such that first functional projections 306 project at least partially between the bottles and first bottle receiving cradles 320 cradle each bottle. Thus, in various embodiments, separator 300 may perform its separation/location function on both the bottles from a single location between to the two layers, thereby replacing the multiple trays or dividers needed with traditional molded pulp fiber, corrugated cardboard, or chipboard separators. One of skill in the art will appreciate that additional rows of separators and bottles may be placed adjacent to these six bottles as needed, if additional bottles are to be packed in the same carton.

Alternatively, in various embodiments, the bottles may be placed in a 2×3 array (e.g., in a shipping carton), and a separator 300 may be slid between the bottles such that the first active side and first functional projections engage a first row of bottles and the second active side and second functional projections engage a second row of adjacent bottles. As with the other packing arrangements described hereon, one of skill in the art will appreciate that additional rows of bottles may be positioned adjacent to these six bottles as needed, and additional separators may be positioned therebetween if additional bottles are to be packed in the same carton.

One of skill in the art will appreciate that in various embodiments, the number of cradles in each row may be increased on each active side of the separator in either the horizontal (laydown) or vertical (standup) orientation, for instance to accommodate a larger number of bottles in each row and thereby reduce the height or depth of the array as desired. Additionally, separators may be positioned next to each other, or with one or more cradles overlapping, in a given row or layer, in order to accommodate a larger number of bottles.

In one example, an eight bottle divider may be formed in accordance with various embodiments. For example, in one specific, non-limiting embodiment, FIGS. 4A, 4B and 4C illustrate a perspective view of a plant-based separator (FIG. 4A) a perspective view of a plant-based separator in vertical engagement with bottles (Figure 4B) and a top or end view of a plant-based separator in engagement with bottles (FIG. 4C). As illustrated, a plant-based separator 400 may have first 402 and second 404 active faces that include a series of first 406 and second 422 functional projections to form four partial or whole receiving cradles 420, 424. As formed, separator 400 may be adapted to engage eight bottles. In various embodiments, as shown, when a second separator is added, twelve bottles (as shown) may be stacked or aligned in a 4×3 matrix to form a traditional case configuration. As described above, in some embodiments, the number of cradles may be increased on each active side of the separator 400 to accommodate a larger number of bottles in each row and thereby reduce the height or depth of the array

In various embodiments, although the separators described herein are illustrated as being fully loaded with bottles, in some embodiments, the same separators may also be used for transporting or displaying fewer than the number of bottles described in the above examples. Further, additional adjacent receiving cradles may be formed as needed, such as embodiments having 5 bottle-receiving cavities, 6 bottle-receiving cavities, and more.

In various embodiments, the separator may be sized to accommodate any size bottle. For instance, in some embodiments, the separator may have a length of from about 6 inches to about 20 inches, and in some instances, from about 8 inches to about 18 inches; a width of from about 3 inches to about 11 inches, and in some instances from about 5 inches to about 9 inches. In various embodiments, the separator may also have a height (e.g., measured from the distal tips of the first functional projections to the distal tips of second functional projections) of from about 1.5 inches to about 6.5 inches (e.g., projecting about 0.75-3.25 inches from the base in each direction), from about 2 inches to about 3.5 inches (e.g., projecting about 1-1.75 inches from the base in each direction), from about 2.4 inches to about 4.5 inches (e.g., projecting 1.2-2.25 inches from the base in each direction), or about 2.75 inches (e.g., projecting about 1.375 inches from the base in each direction) in particular embodiments.

One of skill in the art will appreciate that the dimensions of the separator may be smaller when it is intended to be used with smaller bottles and larger when used with larger bottles. For example, in one specific, non-limiting example, when adapted to be used with 375 ml bottles, a separator may have a length of about 7-9 inches, a width of about 4-6 inches, and a height of about 2-3 inches. In another specific, non-limiting example, when configured to be used with 1.5 L magnum bottles, a separator may have a length of about 17-19 inches, a width of about 8-10 inches, and a height of about 4-5 inches. In particular embodiments, the separator may be adapted to receive six 750 ml bottles, and the length is 11.42 inches, the width is 8.86 inches, and the height is 2.8 inches. In other particular embodiments, the separator may be adapted to receive twelve 750 ml bottles in a 3×4 array, and the length is 11.81 inches, the width is 8.81 inches, and the height is 2.8 inches.

In various embodiments, the separators disclosed herein may be adapted to accommodate different sizes of bottles on each of its two active faces, or include different numbers of cradles. One of skill in the art will appreciate that this may be accomplished by varying the size and/or shape of functional projections in order to achieve a desired configuration. Further, in various embodiments, the thickness of the plant-based separator may range from about 0.010 inches to about 0.25 inches, for example, about 0.03 to about 0.19 inches, about 0.04 inches to about 0.08 inches, or about 0.06 inches in particular embodiments. Finally, in various embodiments, the base of the dividers/separators may have generally flat ends, which may make the dividers suitable for placing in an overlapping or interlocking arrangement to increase the length of the array. For example, two six-cavity separators may be aligned in series such that they become a 10 bottle divider, having a 2×5 arrangement. Alternately, two six-cavity dividers can be interlocked to form the equivalent of an eight-cavity divider.

Although certain embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent embodiments or implementations calculated to achieve the same purposes may be substituted for the embodiments shown and described without departing from the scope of the present invention. Those with skill in the art will readily appreciate that embodiments in accordance with the present disclosure may be implemented in a very wide variety of ways. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that embodiments in accordance with the present disclosure be limited only by the claims and the equivalents thereof.

Claims

1. A plant-based separator for receiving a plurality of substantially cylindrical objects, comprising:

a substantially planar base formed from a plant-based material, the substantially planar base having a first side and a second side,

the first side having a first plurality of projections projecting outward from the first side and away from the base;

the second side having a second plurality of projections projecting outward from the second side and away from the base;

the first and second pluralities of projections being adapted to receive the plurality of substantially cylindrical objects.

2. The plant-based separator of claim 1, wherein the first plurality of projections and the second plurality of projections alternate in a repeating pattern to create one or more receiving cradles on each of the first and second sides of the base.

3. The plant-based separator of claim 1, wherein the plant-based material comprises molded fiber.

4. The plant-based separator of claim 3, wherein the molded fiber comprises paper, newsprint, cardboard, waxed cup stock, non-waxed cup stock, pulp, bark, leaves, miscanthus grass, palm, bamboo, grass, hemp, casaba, corn, tapioca, starch, or a combination thereof.

5. The plant-based separator of claim 1, wherein the plurality of substantially cylindrical objects comprises bottles.

6. The plant-based separator of claim 2, wherein the first plurality of projections creates a corresponding first plurality of recesses on the second side, and wherein the second plurality of projections creates a corresponding second plurality of recesses on the first side.

7. The plant-based separator of claim 1, wherein the first side has a first surface, wherein the second side has a second surface, and wherein the first and second surfaces are both substantially smooth.

8. The plant-based separator of claim 7, wherein the plant-based separator is configured to be nestable and/or de-nestable.

9. The plant-based separator of claim 1, wherein the base, the first plurality of projections, and the second plurality of projections are formed from a continuous layer of molded fiber.

10. The plant-based separator of claim 9, wherein the continuous layer of molded fiber has a substantially uniform thickness.

11. The plant-based separator of claim 10, wherein the thickness is from about 0.01 inches to about 0.25 inches thick.

12. The plant-based separator of claim 11, wherein the thickness is about 0.06 inches thick

13. The plant-based separator of claim 1, wherein the first and/or second pluralities of projections project a distance of from about 1 inches to about 1.75 inches from the base.

14. The plant-based separator of claim 13, wherein the first and/or second pluralities of projections project a distance of about 1.375 inches from the base.

15. The plant-based separator of claim 5, wherein the separator is adapted to receive Alsace style bottles, Hoch style bottles, Burgundy style bottles, champagne bottles, Bordeaux style bottles, or a combination thereof.

16. A plant-based separator for receiving a plurality of substantially cylindrical objects, comprising:

a substantially planar base formed from a plant-based material, the substantially planar base having a first side and a second side,

the first side having a first plurality of projections projecting outward from the first side and away from the base;

the second side having a second plurality of projections projecting outward from the second side and away from the base;

the first and second pluralities of projections being adapted to receive the plurality of substantially cylindrical objects; wherein the first plurality of projections and the second plurality of projections alternate in a repeating pattern to create one or more receiving cradles on each of the first and second sides of the base; wherein the first plurality of projections creates a corresponding first plurality of recesses on the second side, and wherein the second plurality of projections creates a corresponding second plurality of recesses on the first side.

17. The plant-based separator of claim 16, wherein the first side has a first surface, wherein the second side has a second surface, wherein the first and second surfaces are both substantially smooth; and wherein the plant-based separator is configured to be nestable and/or de-nestable.

18. A method of packing a multi-pack of bottles comprising:

providing a plant-based bottle separator comprising a substantially planar base formed from a plant-based material, the substantially planar base having a first side and a second side, the first side having a first plurality of projections projecting outward from the first side and away from the base, the second side having a second plurality of projections projecting outward from the second side and away from the base, the first plurality of projections being adapted to receive a plurality of bottles in a first plurality of receiving cradles created therebetween, and the second plurality of projections being adapted to receive a plurality of bottles in a second plurality of receiving cradles created therebetween;

providing a carton or box;

aligning a first plurality of bottles in the carton or box in a substantially horizontal orientation;

placing the plant-based bottle separator on top of the first plurality of bottles such that the second set of receiving cradles of the plant-based bottle separator receives the first plurality of bottles; and

aligning a second plurality of bottles in the first plurality of receiving cradles of the plant-based bottle separator.

19. A method of packing a multi-pack of bottles comprising:

providing a plant-based bottle separator comprising a substantially planar base formed from a plant-based material, the substantially planar base having a first side and a second side, the first side having a first plurality of projections projecting outward from the first side and away from the base, the second side having a second plurality of projections projecting outward from the second side and away from the base, the first plurality of projections being adapted to receive a plurality of bottles in a first plurality of receiving cradles created therebetween, and the second plurality of projections being adapted to receive a plurality of bottles in a second plurality of receiving cradles created therebetween;

providing a carton or box;

aligning a first plurality of bottles vertically in the carton or box;

aligning a plant-based bottle separator next to the first plurality of bottles such that the second set of receiving cradles of the plant-based bottle separator receives the first plurality of bottles; and

placing a second plurality of bottles in the first plurality of receiving cradles of the plant-based bottle separator.

20. A method of packing a multi-pack of bottles comprising:

providing a plant-based bottle separator comprising a substantially planar base formed from a plant-based material, the substantially planar base having a first side and a second side, the first side having a first plurality of projections projecting outward from the first side and away from the base, the second side having a second plurality of projections projecting outward from the second side and away from the base, the first plurality of projections being adapted to receive a plurality of bottles in a first plurality of receiving cradles created therebetween, and the second plurality of projections being adapted to receive a plurality of bottles in a second plurality of receiving cradles created therebetween;

positioning a first row of bottles in a suitably-sized box in a substantially vertical orientation;

positioning a second row of bottles in the box such that the second row of bottles substantially aligns with the first row of bottles;

positioning the plant-based bottle separator between the first and second rows of bottles such that the first set of receiving cradles receives the first row of bottles and the second set of receiving cradles receives the second row of bottles.

21. A method of extending a bottle separator comprising:

providing at least a first plant-based bottle separator and a second plant-based bottle separator, wherein each of the first and second bottle separators comprises a substantially planar base, the substantially planar base having a first side and a second side, the first side having a first plurality of projections projecting outward from the first side and away from the base, the second side having a second plurality of projections projecting outward from the second side and away from the base, the first plurality of projections being adapted to receive a plurality of bottles in a first plurality of receiving cradles created therebetween, and the second plurality of projections being adapted to receive a plurality of bottles in a second plurality of receiving cradles created therebetween;

positioning at least one of the second plurality of receiving cradles of the second bottle separator into at least one of the first receiving cradles of the first bottle separators, thereby extending the first bottle separator with the second bottle separator.