NL2017569B1 - Biodegradable food packaging unit from a moulded pulp material, and method for manufacturing such food packaging unit - Google Patents

Abstract

The present invention relates to a biodegradable food packaging unit from a moulded pulp material and a method for manufacturing such biodegradable packaging unit. The packaging according to the invention comprises a food receiving or carrying compartment, wherein the moulded pulp material comprises an amount of polybutylene succinate (PBS). In a preferred embodiment the amount of PBS is in the range of 0.5-20 wt.%, more preferably in the range of 1- 15 wt.%.

Description

NL BI 2017569

Patent center

The Netherlands

Θ 2017569

BI PATENT (51) Int. CL:

D21H 27/10 (2017.01) B65D 65/42 (2017.01) B65D 1/24 (2017.01) D21H 17/53 (2017.01) (21) Application number: 2017569 © Application submitted: 03/10/2016

Application registered: (73) Patent holder (s): 10/04/2018 Huhtamaki Molded Fiber Technology B.V. in Franeker. (43) Application published: θ Inventor (s): Patent granted: Harald John Kuiper in Heerenveen. 10/04/2018 (45) Patent issued: θ Authorized representative: 11/04/2018 ir. P.J. Hylarides et al. In The Hague.

Biodegradable food packaging unit from a molded pulp material and method for manufacturing such a food packaging unit © The present invention relates to a biodegradable food packaging unit from a molded pulp material and a method for manufacturing such biodegradable packaging unit. The packaging according to the invention comprises a food receiving or carrying compartment, the molded pulp material comprises an amount or polybutylene succinate (PBS). In a preferred embodiment the amount of PBS is in the range of 0.5-20 wt.%, More preferably in the range or 1-15 wt.%.

This patent has been granted regardless of the attached result of the research into the state of the art and written opinion. The patent corresponds to the documents originally submitted.

Biodegradable food packaging unit from a molded pulp material, and method for manufacturing such a food packaging unit

The present invention relates to food packaging units from a molded pulp material. Such food packaging unit may relate to cases, boxes, cups, plates, carriers, sip members etc.

Packaging units that are made from a molded pulp material are known. Such molded pulp often originates from recycled paper material and / or virgin fibers. These packaging units are used to store, transport and / or display a range of product, including food products such as eggs, tomatoes, kiwis.

Packaging units that come in contact with food products are subject to many restrictions. This often requires providing an additional film layer on or in the packaging unit, with the film layer acting as a barrier. This barrier separates the food product from the molded pulp material or the packaging unit.

One of the problems with such food packaging units including an additional film layer is that the packaging units are often not sustainable, or at least not fully sustainable. Furthermore, this use of an additional film layer also contains restrictions on the recycling possibilities.

The present invention has for its object to obviate or at least reduce the above stated problems in conventional food packaging units and to provide a food packaging unit that is more sustainable and / or has improved recycling possibilities.

For this purpose, the present invention provides a food packaging unit from a molded pulp material, with the packaging unit including a food receiving or carrying compartment, and the molded pulp material comprises an amount or polybutylene succinate (PBS).

The food packaging unit according to the invention comprises a compartment capable of receiving or carrying a food product. For example, a food receiving compartment may relate to a compartment capable of holding a food product, such as eggs, tomatoes, kiwis, or a container for holding a beverage. A carrying compartment may relate to a carrier surface whereon a food product can be placed, such as a plate, bottle divider etc.

According to the invention the molded pulp material or the packaging unit comprises an amount or polybutylene succinate (PBS). This PBS can be mixed in the original molded pulp material such that it is distributed over substantially the entire food packaging unit and / or can be provided as a separate layer on the side of the food packaging unit that may come in contact with a food product , for example. PBS is a biodegradable aliphatic polyester. PBS can also be referred to as polytetramethylene succinate.

PBS decomposes naturally into water, CO ₂ and biomass, providing a biodegradable alternative material to plastics, for example. The use of PBS as a compostable material contributor to providing a sustainable product.

The use of PBS is possible in food-contact applications including food packaging units from a molded pulp material. As mentioned PBS has good biodegradable properties and PBS can be decomposed to H ₂ O and CO ₂ . This improves recycling properties of the packaging units that are made from molded pulp and comprise PBS.

A further advantage of adding an amount of PBS is that the packaging unit can also be decomposed using microorganisms in soil, for example. This allows decomposing the food packaging unit including PBS as a whole. In such preferred embodiment, the food packaging unit can be decomposed at home. For example, the decomposition rate of PBS is much higher as compared to other agents or components such as PLA.

Therefore, the use of PBS in a food packaging unit from molded pulp significantly improves the sustainability of the packaging unit. This improves recycling possibilities and biodegrading or decomposing the packaging unit.

Another advantage when using PBS in a food packaging unit is the constancy of size or dimensional stability.

As a further advantage of the use of PBS, the so-called heat sealability of the packaging unit is improved. This further improves food packaging characteristics.

Another advantage of introducing an amount or PCS in a food packaging unit is that the properties of the packaging unit can be adjusted by mixing or blending PBS with other polymers or agents. Also, it is possible to prepare the PBS material for (paper) coating and printing. This further improves the sustainability of the packaging unit.

In one of the presently preferred embodiment of the invention, the amount of PBS in the food packaging unit is in a range of 0.5-20 wt.%, More preferably in the range or 1-15 wt.%.

By applying an amount or PBS in one of the aforementioned ranges, the sustainability and packaging characteristics of the food packaging unit according to the present invention is significantly improved.

As mentioned earlier, the food packaging unit may include one or more further agents in addition to the use of PBS. This allows a specific design of the food packaging unit characteristics and properties according to customer specifications or needs taking into account the specific food product.

Preferably, the one or more further agents comprise a biodegradable aliphatic polyester. The use of such biodegradable aliphatic polyester achieves that the food packaging unit maintains its sustainability and recycling properties, while improving specific characteristics of the food packaging unit. For example, the biodegradable aliphatic polyester may comprise an amount or one or more of PHB, PHA, PCL, PLA, PGA and PHBV. Preferably, the use of biodegradable aliphatic polyester is combined with the use of further additives or substances that aim at improving or achieving specific properties of the packaging unit. In further presently preferred out of the bio-polymers that are applied originate from so-called non-GMO (non-genetically modified organisms) biopolymers.

In one of the preferred possibilities of the invention the food packaging unit is biodegradable. More preferably, the unit is biodegradable at a temperature in the range of 5 to 60 ° C, preferably in the range of 5-40 ° C, more preferably in the range or 10-30 ° C, equally more preferably in the range or 15-25 ° C, and most preferably at a temperature of about 20 ° C. This renders decomposing or the packaging unit easier. Furthermore, this allows so-called ambient or at home decomposing or the packaging unit according to the invention.

Optionally, PBS can be manufactured from fossil resources. More preferably, PBS is bio-based and made from plant resources, for example. Such a bio-based PBS further improves the sustainability of the food packaging unit.

Optionally, the molded pulp material can be colored using additives, dyes, pigments or other components that provide color to the packaging unit. This allows providing the packaging unit with a color representative for its (intended) contents.

The present invention further relates to a method for manufacturing a food packaging unit from a molded pulp material, the method including the steps of:

preparing molded pulp material;

adding an amount or polybutylene succinate (PBS);

molding the food packaging unit; and releasing the food packaging unit from the mold.

Such method provides the same effects and advantages as described in relation to the food packaging unit. By adding an amount or PBS to the molded pulp material, a packaging unit can be manufactured from a blend comprising fibers and PBS, and / or a separate layer including PBS, can be achieved. This provides a food packaging unit that is more sustainable than conventional packaging units that are molded for food products. Optionally, other bio-material can be used in combination with PBS or as an alternative.

Preferably, the method comprises the step of adding an amount or PBS in the range or 0.520 wt.%, More preferably in the range or 1-15 wt.%. Experiments showed that adding an amount or PBS in these ranges provides a sustainable food packaging unit with appropriate characteristics.

Preferably, in the molding step of the food packaging unit, the PBS connects to the celluloid fibers or the molded pulp material. This provides a food packaging unit with sufficient strength.

In the fife cycle of the packaging unit, in the context of the present invention, the manufacturing process of the food packaging unit preferably also comprises the step of biodegrading the packaging unit. Therefore, in relation to the present invention, preferably also the biodegradation of the packaging unit is considered part of the entire manufacturing process. The biodegradation constitutes a significant part of the life cycle in view of the sustainability.

Preferably, the biodegrading comprises decomposing the food packaging unit.

Even more preferably, the decomposing is performed at a temperature in the range of 5-40 ° C, preferably in the range of 10-30 ° C, more preferably in the range of 15-25 ° C, and most preferably at a temperature or about 20 ° C, related to ambient decomposing.

In one of the presently preferred embodiment of the invention the manufacturing method further comprises the step of adding one or more further agents in addition to the PBS. The agents preferably include a biodegradable aliphatic polyester, preferably including an amount or one or more of PHB, PHA, PCL, PLA, PGA and PHBV. This further improves the product characteristics, preferably maintaining the sustainable properties. In presently preferred bio-polymers that are applied originate from so-called non-GMO biopolymers.

In a further preferred embodiment of the present invention, the method further comprises the step or in-mold drying of the packaging unit. In other variables, the method involves rough molding. The in-mold drying further improves the overall manufacturing possibilities. As a further effect, the connection between the PBS and the fiber material is enhanced.

In a presently preferred embodiment the unit is first molded into molds, where after the raw unit is transferred to drying molds to perform the in-mold drying. After drying the unit has been released and a high quality product has been achieved with a significantly lower surface roughness as compared to conventional products. Surface roughness can be measured using the Bendtsen measurement process, for example.

In one of the presently preferred expired surface roughness is further reduced by providing an amount of a surface roughness reducing agent, in some of these presently preferred expired agent including a biodegradable aliphatic polyester.

Further advantages, features and details of the invention are elucidated on the basis or preferred otherwise, where reference is made to the accompanying drawings, in which:

- Figure 1A and IB shows a packaging unit according to the invention including PBS;

- Figure 2 shows an example or an alternative food packaging product according to the present invention;

- Figure 3A and 3B shows an example of a further alternative food packaging product according to the present invention; and

- Figure 4A and B shows further packaging units for eggs according to the present invention.

Packaging unit 2 (figure 1A and B) carries or holds eggs and comprises cover part 4 and bottom part 6. Bottom part 6 is provided with back surface 8, sides 10 and front surface 12, and bottom surface 14. Cover part 4 is provided with back surface 16, side surfaces 18, front surface 20 and top surface 22. In the illustrated embodiment transition 24 is provided between top surface 22 and back and front surfaces 16, 20.

In the illustrated embodiment, top surface 22 or cover part 4 is provided with groove 26 including a number of aperture 28. Apertures 28 are defined by two adjacent arch-shaped edges 30, 32 having a larger thickness as compared to the average thickness of cover part 4.

Side surfaces 18 or cover part 4 are provided with denest nocks or denest elements 34. In the illustrated embodiment, bottom part 6 is provided with similar elements 36 mirroring denest elements 34. Hinge 38 connects back surface 16 or cover part 4 with back surface 8 or bottom part

6. Lock 40 comprises nose-shaped lock element 42 that is connected to flap 44 or bottom part 6. Cover part 4 is provided with opening 46 that capture lock elements 42 therewith defining lock 40.

In the illustrated embodiment, bottom part 6 is provided with a number of product receiving compartments 48, cones 50 and separating walls 52. Cone 50 extends from the bottom or bottom part 6 in an upward direction. Cover part 4 comprises cone support 54. Inner surface 58 or packaging unit 2 comprises PBS material, optionally as a film layer or alternatively blended and / or integrated with the fibers of the molded pulp material.

In the illustrated embodiment, packaging unit 2 comprises twelve product receiving compartments 48 that are provided in two rows or six compartments 48. Individual compartments 48 are separated from each other by walls 52 and cones 50. It will be understood that other configurations can also be envisage in accordance with the invention.

Packaging unit 2 may also be configured to receive other products, such as tomatoes, kiwis.

It will be understood that other types of food packaging units can also be envisaged in accordance with the present invention. As a further example, bottle divider 101 (Figure 2) is illustrated. Also, bottle divider 102 may contain a film layer or PBS and / or may contain an amount or PBS that is blended into the molded pulp.

A further example in accordance with the present invention is cover 202, for example for an ice cup. Another example of a packaging unit according to the invention is sip member 302 (Figure 3B). cover 202 and sip member 302 include a film layer or PBS and / or may include an amount of PBS that is blended into the molded pulp. This renders cover 202 and sip member 302 water or liquid repellent. One of the further advantages of PBS is the reduction or prevention of the liquid entering or migrating into the sip member material during use. Another advantage is the constancy of size or dimensional stability. In this specific case this prevents sip paragraph 302 loosening from a cup or beaker for hot beverages such as coffee, tea or soup, or cold beverages such as carbonated drinks, and cup 202 from loosing from an ice cup, for example. It will be understood that such members

302 can also be applied to other food containers. For example, paragraphs 302 can be applied to containers for milkshakes, for example. Further details and examples of paragraphs 302 are disclosed in WO 2010/064899, including various with specific flanges and notches.

It will be understood that other designs for packaging units are in accordance with the 5 invention can be envisaged. For example, containers 402, 502 (Figure 4 A and B) illustrate different designs for egg cartons capable of holding eggs P.

Other examples of food packaging products may relate to cup carriers, cups, plates and other table ware etc.

When manufacturing a food packaging unit 2, 102, 202, 302, 402, 502 a molded pulp 10 material is prepared. Optionally, an amount of PBS is blended or mixed into the molded pulp material and / or an amount of PBS is included in a separate layer that is provided in or on unit 2, 102, 202, 302, 402, 502. Such a separate layer may come in contact with a food product. Next, the raw unit is molded. Optionally, the raw unit is three-in-mold applying an in-mold drying process. Finally the product is released from the mold. Several post-molding operations may optionally have been performed in relation to unit 2, 102, 202, 302, 402, 502 optionally including, but not limited to, labeling, marking, testing.

The present invention is by no means limited to the above described preferred expend. The rights sought are defined by the following claims, within the scope of which many modifications can be envisaged.

Claims (17)

Clauses 1. Food packaging unit from a molded pulp material, the packaging unit including a food receiving or carrying compartment, the molded pulp material comprises an amount or polybutylene succinate (PBS). 2. Food packaging unit according to clause 1, whether the amount of PBS is in the range or 0.5-20 wt.%, More preferably in the range or 1-15 wt.%. 3. Food packaging unit according to clause 1 or 2, further including one or more further agents in addition to the PBS. 4. Food packaging unit according to clause 3, the one or more further agents comprising a biodegradable aliphatic polyester. 5. Food packaging unit according to clause 4, according to biodegradable aliphatic polyester comprises an amount or one or more or PHB, PHA, PCL, PLA, PGA and PHBV. 6. Food packaging unit according to one or more of the foregoing clauses, where the unit is biodegradable. 7. Food packaging unit according to clause 6, where the unit is biodegradable at a temperature in the range of 5 to 60 ° C, preferably in the range of 5 to 40 ° C, more preferably in the range or 10 to 30 ° C , even more preferably in the range of 15 to 25 ° C, and most preferably at a temperature of about 20 ° C. 8. Food packaging unit according to one or more of the foregoing clauses, according to the PBS is bio based. 9. Method for manufacturing a food packaging unit from a molded pulp material, the method including the steps of: preparing molded pulp material; adding an amount or polybutylene succinate (PBS); molding the food packaging unit; and releasing the food packaging unit from the mold. 10. Method according to clause 9, adding an amount or PBS in the range or 0.5-20 wt.%, More preferably in the range or 1-15 wt.%. 11. Method according to clause 9 or 10, molding the food packaging unit comprises 5 connecting PBS to cellulose fibers or the molded pulp material. 12. Method according to clause 9, 10 or 11, further including the step of biodegrading the packaging unit. 13. Method according to clause 12, biodegrading comprises decomposing the food packaging unit. 14. Method according to clause 13, where the decomposing is performed at a temperature in the range of 5 to 40 ° C, preferably in the range or 10 to 30 ° C, more preferably in the 15 range of 15 to 25 ° C, and most preferably at a temperature of about 20 ° C. 15. Method according to one or more of the clauses 9-14, further including the step of adding one or more further agents in addition to the PBS, the agents preferably including a biodegradable aliphatic polyester, preferably including an amount of one or more of PHB, PHA, PCL, PLA, PGA and PHBV. 16. Method according to one or more of the clauses 9-15, further including the step or in-mold drying of the packaging unit. Conclusions A food packaging made from a deformed pulp material, the packaging unit comprising a food receiving or carrying compartment, wherein the pulp material formed comprises an amount of polybutylene succinate (PBS). A food packaging unit according to claim 1, wherein the amount of PBS is in the range of 0.5-20% by weight, more preferably in the range of 1-15% by weight. A food packaging unit according to claim 1 or 2, further comprising one or more further agents in addition to the PBS. A food packaging unit according to claim 3, wherein the one or more further agents comprise a biodegradable aliphatic polyester. The food packaging unit according to claim 4, wherein the biodegradable aliphatic polyester comprises an amount of one or more of PHB, PHA, PCL, PLA, PGA and PHBV. Food packaging unit according to one or more of the preceding claims, wherein the unit is biodegradable. Food packaging unit according to claim 6, wherein the unit is biodegradable at a temperature in the range of 5 to 40 ° C, preferably in the range of 5-40 ° C, more preferably in the range of 10-30 ° C, even more preferably in the range of 15-25 ° C and most preferably at a temperature of about 20 ° C. A food packaging unit according to one or more of the preceding claims, wherein the PBS is of biological origin. 9. Method for manufacturing a food packaging unit from a formed pulp material, the method comprising the steps of: - manufacturing a shaped pulp material; - adding an amount of polybultylene succinate (PBS); - forming the food packaging unit; and - releasing the food packaging unit from the mold. The method of claim 9, wherein adding an amount of PBS is in the range of 0.5-20% by weight, preferably in the range of 1-15% by weight. A method according to claim 9 or 10, wherein forming the food packaging unit 5 comprising joining PBS with cellulose fibers of the formed pulp material. The method of claim 9, 10 or 11, further comprising the step of biodegrading the packaging unit. The method of claim 12, wherein the biodegradation comprises composting the food packaging unit. The method of claim 13, wherein the composting is performed at a Temperature in the range of 5 - 40 ° C, preferably in the range of 10 - 30 ° C, more preferably in the range of 15 - 25 ° C, and most preferably at a temperature of about 20 ° C. The method of any one of claims 9-14, further comprising the step of adding one or more further agents in addition to PBS, wherein the agents at Preferably comprising a biodegradable aliphatic polyester, preferably comprising an amount of one or more of PHB, PHA, PCL, PLA, PGA and PHBV. Method according to one or more of claims 9-15, further comprising the step of drying the packaging unit in the mold. 2/5 3/5 4/5 202 302 5/5 502 /? 7