SE2230125A1

SE2230125A1 - Method for manufacturing a disposable item

Info

Publication number: SE2230125A1
Application number: SE2230125A
Authority: SE
Inventors: Maria Törnblom; Martin Malmqvist
Original assignee: Stora Enso Oyj
Priority date: 2022-04-29
Filing date: 2022-04-29
Publication date: 2023-10-30
Also published as: WO2023209496A1

Abstract

A method for manufacturing a disposable item (10) comprises moistening (S1, S11) at least a portion of a sheet (110) or multiple sheets (210, 220, 230, 310, 320) with an aqueous solution, emulsion, dispersion and/or suspension to reduce a stiffness of the sheet(s) (110, 210, 220, 230, 310, 320). The sheet(s) (110, 210, 220, 230, 310, 320) is(are) a paper sheet, a paper board sheet or a pulp sheet. The method comprises providing (S2, S12), after the moistening step (S1, S11), a blank (100, 200, 300) comprising the sheet (110) or the multiple sheets (210, 220, 230, 310, 320) superimposed onto each other. The blank (100, 200, 300) has an average moisture content selected within a range of from 15 up to 60 weight-%. The method also comprises hot pressing (S3, S13) the blank (100, 200, 300) between heated matched molds defining a three-dimensional (3D) shape of the disposable item (10) to remove water from the blank (100, 200, 300) and form the disposable item (10). The disposable item (10) is cut out (S4, S13) simultaneously with or after hot pressing (S3, S13) the blank (100, 200, 300).

Description

METHOD FOR MANUFACTURING A DISPOSABLE ITEM TECHNICAL FIELD The present invention is generally directed to a method for manufacturing disposable items, and in particular disposable items that can be recycled within existing recycling streams.

BACKGROUND With growing awareness about our environment, disposable or single use plastic items have come more and more into question. Still, the use of these disposable plastic items has grown vastly with new trends in lifestyles and consumer habits of the last decade. ln particular, such disposable plastic items are frequently used within the fast food and takeaway food service sectors. Many brand owners are, however, looking for more sustainable solutions than disposable plastic items to decrease their environmental impact and climate footprint. ln particular, disposable plastic cutlery will be banned in European countries in the nearfuture following the implementation of the European Union Single Use Plastics (SUP) directive in national law. Many other countries have also begun to take legislative actions against disposable plastic items. All this increases the pressure to find new solutions.

More sustainable alternatives to plastics in the food service industry in the form of products made from wood or cellulose or lignocellulose fibers have existed for a long time. For instance, cups and trays made from board laminated with a thin polymer layer can be manufactured in a deep drawing process. Deeper trays, bowls and beakers can be made by a process known as pulp molding, wherein a ﬁber suspension is sucked against a wire mold by vacuum.

Cutlery items, however, present different challenges and the existing manufacturing processes, such as deep drawing and pulp molding, are not suitable for production of cutlery items. ln particular, cutlery items need to be sufﬁciently stiff not to bend much when used and still have comparatively small dimensions, such as thickness. Other requirements for cutlery items include the need for sharp edges, for knives, or prongs, for forks, that should be able to cut or penetrate most foodstuffs. lt is very hard to meet such requirements when producing cutlery items using the existing manufacturing processes.

Thus, there is a need for improved methods for manufacturing recyclable disposable items.

SUMMARY lt is a general objective to provide a method for manufacturing disposable items that can be recycled within existing recycling streams.

This and other objectives are met by embodiments of the present invention.

The present invention is deﬁned in the independent claims. Further embodiments of the invention are deﬁned in the dependent claims.

An aspect of the invention re|ates to a method for manufacturing a disposable item. The method comprises moistening at least a portion of a sheet or multiple sheets with an aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension to reduce a stiffness of the sheet or the multiple sheets. The sheet or each sheet of the multiple sheets is independently selected from the group consisting of a paper sheet, a paper board sheet and a pulp sheet. The method also comprises providing, after the moistening step, a blank comprising the sheet or the multiple sheets superimposed onto each other. The blank has an average moisture content selected within a range of from 15 up to 60 weight-%. The method further comprises hot pressing the blank betvveen heated matched molds defining a three- dimensional (3D) shape of the disposable item to remove water from the blank and form the disposable item. The method further comprises cutting out the disposable item simultaneously with or after hot pressing the blank.

Another aspect of the invention re|ates to a disposable item obtained by the method above.

The present method can produce disposable items based on paper sheets, paper board sheets and/or pulp sheets. The manufactured disposable items are recyclable in the existing recycling streams for such paper, paper board or pulp sheets. These disposable items are useful as environmentally friendly replacements of disposable plastic items, which are frequently used within the fast food and takeaway food service sectors.

BRIEF DESCRIPTION OF THE DRAWINGS The embodiments, together with further objects and advantages thereof, may best be understood by making reference to the following description taken together with the accompanying drawings, in which: Fig. 1 is a ﬂow chart illustrating a method for manufacturing a disposable item according to an embodiment; Fig. 2 is a ﬂow chart illustrating a method for manufacturing a disposable item according to another embodiment; Fig. 3 is a flow chart illustrating an additional, optional step of the method shown in Figs. 1 and 2; Fig. 4 is a flow chart illustrating an embodiment of the moistening step in Figs. 1 and 2; Fig. 5 is a flow chart illustrating an embodiment of the treating step in Fig. 4; Fig. 6 is a ﬂow chart illustrating an embodiment of the moistening and providing step in Figs. 1 and 2 and an additional, optional step of the method shown in Figs. 1 and 2; Fig. 7 is a flow chart illustrating an embodiment of the treating step in Fig. 6; Fig. 8 is a flow chart illustrating an additional, optional step of the method shown in Figs. 1 and 2; Fig. 9 schematically illustrates a blank according to an embodiment; Figs. 10A and 10B schematically illustrate superimposing multiple sheets (A) and a blank (B) according to another embodiment; Figs. 11A and 11B schematically illustrate superimposing multiple sheets (A) and a blank (B) according to a further embodiment; Fig. 12 schematically illustrates a blank according to yet another embodiment; and Fig. 13 schematically illustrates a disposable item according to an embodiment.

DETAILED DESCRIPTION The present invention is generally directed to a method for manufacturing disposable items, and in particular disposable items that can be recycled within existing recycling streams.

The present invention relates to a method for manufacturing disposable items as environmentally friendly alternatives to disposable plastic items. The disposable items are manufactured from one or more paper sheets, paper board sheets and/or pulp sheets. This means that the disposable items can, following use, be recycled in existing recycling streams for such paper, paper board or pulp materials.

The manufacturing method of the invention additionally enables manufacture of such disposable items that have mechanical properties, such as in terms of stiffness, flexural modulus and material thickness, to be used for various applications and purposes including, but not limited to, within the fast food and takeaway food service sectors.

Figs. 1 and 2 illustrate different embodiments of a method for manufacturing a disposable item, such as a disposable item 10 as shown in Fig. 13. Reference is also made to Figs. 9 to 11B. The method comprises moistening, in step S1 or S11, at least a portion of a sheet 110 (see Fig. 9) or multiple sheets 210, 220, 230, 310, 320 (see Figs. 10A to 11B) with an aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension to reduce a stiffness of the sheet 110 or the multiple sheets 210, 220, 230, 310, 320. The sheet 110 or each sheet 210, 220, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320 is independently selected from the group consisting of a paper sheet, a paper board sheet and a pulp sheet.

The method also comprises providing, in step S2 or S12 and after the moistening step S1 or S1 1, a blank 100, 200, 300 comprising the sheet 110 or the multiple sheets 210, 220, 230, 310, 320 superimposed onto each other. The blank 100, 200, 300 has an average moisture content selected within a range of from 15 up to 60 weight-% before hot pressing in step S3 or S13. The blank 100, 200, 300 is then hot pressed in step S3 or S13 between heated matched molds defining a three-dimensional (3D) shape of the disposable item 10 to remove water from the blank 100, 200, 300 and form the disposable item 10. The method further comprises cutting out, in step S4 or S13, the disposable item 10 simultaneously with hot pressing in step S13 (see Fig. 2) or after hot pressing in step S3 (see Fig. 1). ln Fig. 1, the cutting step S4 is a method step separate from and following the hot pressing step S3, whereas in Fig. 2, step S13 is a combined hot pressing and cutting step.

The moistening of the one or more sheets 110, 210, 220, 230, 310, 320 in step S1 or S11 is performed to at least partly break hydrogen bonds between fibers in the one or more sheets 110, 210, 220, 230, 310, 320. As a result of this moistening in step S1 or S11, the stiffness of the one or more sheets 110, 210, 220, 230, 310, 320 is reduced to make the one or more sheets 110, 210, 220, 230, 310, 320 more malleable and moldable. ln more detail, water in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension applied to at least a portion of the one or more sheets 110, 210, 220, 230, 310, 320 in step S1 or S11 interferes with ﬁber-to-fiber hydrogen bonds in the sheet material to thereby loosen these hydrogen bonds and the ﬁber-to-fiber bonds, such as by at least partly breaking these bonds. Such a loosening of the fiber-to-ﬁber bonds reduces the stiffness of the one or more sheets 110, 210, 220, 230, 310, 320 and thereby of the blank 100, 200, 300 provided in step S2 or S12 from the one or more sheets 110, 210, 220, 230, 310, 320. The stiffness reduction of the blank 100, 200, 300 and its one or more sheets 110, 210, 220, 230, 310, 320 is performed according to the invention in order to form the disposable item 10 from the blank 100, 200, 300 in the hot pressing step S3 or S13. The initial stiffness of the one or more sheets 110, 210, 220, 230, 310, 320 prior to moistening in step S1 or S11 is generally too high to effectively form disposable items 10 having a 3D shape in the heated matched molds during hot pressing in step S3 or S13. The initial high stiffness of the one or more sheets 110, 210, 220, 230, 310, 320 could interfere with the hot pressing of the blank 100, 200, 300 as the blank 100, 200, 300 is then less moldable. As a consequence, the blank 100, 200, 300 may in fact break during hot pressing due to low moldability and strainability. The present invention reduces these problems of paper sheets, paper board sheets and pulp sheets to enable hot pressing of a blank 100, 200, 300 made of one or more such sheets 110, 210, 220, 230, 310, 320 into a disposable item 10 having a defined 3D shape. This means that the method of the invention as shown in Figs. 1 and 2 thereby enables usage of one or more paper sheets, paper board sheets and/or pulp sheets in the manufacture of disposable items 10.

Moisture content or average moisture content as referred to herein for the blank 100, 200, 300 or for each of the one or more sheets 110, 210, 220, 230, 310, 320 relates to the moisture content or average moisture content at ambient conditions (relative humidity (Rh) of 30-50% and room temperature (20- 25°C)). The moisture content can be determined according to an oven-drying method as speciﬁed in ISO 287:201? Paper and board - Determination of moisture content of a lot- Oven-drying method.

Generally, the average moisture content of each of the one or more sheets 110, 210, 220, 230, 310, 320 prior to moistening in step S1 or S11 is low, typically no more than 10 % by weight at ambient conditions. For instance, paper sheets, paper board sheets and pulp sheets generally have an average moisture content within 3 to 10 % by weight in ambient conditions, most typically within 7 to 10 % by weight in ambient conditions. The average moisture content at such ambient conditions is sometimes referred to as equilibrium moisture content.

The corresponding average moisture content of each of the one or more sheets 110, 210, 220, 230, 310, 320 after the moistening step S1 or S11 and therefore of the blank 100, 200, 300 provided in step S2 or S12 is at least 15 % by weight, preferably at least 20 % by weight, such as selected within a range of from 15 to 60 % by weight or preferably from 20 to 60 % by weight. ln a particular embodiment, the average moisture content of each of the one or more sheets 110, 120, 130 after the moistening step S1 or S11 and the blank 100, 200, 300 provided in step S2 or S12 is preferably selected within a range of from 15 to 50 % by weight, such as from 20 to 50 % by weight, and more preferably selected within a range of from 15 to 40 % by weight, such as from 20 to 40 % by weight. This increase in average moisture content makes the one or more sheets 110, 210, 220, 230, 310, 320 and therefore the blank 100, 200, 300 sufﬁciently malleable and moldable to form the disposable item 10 by hot pressing the blank 100, 200, 300 betvveen heated matched molds in step S3 or S13.

The hot pressing of step S3 or S13 then removes water from the blank 100, 200, 300 and form the disposable item 10. The removal of water during hot pressing mediates the formation of new fiber-to-ﬁber hydrogen bonds in the formed disposable item 10. This in turn contributes to improving the stiffness and stability of the disposable item 10. Water may be removed from the blank 100, 200, 300 during hot pressing in step S3 or S13 at least partly by being pressed out from the blank 100, 200, 300 by the heated matched molds pressing into the blank 100, 200, 300. Alternatively, or in addition, heat from the heated matched molds may cause evaporation of water and moisture in the blank 100, 200, 300 and thereby at least partly removal of water through evaporation from the blank 100, 200, 300. ln most cases, water is removed from the blank 100, 200, 300 both by pressing out and by evaporation depending, for example, at least partly on the temperature of the heated matched molds and the pressing time of the hot pressing in step S3 or S13.

At least one of the heated matched molds may be perforated or porous to facilitate removal of water and/or steam during the hot pressing in step S3 or S13. Porous molds are known in the art, for instance, as disclosed in WO 2020/141208. As an example, a porous mold comprises a mold body arranged with small holes, passages or pores allowing liquid / gas to pass through. ln an embodiment, a pressure difference may be applied over the perforated or porous mold(s) to facilitate removal of water from the hot pressed blank 100, 200, 300 through the holes, passages, or pores in the perforated or porous mold(s) during the hot pressing in step S3 or S13.

The average moisture content of the disposable item 10 as manufactured in step S4 or S13 is typically equal to or below 10 % by weight in ambient conditions, such as equal to or below 8 % by weight or equal to or below 6 % by weight in ambient conditions.

Depending on the average moisture content of the one or more sheets 110, 210, 220, 230, 310, 320 following the moistening in step S1 or S11 and thereby also of the blank 100, 200, 300 as provided in step S2 or S12, it may be beneﬁcial to include an additional step in the method as indicated in Fig. 3. ln such an embodiment, the method continues from step S2 in Fig. 1 or step S12 in Fig. 2. A next step S20 comprises cold pressing the blank 100, 200, 300 between matched molds deﬁning a 3D shape of a precursor of the disposable item 10 in the blank 100, 200, 300 to remove water from the blank 100, 200, 300. The method then continues to step S3 in Fig. 1 or step S13 in Fig. 2, which, in this embodiment, comprises hot pressing the precursor in the blank 100, 200, 300 between the heated matched molds to remove water from the blank 100, 200, 300 and form the disposable item 10. The cold pressing in step S20 is preferably conducted with unheated matched molds, such as in ambient temperatures. ln this embodiment, a cold pressing step S20 is performed prior to hot pressing in step S3 or S13. The initial cold pressing is then performed to remove at least a portion of the water or moisture in the blank 100, 200, 300 prior to exposing the blank 100, 200, 300 to heat in the hot pressing. ln some instances, and depending on the hot pressing conditions, a large quantity of steam or water vapor may be generated in a short period of time when hot pressing the blank 100, 200, 300 between the heated matched molds if the blank 100, 200, 300 has a high average moisture content together with using comparatively high temperatures and short hot pressing time. Such a large quantity of steam may be hard to effectively divert away from the hot pressed blank 100, 200, 300. ln such a case, it may therefore be beneﬁcial to cold press out at least a portion of the water or moisture from the blank 100, 200, 300 before hot pressing in step S3 or S13. This then means that less water evaporation will take place during the hot pressing, which in turn simplifies an effective diversion of the generated steam or water vapor.

The cold pressing in step S20 may also contribute to moisten also deeper portions of the sheets 110, 210, 220, 230, 310, 320 to thereby press the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension into the interior of the sheets 110, 210, 220, 230, 310, 320. The cold pressing may, thus, even out the moisture content in the sheets 110, 210, 220, 230, 310, 320.

The matched molds used in the cold pressing of step S20 may have substantially the same molding shape as the heated matched molds used in the hot pressing. This means that the precursor cold pressed in the blank 100, 200, 300 in step S20 will have substantially the same 3D shape as the disposable item 10. ln another embodiment, the matched molds used in the cold pressing of step S20 may impart a different 3D shape into the blank 100, 200, 300 as compared to the heated matched molds. ln such a case, the precursor may have a different 3D shape as compared to the disposable item 10. As an illustrative, but non-limiting, example the precursor could have the general 3D shape of the disposable item 10, such as spoon-shaped for a disposable item 10 as shown in Fig. 13, but have a larger overall size as compared to the disposable item 10. The precursor in the blank 100, 200, 300 will then be hot pressed in step S3 or S13 into the intended 3D shape of the disposable item 10.

At least one of the matched molds may be perforated or porous to facilitate removal of water during the cold pressing in step S20. ln an embodiment, a pressure difference may be applied over the perforated or porous mold(s) to facilitate removal of water from the pressed blank 100, 200, 300 through the holes, passages, or pores in the perforated or porous mold(s) during the cold pressing in step S20. ln an embodiment, the moistening step S1 or S11 is performed as shown in Fig. 4. ln such an embodiment, at least a portion of at least one surface 112, 114 of the sheet 110 or at least a portion of a surface 212, 234, 312, 324 of one or two sheets 210, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320 is treated in step S30 with a surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. ln this embodiment, the providing step S2 in Fig. 1 or S12 in Fig. 2 comprises providing, after the treating step S30, the blank 100, 200, 300 comprising the sheet 110 or the multiple sheets 210, 220, 230, 310, 320 superimposed onto each other with the treated surface 212, 234, 312, 324 of the one or two sheets 210, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320 forming an outer surface 202, 204, 302, 304 of the blank 200, 300. ln the embodiment as shown in Fig. 9, at least a portion of one of the surfaces 112, 114 of the sheet 110 could be treated with the surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension in step S30. This treated surface 112, 114 then constitutes an outer surface 102, 104 of the blank 100. ln another embodiment, at least a portion of both the surfaces 112, 114 of the sheet 110 in Fig. 9 is treated with the surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension in step S30. These treated surfaces 112, 114 are then the outer surfaces 102, 104 of the blank 100. ln these embodiments, the complete surface or surfaces 112, 114 of the sheet 110 could be treated in step S30. Alternatively, only a portion of the surface or surfaces 112, 114 of the sheet 110 is treated in step S30. ln this latter case, the portion of the surface or surfaces 112, 114 treated with the surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension could correspond to the portion of the blank 100 that is hot pressed in step S3 or S13 to form the disposable item 10. Alternatively, the portion of the surface or surfaces 112, 114 treated in step S30 corresponds to a part of the portion of the blank 100 that is hot pressed in step S3 or S13 to form the disposable item 10, such as the part corresponding to the spoon head of the disposable item 10 shown in Fig. 13. ln the embodiment as shown in Figs. 10A to 10B, at least a portion of one of the surfaces 212 of a ﬁrst sheet 210 or at least a portion of one of the surfaces 234 of a third sheet 230 is treated with the surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension in step S30. The first sheet 210, a second sheet 220 and the third sheet 230 are then superimposed onto each other as shown in Fig. 10B with the second sheet 220 sandwiched in between the ﬁrst sheet 210 and the third sheet 230. ln such a case, the treated surface 212 of the ﬁrst sheet 210 or the treated surface 234 of the third sheet 230 forms an outer surface 202, 204 of the blank 200. Hence, the treated surface 212, 234 faces opposite to and away from an adjacent sheet 220 in the blank 200 once the sheets 210, 220, 230 have been superimposed or stacked onto each other in step S2 or S12. ln another embodiment, at least a portion of one of the surfaces 212 of the ﬁrst sheet 210 and at least a portion of one of the surfaces 234 of the third sheet 230 are treated in step S30. This then means that both outer surfaces 202, 204 of the blank 200 will be treated surfaces once the sheets 210, 220, 230 have been superimposed onto each other as shown in Fig. 10B. ln these embodiments, the complete surface 212 of the first sheet 210 and/or the complete surface 234 of the third sheet 230 could be treated in step S30. Alternatively, merely a portion of the surface 212 of the ﬁrst sheet 210 and/or a portion of surface 234 of the third sheet 230 is/are treated with the surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. ln yet other embodiments, the complete surface 212 of the ﬁrst sheet 210 but only a portion of the surface 234 of the third sheet 230 are treated in step S30 or a portion of the surface 212 of the ﬁrst sheet 210 but the complete surface 234 of the third sheet 230 are treated in step S30.

The embodiments described above with reference to Figs. 10A and 10B also apply to the case where the blank 200 comprises more than three sheets 210, 220, 230, i.e., more than one so-called intermediate sheet 220 arranged in the blank 200 between the two outer sheets 210, 230. ln the embodiment as shown in Figs. 11A to 11B, at least a portion of one of the surfaces 312 of a ﬁrst sheet 310 or at least a portion of one of the surfaces 324 of a second sheet 320 is treated with a surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. The first sheet 310 and the second sheet 320 are then superimposed onto each other as shown in Fig. 11B. ln such a case, the treated surface 312 of the first sheet 310 or the treated surface 324 of the second sheet 320 constitute an outer surface 302, 304 of the blank 300. Hence, the treated surface 312, 324 faces opposite to and away from an adjacent sheet 320, 310 in the blank 300 once the sheets 310, 320 have been superimposed or stacked onto each other. ln another embodiment, at least a portion of one of the surfaces 312 of the ﬁrst sheet 310 and at least a portion of one of the surfaces 324 of the second sheet 320 are treated in step S30. This then means that both outer surfaces 302, 304 of the blank 300 will be treated surfaces once the sheets have been superimposed onto each other as shown in Fig. 11B. ln these embodiments, the complete surface 312 of the first sheet 310 and/or the complete surface 324 of the second sheet 320 could be treated in step S30. Alternatively, merely a portion of the surface 312 of the ﬁrst sheet 310 and/or a portion of the surface 324 of the second sheet 320 is/are treated with the surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. ln yet other embodiments, the complete surface 312 of the first sheet 310 but only a portion of the surface 324 of the second sheet 320 are treated in step S30 or a portion of the surface 312 of the ﬁrst sheet 310 but the complete surface 324 of the second sheet 320 are treated in step S30. ln a particular embodiment, step S30 comprises treating at least a portion of both surfaces 112, 114 of the sheet 110 or at least a portion of one surface 212, 234, 312, 324 of two sheets 210, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320 with the surface treatment agent in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. ln this particular embodiment, step S2 in Fig. 1 or step S12 in Fig. 2 comprises providing, after the treating step S30, the blank 100, 200, 300 comprising the sheet 110 or the multiple sheets 210, 220, 230, 310, 320 superimposed onto each other with the treated surfaces 212, 234, 312, 324 of the two sheets 210, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320 forming outer surfaces 202, 204, 302, 304 of the blank 200, 300. 11 Hence, in this particular embodiment, both the outer surfaces 102, 104, 202, 204, 302, 304, or a respective portion thereof, of the blank 100, 200, 300 are treated with the surface treatment agent in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension.

The treatment of at least a portion of at least one surface 112, 114 of the sheet 110 in Fig. 9 or at least a portion of a surface 212, 234, 312, 324 of one or two sheets 210, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320 in Figs. 10A to 11B is performed in order to obtain a blank 100, 200, 300 having at least a portion of one or both its outer surfaces 102, 104, 202, 204, 302, 304 treated with the surface treatment agent. The surface treatment agent thereby provides a treatment effect to at least a portion of the outer surface(s) 102, 104, 202, 204, 302, 304 of the blank 100, 200, 300. This treatment effect is then obtained on at least a portion of the surface of the disposable item 10. Hence, at least a portion of a surface of the disposable item 10 has a surface treatment obtained from the surface treatment agent.

The surface treatment agent in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension is applied onto at least a portion of a surface 112, 114, 212, 234, 312, 324 of at least one sheet 110, 210, 230, 310, 320. However, water in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension may penetrate into at least a portion of the thickness of the treated sheet 110, 210, 230, 310, 320 to thereby moisten, dampen, wet or hydrate also internal parts of the one or more sheets 110, 210, 230, 310, 320. The surface treatment agent may also penetrate into a depth of the one or more sheets 110, 210, 230, 310, 320 with the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. Hence, surface treatment with the surface treatment agent as used herein also encompasses that not merely the outer surface of a sheet 110, 210, 230, 310, 320 is treated with the surface treatment agent but also a portion of the sheet 110, 210, 230, 310, 320 beneath the treated surface may be treated with the surface treatment agent. However, water from the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension may penetrate into at least a portion of the thickness of the sheet 110, 210, 230, 310, 320 or indeed the complete thickness of the sheet 110, 210, 230, 310, 320.

The treatment in step S30 in Fig. 4 or step S40 in Fig. 5 has dual purposes. Firstly, the surface treatment agent provides a surface treatment to at least a portion of a surface treated with the surface treatment agent in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. Secondly, water in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension penetrates into the treated sheet 110, 210, 230, 310, 320 and will thereby moisten the sheet 110, 210, 230, 310, 320. This moistening loosens, as previously described herein, ﬁber-to-ﬁber hydrogen 12 bonds and thereby improves the moldability of the treated sheet 110, 210, 230, 310, 320 and therefore of the blank 100, 200, 300 as provided in step S2 or S12. As a consequence, the blank 100, 200, 300 is more easily hot pressed in step S3 or S13 to form the disposable item 10.

Various surface treatment agents could be used according to the embodiments depending on which treatment effect or effects that is desired for the disposable agent 10. ln an embodiment, the surface treatment agent is a surface protective agent, which thereby achieves a protective effect to the surface. lllustrative, but non-limiting, examples of such surface protective agents include hydrophobation or sizing agents, wet-strength agents, dry-strength agents, barrier forming agents and grease-proofing agents.

Hydrophobation or sizing agents are used to change the absorption characteristics of the treated surface(s), or a portion thereof, of the blank 100, 200, 300 and thereby of at least a portion of a surface of the disposable item 10. ln particular, hydrophobation or sizing agents can be used to make the treated surface, or the treated portion thereof, more resistant against absorption of water and aqueous liquids from goods, articles, foodstuff and beverages that may be in contact with surface(s) of the disposable item 10 during use. lllustrative, but non-limiting, examples of such hydrophobation or sizing agents include waxes, alkyl keten dimer (AKD) and/or alkenylsuccinic anhydride (ASA).

Wet-strength agents typically act by making the treated surface(s) or surface portion(s) more hydrophobic, such as by forming water resistant bonds between ﬁbers, in the treated sheet 110 or sheets 210, 230, 310, 320. This means that a disposable item 10 formed from a blank 100, 200, 300 having one or both of its outer surfaces 102, 104, 202, 204, 302, 304, or a portion thereof, treated with wet-strength agent will be more resistant against absorption of water and liquids during use.

Dry-strength agents, sometimes referred to as dry-strength resins, are multifunctional agents that can be used to enhance the sheet strength, such as bursting strength, compressing strength, tensile strength and/or internal bond strength, but also to improve drainage of liquids from the ﬁbers in the sheet. lllustrative, but non-limiting, examples of such dry-strength agents include polyacrylamide (PAM) co- polymers, Hoffman type PAM, anionic PAM, starch grafted PAM, and cationic starch.

Barrier forming agents that could be used according to the invention are conﬁgured to form a water and/or grease-resistant barrier or ﬁlm, such as during hot pressing. Such agents thereby restrict absorption of 13 liquids and/or grease by a surface of a disposable item 10 formed from a blank 100, 200, 300 having one or both its outer surfaces 102, 104, 202, 204, 302, 304, or a portion thereof, treated with a barrier forming agent. Examples of such barrier forming agents include various types of polymers and polymer including compositions.

Grease-proofing agents used to change the absorption characteristics of the treated surface(s), or a portion thereof, of the blank 100, 200, 300 and thereby of at least a portion of a surface of the disposable item 10. ln particular, grease-prooﬁng agents can be used to make the treated surface, or the treated portion thereof, more resistant against absorption of grease and hydrophobic liquids from goods, articles, foodstuff and beverages that may be in contact with surface(s) of the disposable item 10 during use. Examples of such grease-proofing agent are waxes.

Hence, in an embodiment, the surface treatment agent is a surface protective agent selected from the group consisting of a hydrophobation or sizing agent, a wet-strength agent, a dry-strength agent, a barrier forming agent conﬁgured to form a water and/or grease-resistant barrier, a grease-prooﬁng agent and any combination thereof.

Other examples of surface treatment agents that could be used according to the invention include pigments, dyes, surface structure agents, etc.

Fig. 5 is a flow chart illustrating various embodiments of the treating step S30 in Fig. 4. Step S40 of Fig. 5 comprises spraying, roll coating, blade coating and/or curtain coating at least the portion of at least one surface 112, 114 of the sheet 110 or at least the portion of the surface 212, 234, 312, 324 of the one or two sheets 210, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320 with the surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension.

The spraying embodiment typically comprises spraying the surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension from one or more spray nozzles in the form of an aerosol or spray onto the at least one portion of the one or tvvo surfaces 112, 114, 212, 234, 312, 324. ln roll coating, one or a series of rollers are used to apply coating of the surface treatment agent onto the one or more sheets 110, 210, 230, 310, 320. Blade coating, also referred to as doctor blade coating, uses a blade or knife to form a ﬁlm of the surface treatment agent onto at least the portion of the one or more surfaces 112, 114, 212, 234, 312, 324. Curtain coating is a process, in 14 which a sheet 110, 210, 230, 310, 320 is guided through a curtain of the surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension in a gap betvveen tvvo conveyors.

Fig. 6 is a ﬂow chart illustrating another embodiment of the moistening step S1 in Fig. 1 and S11 in Fig. 2 applicable for the case with multiple sheets 210, 220, 230, 310, 320 in blank 200, 300 as provided in step S2 or S12. This embodiment comprises treating, in step S50, at least a portion of a surface 214, 222, 224, 232, 314, 322 of at least one sheet 210, 220, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320 with a binder in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension to form a binder-treated surface 214, 222, 224, 232, 314, 322. ln this embodiment, the providing step is performed as shown in step S51 of Fig. 6. This step S51 comprises superimposing the multiple sheets 210, 220, 230, 310, 320 onto each other with the binder-treated surface 214, 222, 224, 232, 314, 322 of the at least one sheet 210, 220, 230, 310, 320 facing another sheet 210, 220, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320 to provide the blank 200, 300.

The binder-treated surface or surfaces 214, 222, 224, 232, 314, 322 is or are, thus, so-called internal surface or surfaces in the blank 200, 300 in terms of not being any outer surface 202, 204, 302, 304 of the blank 200, 300 but rather facing an adjacent sheet 210, 220, 230, 310, 320 in the blank 200, 300. ln the embodiment as shown in Figs. 10A to 10B, at least a portion of one of the surfaces 214 of the first sheet 210, at least a portion of one or both surfaces 222, 224 of the second sheet 220 or at least a portion of one of the surfaces 232 of the third sheet 230 is treated with a binder present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. ln such a case, the binder-treated surface 214 of the first sheet 210, the binder-treated surface or surfaces 222, 224 of the second sheet 220 or the binder-treated surface 232 of the third sheet 230 forms an internal surface of the blank 200. Hence, the binder-treated surface or surfaces 214, 222, 224, 232 faces or face an adjacent sheet 210, 220, 230 in the blank 200 once the multiple sheets 210, 220, 230 have been superimposed or stacked onto each other. ln another embodiment, at least a portion of one of the surfaces 214 of the ﬁrst sheet 210, at least a portion of one or both surfaces 222, 224 of the second sheet 220 and at least a portion of one of the surfaces 232 of the third sheet 230 are treated in step S50. This then means that all internal surfaces of the blank 200 will be binder-treated surfaces once the sheets 210, 220, 230 have been superimposed onto each other as shown in Fig. 10B. However, the embodiments are not limited thereto. ln clear contrast, only one, two, three or indeed all of the internal surfaces 214, 222, 224, 232 in Figs. 10A, 10B could be binder-treated surfaces. For instance, at least a portion of one of the surfaces 214 of the ﬁrst sheet 210 and at least a portion of one of the surfaces 234 of the third sheet 230 or at least a portion of both surfaces 222, 224 of the second sheet 220 are treated in step S50. ln case of treating three surfaces, at least a portion of one of the surfaces 214 of the first sheet 210 and at least a portion of both surfaces 222, 224 of the second sheet 220; at least a portion of one of the surfaces 214 of the ﬁrst sheet 210, at least a portion of one of the surfaces 222, 224 of the second sheet 220 and at least a portion of one of the surfaces 234 of the third sheet 230; or at least a portion of both surfaces 222, 224 of the second sheet 220 and at least a portion of one of the surfaces 234 of the third sheet 230 are treated in step S50. ln these embodiments, the complete surface 214 of the ﬁrst sheet 210, the complete surface or surfaces 222, 224 of the second sheet 220 and/or the complete surface 232 of the third sheet 230 could be treated in step S50. Alternatively, merely a portion of the surface 212 of the ﬁrst sheet 210, a portion of the surface or surfaces 222, 224 of the second sheet 220 and/or a portion of the surface 232 of the third sheet 230 is/are treated with the binder present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. lt is also possible to combine treatment of a complete surface of one sheet with a partial treatment of another surface of the sheet or of a surface of another sheet.

The embodiments described above with reference to Figs. 10A and 10B also apply to the case where the blank 200 comprises more than three sheets 210, 220, 230, i.e., more than one so-called intermediate sheet 220 arranged in the blank 200 between the tvvo outer sheets 210, 230. ln the embodiment as shown in Figs. 11A to 11B, at least a portion of one of the surfaces 314 of the first sheet 310 or at least a portion of one of the surfaces 322 of the second sheet 320 is treated with a binder present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. The first sheet 310 and the second sheet 320 are then superimposed onto each other as shown in Fig. 11B. ln such a case, the binder-treated surface 314 of the first sheet 310 faces the second sheet 320 in the blank 300 or the binder-treated surface 322 of the second sheet 320 faces the ﬁrst sheet 310 in the blank 300. ln another embodiment, at least a portion of one of the surfaces 314 of the ﬁrst sheet 310 and at least a portion of one of the surfaces 322 of the second sheet 320 are treated in step S50. This then means that both internal surfaces of the blank 300 will be binder-treated surfaces once the sheets 310, 320 have been superimposed onto each other as shown in Fig. 11B. 16 ln these embodiments, the complete surface 314 of the first sheet 310 and/or the complete surface 322 of the second sheet 320 could be treated in step S50. Alternatively, merely a portion of the surface 314 of the ﬁrst sheet 310 and/or a portion of the surface 322 of the second sheet 320 is/are treated with the binder present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. ln yet other embodiments, the complete surface 314 of the ﬁrst sheet 310 but only a portion of the surface 322 of the second sheet 320 are treated in step S50 or a portion of the surface 314 of the first sheet 310 but the complete surface 322 of the second sheet 320 are treated in step S50.

The treatment in step S50 may be performed according to any of the embodiments shown in step S60 in Fig. 7. This step S60 comprises spraying, roll coating, blade coating and/or curtain coating at least the portion of the surface 214, 222, 224, 232, 314, 322 of the at least one sheet 210, 220, 230, 310, 320 with the binder in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension to form the binder-treated surface 214, 222, 224, 232, 314, 322.

The various implementation examples of these treatment embodiments as described above in connection with Fig. 5 also apply to the treatment embodiments of Fig. 7.

The treatment in step S50 in Fig. 6 or step S60 in Fig. 7 has dual purposes. Firstly, the binder achieves binding of the adjacent sheets 210, 220, 230, 310, 320 in the blank 200, 300. Hence, the binder promotes binding of fibers in the adjacent sheets 210, 220, 230, 310, 320 to each other. This will increase the adhesion between the different sheets 210, 220, 230, 310, 320 in the blank 200, 300 and further contributes to the stiffness of the disposable item 10 following hot pressing in step S3 or S13. Secondly, water in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension penetrates into the treated sheet(s) 210, 220, 230, 310, 320 and will thereby moisten the sheet(s) 210, 220, 230, 310, 320. This moistening loosens, as previously described herein, ﬁber-to-ﬁber hydrogen bonds and thereby improves the moldability of the treated sheet(s) 210, 220, 230, 310, 320 and therefore of the blank 200, 300 as provided in step S2 or S12. As a consequence, the blank 200, 300 is more easily hot pressed in step S3 or S13 to form the disposable item 10.

The binder in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension is applied onto at least a portion of a surface 214, 222, 224, 232, 314, 322 of at least one sheet 210, 220, 230, 310, 320. However, water in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension may penetrate into at least a portion of the thickness of the treated sheet 210, 220, 17 230, 310, 320 to thereby moisten or wet also internal parts of the one or more sheets 210, 220, 230, 310, 320. The binder may also penetrate into a depth of the one or more sheets 210, 220, 230, 310, 320 with the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. Hence, treatment with the binder as used herein also encompasses that not merely the outer surface of a sheet 210, 220, 230, 310, 320 is treated with the binder but also a portion of the sheet 210, 220, 230, 310, 320 beneath the treated surface may be treated with the binder. However, water from the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension may penetrate into at least a portion of the thickness of the sheet 110, 210, 230, 310, 320 or indeed the complete thickness of the sheet 110, 210, 230, 310, 320.

The treatment with the binder in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension as disclosed in step S50 in Fig. 6 or step S60 in Fig. 7 can be combined with the treatment with the surface treatment agent in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension in step S30 in Fig. 4 or step S40 in Fig. 5. ln such an embodiment, at least a portion of a surface 212, 234, 312, 324 of one or tvvo sheets 210, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320 is treated with the surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension and at least a portion of a surface 214, 222, 224, 232, 314, 322 of at least one sheet 210, 220, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320 is treated with the binder in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. The one or tvvo surfaces 212, 234, 312, 324 treated with the surface treatment agent then form outer surface or surfaces 202, 204, 302, 304 of the blank 200, 300, whereas the at least one surface 214, 222, 224, 232, 314, 322 treated with the binder will be internal surfaces of the blank 200, 300 and thereby face an adjacent sheet 210, 220, 230, 310, 320 in the blank 200, 300. The treatment with the surface treatment agent and the treatment with the binder can be performed at least partly in parallel or sequentially in any order. ln this embodiment, different aqueous solutions, aqueous emulsions, aqueous dispersions and/or aqueous suspensions are used to treat the sheets 210, 220, 230, 310, 320. A ﬁrst such aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension comprises the surface treatment agent and is used to treat at least a portion of a surface 212, 234, 312, 324 of one or two sheets 210, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320. Correspondingly, a second aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension comprises the binder and is used to treat at least a portion of a surface 214, 222, 224, 232, 314, 322 of at least one sheet 210, 220, 230, 310, 320 of the multiple sheets 210, 220, 230, 310, 320. Hence, in an embodiment, the surface(s) 18 treated with the ﬁrst aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension comprising the surface treatment agent is different from the surface(s) with the second aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension comprising the binder. ln an embodiment, the binder is selected from the group consisting of a natural glue, a synthetic glue, and any combination thereof. lllustrative, but non-limiting, examples of natural glues or adhesives include wheat or flour paste, corn starch, wheat starch, potato starch, pea starch, protein-based glues, such as casein glues or albumen glues, natural resins, such as gum Arabic, tragacanth, colophony, natural rubber, waxes. lllustrative, but non-limiting, examples of synthetic glues or adhesives include such glues or adhesives based on elastomers, thermoplastics, emulsions, and thermosets. Examples include poly(vinyl acetate), poly(vinyl alcohol), poly(vinyl acetal)s, polystyrene, polyaerylates, polymethacrylates, polyacrylamides, poly(cyanoacrylate)s, polyamides and saturated polyesters, polyurethanes, cellulose acetate, cellulose nitrate, cellulose acetate-butyrate, methyl cellulose, hydroxy ethyl cellulose, carboxy ethyl cellulose, phenol-formaldehydes, resorcinol formaldehydes, urea-formaldehydes, melamine formaldehydes, polyepoxides, epoxy-polyamide, epoxy-bitumen, epoxy-polysulphide, unsaturated polyesters, polybenzimidazole, polyimide, and polybenzothiazole. ln another embodiment, the binder is selected from the group consisting of a natural polymer, a synthetic polymer and any combination thereof. lllustrative, but non-limiting, examples of natural polymers include starch, agar, carrageenan, guar gum, locust been gum, and micro-fibrillated cellulose (MFC).

MFC as used herein means a cellulose particle, ﬁber or ﬁbril having a width or diameter of from 20 nm to 1000 nm.

Various methods exist to make MFC, such as single or multiple pass reﬁning, pre-hydrolysis followed by reﬁning or high shear disintegration or liberation of ﬁbrils. One or several pre-treatment steps is usually required in order to make MFC manufacturing both energy efficient and sustainable. The cellulose ﬁbers of the pulp used when producing MFC may, thus, be native or pre-treated enzymatically or chemically, for example to reduce the quantity of hemicellulose and/or lignin. The cellulose fibers may be chemically modiﬁed before fibrillation, wherein the cellulose molecules contain functional groups other (or more) than found in the original cellulose. Such groups include, among others, carboxymethyl (CM), aldehyde and/or carboxyl groups (cellulose obtained by N-oxyl mediated oxidation, for example "TEMPO"), or quaternary 19 ammonium (cationic cellulose). After being modified or oxidized in one of the above-described methods, it is easier to disintegrate the fibers into MFC.

MFC can be produced from wood cellulose ﬁbers, both from hardwood or softvvood ﬁbers. lt can also be made from microbial sources, agricultural ﬁbers, such as wheat straw pulp, bamboo, bagasse, or other non-wood ﬁber sources. lt can be made from pulp, including pulp from virgin fiber, e.g., mechanical, chemical and/or thermomechanical pulps. lt can also be made from broke or recycled paper. lllustrative, but non-limiting, examples of synthetic polymers include poly(vinyl acetate), poly(vinyl poly(vinyl poly(cyanoacrylate)s, polyamides and saturated polyesters, polyurethanes, cellulose acetate, cellulose alcohol), acetal)s, polystyrene, polyaerylates, polymethacrylates, polyacrylamides, nitrate, cellulose acetate-butyrate, methyl cellulose, hydroxy ethyl cellulose, carboxy ethyl cellulose, phenol-formaldehydes, resorcinol formaldehydes, urea-formaldehydes, melamine formaldehydes, polyepoxides, epoxy-polyamide, epoxy-bitumen, epoxy-polysulphide, unsaturated polyesters, polybenzimidazole, polyimide, and polybenzothiazole.

Paper as used herein generally refers to a material manufactured in thin sheets from the pulp of wood or other fibrous substances comprising cellulose ﬁbers, used for e.g., writing, drawing, or printing on, or as packaging material. Paper as used herein also encompass tissue paper.

Paperboard generally refers to strong, thick paper or cardboard comprising cellulose ﬁbers used for e.g., boxes and other types of packaging. Paperboard can either be bleached or unbleached, coated or uncoated, and produced in a variety of thicknesses, depending on the end use requirements.

Examples of pulp sheets that can be used according to the invention include pulp dried in sheets, for instance on rolls, or cut to bales. An example of such pulp sheets includes fluff pulp sheets. ln an embodiment, pulp sheets, sometimes also referred to cellulose pulp sheets, include any commodity form of pulp dried in the form of sheets in the pulp production. ln an embodiment, the blank 200, 300 comprises multiple sheets 210, 220, 230, 310, 320, such as shown in Figs. 10B or 11B. This embodiment is in particular preferred to achieve a sufﬁcient thickness of the blank 200, 300 to be hot pressed in step S3 or S13 to form the disposable item 10 even though individual sheets 210, 220, 230, 310, 320 may be too thin to be hot pressed into such a disposable item 10. A further advantage of using multiple sheets 210, 220, 230, 310, 320 is that the stiffness of the disposable item 10 once hot pressed and cut out from the blank 200, 300 is generally higher as compared to merely using a blank 100 with a single sheet 110. ln these embodiments, all the sheets 210, 220, 230, 310, 320 provided in the blank 200, 300 could be of a same type, i.e., same material and having same characteristics. However, it is also possible to use different types of sheets 210, 220, 230, 310, 320 in the blank 200, 300 to tailor or control the characteristics or properties of the blank 200, 300 and thereby of the disposable item 10, such as basis weight, density, ﬁber composition, thickness, stiffness, flexural modulus, etc. Hence, by using multiple sheets 210, 220, 230, 310, 320 in the blank 200, 300, the characteristics or properties can be more easily controlled as compared to using only a single sheet 100. This is schematically shown in Figs. 10A and 10B where the ﬁrst and third sheets 210, 230 are of the same type of sheet, whereas the second sheet 220 is of another type. Correspondingly, Figs. 11A and 11B illustrate a case when using two different types of sheets 310, 320.

As an illustrative example for the embodiment shown in Figs. 10A and 10B, the outer sheets 210, 230 of the blank 200 could be sheets having a higher tensile strength as compared to the intermediate sheet 220. This intermediate sheet 220 could then be used as a bulk material for the blank 200 and thereby for the disposable item 10 manufactured from the blank 200.

Hence, in an embodiment, the blank 200, 300 comprises a ﬁrst type of sheet 21 0, 230, 310 and a second, different type of sheet 220, 320. The blank 200, 300 could then comprise one or multiple sheets 210, 230, 310 of the first type and one or multiple sheets 220, 320 of the second type. This embodiment can further be extended to cases with three or more different types of sheets in the blank 200, 300.

Fig. 6 also illustrates an optional step S52, which comprises pressing the multiple sheets 210, 220, 230, 310, 320 together following step S51 but prior to hot pressing in step S3 or S13. This pressing in step S52 facilitates binding of the multiple sheets 210, 220, 230, 310, 320 together to thereby simplify handling of the blank 200, 300 in the hot pressing since the multiple sheets 210, 220, 230, 310, 320 are thereby bonded together and can more easily be handled as a single unit.

The solvent used in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension used in the treatment step S30 or S40 could be the same solvent as used in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension as used in the treatment step S50 or S60. Alternatively, different solvents could be used. The solvent or solvents is preferably water or an aqueous solvent that is mixture of water and at least one other solvent, such as one or more low chain alcohols.

The aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension used in step S30 or S40 may comprise a single surface treatment agent or a mixture of different surface treatment agents. Correspondingly, one aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension comprising at least one surface treatment agent could be used to moisten and treat one surface, or a portion thereof, whereas another aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension comprising at least one surface treatment agent is used to moisten and treat another surface, or a portion thereof. However, it is generally preferred if all surfaces, or portions thereof, treated in step S30 or S40 are treated with the same at least one surface treatment agent in the same aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension.

Correspondingly, the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension used in step S50 or S60 may comprise a single binder or a mixture of different binders. Correspondingly, one aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension comprising at least one surface treatment agent could be used to moisten and treat one surface, or a portion thereof, whereas another aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension comprising at least one surface treatment agent is used to moisten and treat another surface, or a portion thereof. However, it is generally preferred if all surfaces, or portions thereof, treated in step S50 or S60 are treated with the same at least one binder in the same aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension. ln an embodiment, the blank 300 may comprise at least one surface layer or liner disposed on an outer surface 302, 304 of the blank 300. Fig. 12 illustrates an example of a blank 300 comprising such a surface layer 340 provided on an outer surface 302 of the blank 300. Such a surface layer 340 is preferably a paper or board product, such as a liner, e.g., a kraft liner, or tissue paper, which could be added to promote the strength and/or stiffness of the disposable item 10 as manufactured from the blank 300 or provide a desired surface characteristic of the disposable item 10. ln such an embodiment, the method may comprise an additional step S70 as shown in Fig. 8. This step S70 comprises providing at least one surface layer 340 of a paper product to at least one outer surface 302, 304 of the blank 300.

The hot pressing in step S3 or S13 preferably uses a heated pressing tool that has heated matched molds with rigid pressing surfaces that deﬁne the 3D shape of the disposable item 10. ln an embodiment, the heated matched molds are heated rigid matched molds. The rigid molds may contain movable parts but are preferably made to be rigid, i.e., non-deformable. These molds, or at least the pressing surfaces 22 thereof, are typically made of metal or a metal alloy, such as steel or aluminum, but also polymer materials could be used. The hot pressing not only presses a portion of the blank 100, 200, 300 to form the disposable item 10 but also heats at least a portion of the blank 100, 200, 300. The heating causes removal of water through evaporation but also promotes binding of the sheets 210, 220, 230, 310, 320 together if the blank 200, 300 comprises multiple sheets 210, 220, 230, 310, 320. The blank 100, 200, 300, or at least a portion thereof aligned with the heated matched molds, is preferably heated to a temperature above 100°C but below 250°C. The higher temperature limit is typically dependent on the fiber material or materials of the sheet(s) 110, 210, 220, 230, 310, 320 in the blank 100, 200, 300 and should not be too high to damage the fibers in the sheet(s) 110, 210, 220, 230, 310, 320. ln a preferred embodiment, the blank 100, 200, 300, or at least a portion thereof, is heated to a temperature selected within a range of from 150 up to 220°C in the hot pressing step S3 or S13. ln an embodiment, the pressure used in the hot pressing in step S3 or S13 is preferably at least 5 MPa. ln a preferred embodiment, the blank 100, 200, 300 is hot pressed with a pressure selected within a range of from 5 up to 100 MPa, such as within a range of from 21 up to 100 MPa, preferably within a range of from 25 up to 100 MPa. ln an embodiment, the disposable item 10 is cut out of the blank 100, 200, 300 after hot pressing as shown in step S4 in Fig. 1. ln such an embodiment, the hot pressing in step S3 and the cutting in step S4 are two separate operations. The cutting step S4 may then be performed using various types of cutting tools including, but not limited to, a saw, a cutter and a stamping die. ln another embodiment, the disposable item 10 is cut out of the blank in step S13 simultaneously with hot pressing the blank 100, 200, 300. ln such an embodiment, one or both heated matched molds comprise one or more cutting tools to cut out the disposable item 10 simultaneously with hot pressing these heated matched molds into the blank 100, 200, 300. Alternatively, a separate cutting tool could be arranged in vicinity of the heated matched molds and could then be operated for cutting out the disposable item 10 from the blank 100, 200, 300 when the heated matched molds are hot pressed into the blank 100, 200, 300. ln a typical embodiment, multiple disposable items 10 are formed and cut out from the blank 100, 200, 300 in steps S3 and S4 or S13. Hence, a single blank 100, 200, 300 is preferably used to manufacture a plurality of disposable items 10. 23 ln an embodiment, the blank 100, 200, 300 has a grammage selected within a range of from 500 up 3000 g/m2 dry weight. ln a particular embodiment, the blank 100, 200, 300 has a grammage selected within a range of from 800 up to 3000 g/m2 dry weight. ln these embodiments, the combined grammage of the at least one sheet 110, 210, 220, 230, 310, 320 in the blank 100, 200, 300 has the above listed grammage. ln an embodiment, the sheet 110 or the multiple sheets 210, 220, 230, 310, 320 comprises or comprise natural ﬁbers, and in particular wood ﬁbers. ln a particular embodiment, the wood ﬁbers are cellulose and/or lignocellulose fibers. Hence, in an embodiment, the one or more sheets 110, 210, 220, 230, 310, 320 comprise cellulose, such as in the form of cellulose and/or lignocellulose, i.e., a mixture of cellulose and lignin. The natural ﬁbers may also contain lignin, such as in the form of lignocellulose. The natural fibers may additionally contain hemicellulose. ln a particular embodiment, the natural fibers are cellulose and/or lignocellulose pulp ﬁbers produced by chemical, mechanical and/or chemi-mechanical pulping of softvvood and/or hardwood. For instance, the cellulose and/or lignocellulose pulp ﬁbers are in a form selected from the group consisting of sulfate pulp, sulfite pulp, dissolving pulp, thermomechanical pulp (TMP), high temperature thermomechanical pulp (HTMP), mechanical ﬁber intended for medium density (MDF-ﬁber), (CTMP), high thermomechanical pulp (HTCTMP), and a combination thereof. fiberboard chemi-thermomechanical pulp temperature chemi- The natural ﬁbers can also be produced by other pulping methods and/or from other cellulosic or lignocellulosic raw materials, such as flax, jute, hemp, kenaf, bagasse, cotton, bamboo, straw or rice husk. ln an embodiment, the one or more sheets 110, 210, 220, 230, 310, 320 has a fiber composition of 100 % natural ﬁbers, such as 100 % wood fibers, or 100 % cellulose and/or lignocellulose ﬁbers. ln an embodiment, the one or more sheets 110, 210, 220, 230, 310, 320 comprise at least 90 % by dry weight cellulose and/or lignocellulose ﬁbers. ln a particular embodiment, the one or more sheets 110, 210, 220, 230, 310, 320 comprise at least 95 % by dry weight, such at least 97 % by dry weight, and preferably at least 99 % by dry weight of cellulose and/or lignocellulose ﬁbers.

The one or more sheets 110, 210, 220, 230, 310, 320 may, thus, also contain one or more additives, already present in the one or more sheets 110, 210, 220, 230, 310, 320 as input to the method. The one or more optional additives are preferably selected among additives commonly used in the production of 24 paper sheets, paper board sheets and/or pulp sheets. lllustrative, but non-limiting, examples of such additives include retention agents, sizing agents, starches, ﬁllers and dyes.

The method of the invention can be used to produce various types of disposable items 10, and in particular such disposable items that can be used as rep|acements of disposable p|astic items, for instance within the fast food and takeaway food service sectors. lllustrative, but non-Iimiting, examples of such disposable items 10 include cutlery items, such as knives, forks, spoons and/or stirrers, lids, such as cup lids, blister packs, portion packing and caps, such as screw caps.

The invention therefore also relates to a disposable item 10 obtainable by the method according to any of the embodiments.

The embodiments described above are to be understood as a few illustrative examples of the present invention. lt will be understood by those skilled in the art that various modifications, combinations and changes may be made to the embodiments without departing from the scope of the present invention. ln particular, different part solutions in the different embodiments can be combined in other configurations, where technically possible.

Claims

1. A method for manufacturing a disposable item (10), the method comprises the steps of: moistening (S1, S11) at least a portion of a sheet (110) or multiple sheets (210, 220, 230, 310, 320) with an aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension to reduce a stiffness of the sheet (110) or the multiple sheets (210, 220, 230, 310, 320), wherein the sheet (110) or each sheet (210, 220, 230, 310, 320) of the multiple sheets (210, 220, 230, 310, 320) is independently selected from the group consisting of a paper sheet, a paper board sheet and a pulp sheet; providing (S2, S12), after the moistening step (S1, S11), a blank (100, 200, 300) comprising the sheet (110) or the multiple sheets (210, 220, 230, 310, 320) superimposed onto each other, wherein the blank (100, 200, 300) has an average moisture content selected within a range of from 15 up to 60 weight- %; hot pressing (S3, S13) the blank (100, 200, 300) betvveen heated matched molds deﬁning a three- dimensional (3D) shape of the disposable item (10) to remove water from the blank (100, 200, 300) and form the disposable item (10); and cutting (S4, S13) out the disposable item (10) simultaneously with or after hot pressing (S3, S13) the blank (100, 200, 300).

2. The method according to claim 1 , further comprising the step of cold pressing (S20) the blank (100, 200, 300) between matched molds deﬁning a 3D shape of a precursor of the disposable item (10) in the blank (100, 200, 300) to remove water from the blank (100, 200, 300), wherein the hot pressing step (S3, S13) comprises hot pressing (S3, S13) the precursor in the blank (100, 200, 300) between the heated matched molds to remove water from the blank (100, 200, 300) and form the disposable item (10).

3. The method according to claim 1 or 2, wherein the moistening step (S1, S11) comprises treating (S30) at least a portion of at least one surface (112, 114) of the sheet (110) or at least a portion of a surface (212, 234, 312, 324) of one or two sheets (210, 230, 310, 320) of the multiple sheets (210, 220, 230, 310, 320) with a surface treatment agent present in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension; and the providing step (S2, S12) comprises providing (S2, S12), after the treating step (S30), the blank (100, 200, 300) comprising the sheet (1 10) or the multiple sheets (210, 220, 230, 310, 320) superimposed onto each other with the treated surface (212, 234, 312, 324) of the one or two sheets (210, 230, 310, 320) of the multiple sheets (210, 220, 230, 310, 320) forming an outer surface (202, 204, 302, 304) of the blank (200, 300).

4. The method according to claim 3, wherein the treating step (S30) comprises spraying, roll coating, blade coating and/or curtain coating (S40) at least the portion of the at least one surface (112, 114) of the sheet (110) or at least the portion of the surface (212, 234, 312, 324) of the one or tvvo sheets (210, 230, 310, 320) of the multiple sheets (210, 220, 230, 310, 320) with the surface treatment agent in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension.

5. The method according to claim 3 or 4, wherein the treating step (S30) comprises treating (S30) at least a portion of both surfaces (112, 114) of the sheet (110) or at least a portion of one surface (212, 234, 312, 324) of tvvo sheets (210, 230, 310, 320) of the multiple sheets (210, 220, 230, 310, 320) with the surface treatment agent in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension; and the providing step (S2, S12) comprises providing (S2, S12), after the treating step (S30), the blank (100, 200, 300) comprising the sheet (1 10) or the multiple sheets (210, 220, 230, 310, 320) superimposed onto each other with the treated surfaces (212, 234, 312, 324) of the tvvo sheets (210, 230, 310, 320) of the multiple sheets (210, 220, 230, 310, 320) forming outer surfaces (202, 204, 302, 304) of the blank (200, 300).

6. The method according to any one of claims 3 to 5, wherein the surface treatment agent is a surface protective agent selected from the group consisting of a hydrophobation or sizing agent, a wet-strength agent, a dry-strength agent, a barrier forming agent conﬁgured to form a water and/or grease-resistant barrier, a grease-prooﬁng agent and any combination thereof.

7. The method according to any one of claims 1 to 6, wherein the moistening step (S1, S11) comprises treating (S50) at least a portion of a surface (214, 222, 224, 232, 314, 322) of at least one sheet (210, 220, 230, 310, 320) of the multiple sheets (210, 220, 230, 310, 320) with a binder in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension to form a binder-treated surface (214, 222, 224, 232, 314, 322); and the providing step (S2, S12) comprises superimposing (S51) the multiple sheets (210, 220, 230, 310, 320) onto each other with the binder-treated surface (214, 222, 224, 232, 314, 322) of the at least one sheet (210, 220, 230, 310, 320) facing another sheet (210, 220, 230, 310, 320) of the multiple sheets (210, 220, 230, 310, 320) to provide the blank (200, 300).

8. The method according to claim 7, wherein the treating step (S50) comprises spraying, roll coating, blade coating and/or curtain coating (S60) at least the portion of the surface (214, 222, 224, 232, 314, 322) of the at least one sheet (210, 220, 230, 310, 320) with the binder in the aqueous solution, aqueous emulsion, aqueous dispersion and/or aqueous suspension to form the binder-treated surface (214, 222, 224, 232, 314, 322).

9. The method according to claim 7 or 8, wherein the blank (200, 300) comprises a ﬁrst type of sheet (210, 230, 310) and a second, different type of sheet (220, 320).

10. The method according to any one of claims 7 to 9, further comprising the step of pressing (S52) the multiple sheets (210, 220, 230, 310, 320) together following the superimposing step (S51) but prior to the hot pressing step (S3, S13).

11. The method according to any one of claims 7 to 10, wherein the binder is selected from the group consisting of a natural glue, a synthetic glue and any combination thereof.

12. The method according to any one of claims 7 to 10, wherein the binder is selected from the group consisting of a natural polymer, a synthetic polymer, and any combination thereof.

13. The method according to any one of claims 1 to 12, further comprising the step of providing (S70) at least one surface layer (340) of a paper product to at least one outer surface (302, 304) of the blank (300).

14. The method according to any one of claims 1 to 13, wherein the cutting step (S4, S13) comprises cutting (S13) the disposable item (10) out of the blank (100, 200, 300) simultaneously with hot pressing (S13) the blank (100, 200, 300).

15. The method according to any one of claims 1 to 13, wherein the cutting step (S4, S13) comprises cutting (S4) the disposable item (10) out of the blank (100, 200, 300) after hot pressing (S3) the blank (100, 200, 300).

16. The method according to any one of claims 1 to 15, wherein at least one of the heated matched molds is a perforated or porous mold.

17. The method according to any one of claims 1 to 16, wherein the hot pressing step (S3, S13) comprises hot pressing (S3, S13) the blank (100, 200, 300) betvveen heated matched rigid molds deﬁning the 3D shape of the disposable item (10) to remove water from the blank (100, 200, 300) and form the disposable item (10).

18. The method according to any one of claims 1 to 17, wherein the blank (100, 200, 300) has a grammage selected within a range of from 500 up to 3000 g/m2 dry weight, preferably selected within a range of from 800 up to 3000 g/m2 dry weight.

19. The method according to any one of claims 1 to 18, wherein the blank (100, 200, 300) has an average moisture content before the hot pressing step (S3, S13) selected within a range of from 20 up to 60 weight-%.

20. The method according to any one of claims 1 to 19, wherein the sheet (110) comprises or the multiple sheets (210, 220, 230, 310, 320) comprise cellulose and/or lignocellulose fibers, preferably cellulose and/or lignocellulose pulp ﬁbers produced by chemical, mechanical and/or chemi-mechanical pulping of softwood and/or hardwood.

21. The method according to claim 20, wherein the cellulose and/or lignocellulose ﬁbers are cellulose and/or lignocellulose pulp fibers in a form selected from the group consisting of sulfate pulp, sulﬁte pulp, dissolving pulp, thermomechanical pulp (TMP), high temperature thermomechanical pulp (HTMP), mechanical ﬁber intended for medium density ﬁberboard (MDF-ﬁber), chemi-thermomechanical pulp (CTMP), high temperature chemi-thermomechanical pulp (HTCTMP), and a combination thereof.

22. The method according to claim 20 or 21 , wherein the sheet (110) comprises or the multiple sheets (210, 220, 230, 310, 320) comprise at least 90 % by dry weight, preferably at least 95 % by dry weight, more preferably at least 97 % by dry weight, and most preferably at least 99 % by dry weight of the cellulose and/or lignocellulose fibers.

23. The method according to any one of claims 1 to 22, wherein the disposable item (10) is selected from the group consisting of a cutlery item, a lid, a blister pack, a portion packing, and a screw cap.

24. A disposable item (10) obtainable by the method according to any one of claims 1 to 23.