US20200109518A1 - Method for manufacturing a compostable plate - Google Patents

Method for manufacturing a compostable plate Download PDF

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Publication number
US20200109518A1
US20200109518A1 US16/617,730 US201816617730A US2020109518A1 US 20200109518 A1 US20200109518 A1 US 20200109518A1 US 201816617730 A US201816617730 A US 201816617730A US 2020109518 A1 US2020109518 A1 US 2020109518A1
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US
United States
Prior art keywords
compostable
mold part
protective layer
manufacturing
plate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US16/617,730
Inventor
Gianluca Clarichetti
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Individual
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Individual
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Filing date
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Publication of US20200109518A1 publication Critical patent/US20200109518A1/en
Abandoned legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/80—Paper comprising more than one coating
    • D21H19/82—Paper comprising more than one coating superposed
    • D21H19/826—Paper comprising more than one coating superposed two superposed coatings, the first applied being pigmented and the second applied being non-pigmented
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G19/00—Table service
    • A47G19/02—Plates, dishes or the like
    • A47G19/03—Plates, dishes or the like for using only once, e.g. made of paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/10—Coatings without pigments
    • D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
    • D21H19/20—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/10—Coatings without pigments
    • D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
    • D21H19/24—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/80—Paper comprising more than one coating
    • D21H19/82—Paper comprising more than one coating superposed
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H25/00—After-treatment of paper not provided for in groups D21H17/00 - D21H23/00
    • D21H25/04—Physical treatment, e.g. heating, irradiating
    • D21H25/06—Physical treatment, e.g. heating, irradiating of impregnated or coated paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/40—Bio-organic fraction processing; Production of fertilisers from the organic fraction of waste or refuse

Definitions

  • the present invention relates to a method for manufacturing a compostable plate.
  • the main limitation of the above mentioned disposable compostable plates consists in the impossibility of carrying out printed designs, for example for personalization.
  • a biodegradable element is not in fact automatically also compostable.
  • a material is defined as biodegradable if it can be broken down, by bacteria, sunlight and other natural physical agents, into simple chemical compounds like water, carbon dioxide and methane. This process applies to a great many materials, but each element has its own degradation time, which may be long. European regulations draw clear lines, however. In order to be considered biodegradable, a product must be broken down by 90% within 6 months.
  • the material In order to be considered compostable (convertible to compost, a natural fertilizer) the material not only must be biodegradable but also must be decomposable, and the decomposition process must occur in less than 3 months.
  • the aim of the present invention is to make available a method for manufacturing a compostable plate which is capable of improving the known art in one or more of the above mentioned aspects.
  • an object of the invention is to make available a compostable plate that can easily be printed.
  • Another object of the invention is to make it possible to personalize compostable plates.
  • Another object of the invention is to provide a compostable plate and a method for manufacturing a compostable plate that are highly reliable, easy to implement and low cost.
  • FIG. 1 is a cutaway perspective view of a supporting layer associated with a printed design and covered by a protective layer;
  • FIG. 2 is a view similar to FIG. 1 ;
  • FIG. 3 is a perspective view of the cardboard of the supporting layer associated with a printed design and covered by a protective layer after cutting or die-punching;
  • FIG. 4 is a perspective view of a plate
  • FIGS. 5 to 7 are views that are similar, respectively, to those in FIGS. 2 to 4 , of a variation of embodiment of the printed design.
  • the compostable plate generally designated by the reference numeral 1 , comprises a supporting layer 2 made of compostable cardboard which has at least one printed portion 3 which is printed with compostable ink.
  • the plate further has at least one protective layer 5 , which is arranged at least above the surface that defines each printed portion 3 .
  • the protective layer 5 comprises a compostable biopolymer.
  • the protective layer 5 is arranged at the surface that is intended to provide the concave part of the compostable plate 1 .
  • the compostable biopolymer comprises a film with a thickness comprised between 12 ⁇ m and 30 ⁇ m, and preferably between 19 ⁇ m and 23.8 ⁇ m.
  • Such film can be obtained by way of extrusion or spreading of the biopolymer on the supporting layer 2 , at the surface that defines the printed portion 3 or the printed portions 3 .
  • the compostable biopolymer has a melting temperature of more than 135° C.
  • the supporting layer 2 made of compostable paper comprises substantially cellulose paste.
  • an ink commercially designated with the wording Hidromat-B 463 made by La Sorgente S.P.A., Italy has been found to be particularly adapted to the purpose.
  • the present invention relates to a method for manufacturing a compostable plate 1 .
  • the method comprises:
  • the compostable biopolymer used to provide the protective layer 5 is mixed, prior to the step of spreading, with a master batch of granules.
  • such master batch is adapted to fluidify the biopolymer and therefore to facilitate the step of spreading.
  • the step of forming comprises a thermoforming.
  • thermoforming is carried out by insertion, between a male mold part and a female mold part, of the supporting layer 2 which has the printed portion or portions 3 and the protective layer 5 .
  • thermoforming is performed at a temperature comprised between 60° C. and 75° C. as regards the male mold part and between 120° C. and 130° C. as regards the female mold part.
  • the male mold part has a coupling surface which is designed to press against the protective layer 5 .
  • the coupling surface of the male mold part has a plastic coating that is adapted to limit the temperature of the coupling surface.
  • such plastic coating comprises a layer of Teflon.
  • the present invention makes it possible to provide a completely compostable plate provided by way of a thermoforming process.

Landscapes

  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Laminated Bodies (AREA)
  • Fertilizers (AREA)
  • Containers Having Bodies Formed In One Piece (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Abstract

A method for manufacturing a compostable plate which comprises:
    • a step of manufacturing a supporting layer made of compostable cardboard;
    • a step of printing at least one portion to be printed of the supporting layer made of compostable cardboard in order to obtain at least one respective printed portion, the step of printing being carried out using compostable inks;
    • a step of spreading, at least over the surface that defines the at least one printed portion, a compostable biopolymer in order to provide a protective layer;
    • a step of forming in order to provide a compostable plate, the step of forming comprising a thermoforming by insertion, between a male mold part and a female mold part, of the supporting layer which has the printed portion or portions and the protective layer.

Description

  • The present invention relates to a method for manufacturing a compostable plate.
  • Nowadays disposable compostable plates are known, which are made of cellulose pulp obtained for the most part from sugar cane.
  • The main limitation of the above mentioned disposable compostable plates consists in the impossibility of carrying out printed designs, for example for personalization.
  • It is furthermore important to emphasize that sometimes the term ‘compostable’ is considered a synonym of the term ‘biodegradable’.
  • On the contrary, there is a substantial difference between the terms ‘compostable’ and ‘biodegradable’.
  • A biodegradable element is not in fact automatically also compostable.
  • A material is defined as biodegradable if it can be broken down, by bacteria, sunlight and other natural physical agents, into simple chemical compounds like water, carbon dioxide and methane. This process applies to a great many materials, but each element has its own degradation time, which may be long. European regulations draw clear lines, however. In order to be considered biodegradable, a product must be broken down by 90% within 6 months.
  • In order to be considered compostable (convertible to compost, a natural fertilizer) the material not only must be biodegradable but also must be decomposable, and the decomposition process must occur in less than 3 months.
  • The aim of the present invention is to make available a method for manufacturing a compostable plate which is capable of improving the known art in one or more of the above mentioned aspects.
  • Within this aim, an object of the invention is to make available a compostable plate that can easily be printed.
  • Another object of the invention is to make it possible to personalize compostable plates.
  • Another object of the invention is to provide a compostable plate and a method for manufacturing a compostable plate that are highly reliable, easy to implement and low cost.
  • This aim and these and other objects which will become better apparent hereinafter are achieved by a method for manufacturing a compostable plate according to claim 1, optionally provided with one or more of the characteristics of the dependent claims.
  • Further characteristics and advantages of the invention will become better apparent from the description of some preferred, but not exclusive, embodiments of the compostable plate and of the method for manufacturing a compostable plate according to the invention, which are illustrated for the purposes of non-limiting example in the accompanying drawings wherein:
  • FIG. 1 is a cutaway perspective view of a supporting layer associated with a printed design and covered by a protective layer;
  • FIG. 2 is a view similar to FIG. 1;
  • FIG. 3 is a perspective view of the cardboard of the supporting layer associated with a printed design and covered by a protective layer after cutting or die-punching;
  • FIG. 4 is a perspective view of a plate;
  • FIGS. 5 to 7 are views that are similar, respectively, to those in FIGS. 2 to 4, of a variation of embodiment of the printed design.
    •
  • With reference to the figures, the compostable plate, generally designated by the reference numeral 1, comprises a supporting layer 2 made of compostable cardboard which has at least one printed portion 3 which is printed with compostable ink.
  • The plate further has at least one protective layer 5, which is arranged at least above the surface that defines each printed portion 3.
  • In particular, the protective layer 5 comprises a compostable biopolymer.
  • The protective layer 5 is arranged at the surface that is intended to provide the concave part of the compostable plate 1.
  • Advantageously, the compostable biopolymer comprises a film with a thickness comprised between 12 μm and 30 μm, and preferably between 19 μm and 23.8 μm.
  • Such film can be obtained by way of extrusion or spreading of the biopolymer on the supporting layer 2, at the surface that defines the printed portion 3 or the printed portions 3.
  • Conveniently, the compostable biopolymer has a melting temperature of more than 135° C.
  • The product commercially designated with the wording MATER-BI CX01A made by Novamont SpA, Italy has been found to be particularly adapted to the purpose.
  • Conveniently, the supporting layer 2 made of compostable paper comprises substantially cellulose paste.
  • With regard to the compostable inks, an ink commercially designated with the wording Hidromat-B 463 made by La Sorgente S.P.A., Italy has been found to be particularly adapted to the purpose.
  • According to a further aspect, the present invention relates to a method for manufacturing a compostable plate 1.
  • The method comprises:
      • a step of manufacturing a supporting layer 2 made of compostable cardboard;
      • a step of printing at least one portion to be printed of the supporting layer 2 made of compostable cardboard in order to obtain at least one respective printed portion 3, the step of printing being carried out using compostable inks;
      • a step of spreading, at least at the surface that defines the printed portion or portions 3, a compostable biopolymer in order to provide a protective layer 5;
      • a step of forming in order to provide a compostable plate.
  • To provide the protective layer, it has been found to be particularly adapted to use the product commercially designated with the wording MATER-BI CX01A made by Novamont SpA, Italy.
  • Preferably, the compostable biopolymer used to provide the protective layer 5 is mixed, prior to the step of spreading, with a master batch of granules.
  • In particular, such master batch is adapted to fluidify the biopolymer and therefore to facilitate the step of spreading.
  • It has been found to be particularly efficacious to use a compostable ink that is free from amines.
  • In this regard, it has been found to be particularly suitable to use a product commercially designated with the wording Hidromat-B 463 made by La Sorgente S.P.A., Italy.
  • The step of forming comprises a thermoforming.
  • Specifically, the thermoforming is carried out by insertion, between a male mold part and a female mold part, of the supporting layer 2 which has the printed portion or portions 3 and the protective layer 5.
  • The thermoforming is performed at a temperature comprised between 60° C. and 75° C. as regards the male mold part and between 120° C. and 130° C. as regards the female mold part.
  • The male mold part has a coupling surface which is designed to press against the protective layer 5.
  • The coupling surface of the male mold part has a plastic coating that is adapted to limit the temperature of the coupling surface.
  • Preferably, such plastic coating comprises a layer of Teflon.
  • In practice it has been found that the invention fully achieves the intended aim and objects by providing a method for manufacturing compostable plates that is extremely reliable and capable of ensuring a high ratio of quality to production cost.
  • The present invention makes it possible to provide a completely compostable plate provided by way of a thermoforming process.
  • By virtue of identifying the compostable biopolymer intended to provide the protective layer 5, a solution has been obtained that makes it possible, notwithstanding the pressures and temperatures of thermoforming, to obtain a plate that is completely compostable and printed.
  • Furthermore, with the same performance, a product has been obtained that is lighter and less voluminous, as well as printed, decorated or personalized.
  • The possibility for personalization is very important for large companies which thus can highlight their respect for the environment by using compostable products with their brand and therefore preferring them to plates made from recycled cardboard.
  • The invention, thus conceived, is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims. Moreover, all the details may be substituted by other, technically equivalent elements.
  • In practice the materials employed, provided they are compatible with the specific use, and the contingent dimensions and shapes, may be any according to requirements and to the state of the art.
  • The disclosures in Italian Patent Application No. 102017000059261 from which this application claims priority are incorporated herein by reference.

Claims (7)

1-6. (canceled)
7. A method for manufacturing a compostable plate which comprises:
a step of manufacturing a supporting layer made of compostable cardboard;
a step of printing at least one portion to be printed of said supporting layer made of compostable cardboard in order to obtain at least one respective printed portion, said step of printing being carried out using compostable inks;
a step of spreading, at least over the surface that defines said at least one printed portion, a compostable biopolymer in order to provide a protective layer;
a step of forming in order to provide a compostable plate, said step of forming comprising a thermoforming by insertion, between a male mold part and a female mold part, of said supporting layer which has the printed portion or portions and the protective layer.
8. The method according to claim 7, wherein said thermoforming is performed at a temperature comprised between 60° C. and 75° C. as regards the male mold part and between 120° C. and 130° C. as regards the female mold part.
9. The method according to claim 7, wherein said male mold part has a coupling surface which is designed to press against the protective layer, said coupling surface of the male mold part having a plastic coating that is adapted to limit a temperature of said coupling surface.
10. The method according to claim 9, wherein said plastic coating comprises a layer of Teflon.
11. The method according to claim 7, wherein said compostable biopolymer used to provide said protective layer is mixed, prior to the step of spreading, with a master batch of granules which is adapted to fluidify the biopolymer and to facilitate the step of spreading.
12. The method according to claim 7, wherein said step of printing is carried out using a compostable ink that is free from amines.
US16/617,730 2017-05-31 2018-05-30 Method for manufacturing a compostable plate Abandoned US20200109518A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
IT102017000059261 2017-05-31
IT102017000059261A IT201700059261A1 (en) 2017-05-31 2017-05-31 COMPOSTABLE PLATE AND PROCEDURE FOR THE PRODUCTION OF A COMPOSTABLE PLATE.
PCT/EP2018/064284 WO2018220070A1 (en) 2017-05-31 2018-05-30 Method for manufacturing a compostable plate

Publications (1)

Publication Number Publication Date
US20200109518A1 true US20200109518A1 (en) 2020-04-09

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US16/617,730 Abandoned US20200109518A1 (en) 2017-05-31 2018-05-30 Method for manufacturing a compostable plate

Country Status (9)

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US (1) US20200109518A1 (en)
EP (1) EP3629846B1 (en)
JP (1) JP2020523186A (en)
AU (1) AU2018275757B2 (en)
CA (1) CA3064139A1 (en)
EA (1) EA037408B1 (en)
IT (1) IT201700059261A1 (en)
MX (1) MX2019014380A (en)
WO (1) WO2018220070A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GR1010055B (en) * 2020-05-20 2021-08-13 Προκος Ανωνυμη Εταιρεια Παραγωγης Και Εμποριας Προιοντων Χαρτου Και Ειδων Οικιακης Χρησεως Method for the manufacture of printed paper plates with use of varnish and without film on their final surface
EP3767031A3 (en) * 2020-09-02 2021-06-16 PPC Paper Print Converting GmbH Crockery, in particular dish or tray, for one-off use and method for its manufacture

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1321289B1 (en) * 2000-09-13 2006-07-12 Nissei Kabushiki Kaisha Biodegradable molded articles, process for producing the same and compositions for foam molding
JP4121874B2 (en) * 2002-03-13 2008-07-23 日世株式会社 Method for producing biodegradable molding and molding die used therefor
JP2004106369A (en) * 2002-09-19 2004-04-08 Toppan Printing Co Ltd Paper-made laminate and paper-made container comprising the laminate
US20060051603A1 (en) * 2004-09-09 2006-03-09 International Paper Company Biodegradable paper-based cup or package and production method
US20110123809A1 (en) * 2008-03-24 2011-05-26 Biovation, Llc Biolaminate composite assembly and related methods
US9452863B2 (en) * 2008-10-01 2016-09-27 Greater Good, Inc. Biodegradable container for liquid and/or semi-solid products
DE102015116119A1 (en) * 2015-09-23 2017-03-23 Leaf Republic GmbH Laminates and process for their preparation

Also Published As

Publication number Publication date
EA037408B1 (en) 2021-03-25
AU2018275757A1 (en) 2019-12-12
IT201700059261A1 (en) 2018-12-01
CA3064139A1 (en) 2018-12-06
AU2018275757B2 (en) 2021-04-01
EA201992783A1 (en) 2020-03-26
JP2020523186A (en) 2020-08-06
EP3629846A1 (en) 2020-04-08
EP3629846B1 (en) 2021-09-01
MX2019014380A (en) 2020-07-27
WO2018220070A1 (en) 2018-12-06

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