The present invention is directed to methods and systems for manufacturing molded fiber products using a pulp slurry and apparatus submerged in pulp slurry. The system utilizes a vacuum and mesh shaping of the product to pull fiber from the pulp slurry to the mesh shape while sucking the water through the mesh shape. The molded fiber product is then pressed to bolster the strength and structure of the product. The product is then coated using centripetal force to uniformly spread the coating across the selected area of the product. After coating, the product is pressed again to ensure the waterproof and airproof structure of the product. The materials used in manufacturing the molded fiber product are biodegradable, and the apparatus to form the molded fiber product is shaped according to the desired shape and size of the product.

Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes one or more of an embedded moisture barrier, vapor barrier, and oil barrier, and the topical coating comprises one or more of a vapor barrier, a moisture barrier, an oil barrier, and an oxygen barrier. For food containers having deep sidewalls, a spray coating system includes a first nozzle for applying a full cone spray pattern to the bottom surface of the container, and a second nozzle for applying a hollow cone spray pattern to the inside surfaces of the side walls.

Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes one or more of an embedded moisture barrier, vapor barrier, and oil barrier, and the topical coating comprises one or more of a vapor barrier, a moisture barrier, an oil barrier, and an oxygen barrier. For food containers having deep sidewalls, a spray coating system includes a first nozzle for applying a full cone spray pattern to the bottom surface of the container, and a second nozzle for applying a hollow cone spray pattern to the inside surfaces of the side walls.

Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes one or more of an embedded moisture barrier, vapor barrier, and oil barrier, and the topical coating comprises one or more of a vapor barrier, a moisture barrier, an oil barrier, and an oxygen barrier. For food containers having deep sidewalls, a spray coating system includes a first nozzle for applying a full cone spray pattern to the bottom surface of the container, and a second nozzle for applying a hollow cone spray pattern to the inside surfaces of the side walls.

Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes one or more of an embedded moisture barrier, vapor barrier, and oil barrier, and the topical coating comprises one or more of a vapor barrier, a moisture barrier, an oil barrier, and an oxygen barrier. For food containers having deep sidewalls, a spray coating system includes a first nozzle for applying a full cone spray pattern to the bottom surface of the container, and a second nozzle for applying a hollow cone spray pattern to the inside surfaces of the side walls.

A process for making a sheet of paper or cardboard from a fiber suspension, includes injection of a polymer P3 into a cellulosic fiber suspension, formation of a sheet of paper or cardboard, and drying of the sheet of paper or cardboard. The P3 polymer is prepared, prior to the injection, from a water-soluble P1 polymer of at least one nonionic monomer, such as acrylamide, methacrylamide, N,N-dimethylacrylamide, and acrylonitrile. The P1 polymer is subjected to a Re1 reaction to give a P2 polymer, which is then subjected to a Re2 reaction to give the P3 polymer, which is injected into the fibrous suspension within 24 hours of the start of the Re1 reaction.

A process for making a sheet of paper or cardboard from a fiber suspension, includes injection of a polymer P3 into a cellulosic fiber suspension, formation of a sheet of paper or cardboard, and drying of the sheet of paper or cardboard. The P3 polymer is prepared, prior to the injection, from a water-soluble P1 polymer of at least one nonionic monomer, such as acrylamide, methacrylamide, N,N-dimethylacrylamide, and acrylonitrile. The P1 polymer is subjected to a Re1 reaction to give a P2 polymer, which is then subjected to a Re2 reaction to give the P3 polymer, which is injected into the fibrous suspension within 24 hours of the start of the Re1 reaction.