Methods and apparatus for manufacturing a microwavable food container include: forming a wire mesh over a mold comprising a mirror image of the microwavable food container; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh including the accumulated fiber particles from the slurry bath; wherein the slurry comprises one or more of a moisture barrier, an oil barrier, and a vapor barrier.

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.

The invention relates to uncoated, fiber/starch composite materials manufactured without the use of fluorochemicals or additional binders that offer superior oil and grease resistance properties. Addition of an internal sizing agent in the preparation of the fiber/starch composite materials results in superior hot water and cold water resistance properties. The fiber/starch composite materials may be used for the manufacture of food service containers. The invention also relates to methods of preparation of the fiber/starch composite materials.

The invention relates to uncoated, fiber/starch composite materials manufactured without the use of fluorochemicals or additional binders that offer superior oil and grease resistance properties. Addition of an internal sizing agent in the preparation of the fiber/starch composite materials results in superior hot water and cold water resistance properties. The fiber/starch composite materials may be used for the manufacture of food service containers. The invention also relates to methods of preparation of the fiber/starch composite materials.

The present invention relates to a method for producing a gypsum-containing foamed prefabricated building material and to a gypsum-containing foamed prefabricated building material.

Methods and apparatus for manufacturing a microwavable food container include: forming a wire mesh over a mold comprising a mirror image of the microwavable food container; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh including the accumulated fiber particles from the slurry bath; wherein the slurry comprises a moisture barrier, an oil barrier, and a vapor barrier.

Methods and apparatus for manufacturing a microwavable food container include: forming a wire mesh over a mold comprising a mirror image of the microwavable food container; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh including the accumulated fiber particles from the slurry bath; wherein the slurry comprises a moisture barrier, an oil barrier, and a vapor barrier.

A method and apparatus for manufacturing medical paper for medical sterilization packaging, medical paper and medical sterilization packaging are disclosed. A paper web is formed of fibrous substrate comprising cellulosic fibers and optionally synthetic fibers, with opposite first and second sides. On-line with the forming of the paper web, reinforcing material is applied on the first side and pressed into structure of the paper web such that delamination resistance of the structure is increased. Sealing material is applied on the second side of the paper web on-line with the forming of the paper web.

Provided herein are mixed pulp compositions comprising a short fiber plant pulp (e.g., sugar cane bagasse) and a long fiber plant pulp (e.g. bamboo fiber). Also provided herein is a process for preparing the compositions.