A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

A deep-drawn paper tray made of paper material, a method and an apparatus for manufacturing the tray, and a closed product package comprising the tray. The tray having a bottom and upwardly expanding side walls around the bottom, the side walls of the tray being shaped to expand through a plurality of circumferential steps dimensioned low enough for obtaining wrinkle-free side walls for the tray. The outermost step is a flat, wrinkle-free rim flange, which enables liquid and gas proof heat-sealing of a lid to form the package. The apparatus may comprise upper and lower moulding tools with concentric movable frames for forming the tray bottom and side wall steps from paper blanks, and moulding tools may be mounted onto a rotating turret carrying a paper blank through working stations arranged along the turret circumference, to shape the tray bottom and the side wall steps at the consecutive stations.

A repulpable insulation material includes a batt formed of a mixture of thermoplastic binder fibers and cellulose fibers bound together by the thermoplastic binder fibers. The thermoplastic binder fibers make up about 0.5% to 25% by weight of the batt. The repulpable insulation material have a weight within a range from 1000 GSM to 1600 GSM. Subjecting the repulpable insulation material to a repulpability test produces greater than 85% fiber yield.

A method of forming a shipping container includes mixing paper fibers with a binder fiber to form a mixture; disposing the mixture onto a surface to form a layer of the mixture; applying heat to form a paper fiber batt from the mixture having a fixed width and fixed length; and inserting the paper fiber batt within an interior of a corrugated box.

A repulpable insulation material includes a batt formed of a mixture of thermoplastic binder fibers and cellulose fibers bound together by the thermoplastic binder fibers. The thermoplastic binder fibers make up about 0.5% to 25% by weight of the batt. The repulpable insulation material have a weight within a range from 1000 GSM to 1600 GSM. Subjecting the repulpable insulation material to a repulpability test produces greater than 85% fiber yield.

A thermoform packaging machine comprising a forming station. The forming station comprises at least one forming tool lower part, the forming tool lower part may be movable transversely to an operating direction of the thermoform packaging machine. The forming tool lower part may comprise at least one reception unit with one or a plurality of troughs for receiving cardboard elements. At a forming position the forming tool lower parts are in contact with the forming tool upper parts such that the first film web may be formed-in into the forming tool lower parts. Further, the first film web may be formed-in into the cardboard elements during the forming process and, in the case of a skin film, an adhering or an adhesive connection may be established between the skin film and the inner surfaces of the cardboard elements.

A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

A method of forming a shipping container includes mixing paper fibers with a binder fiber to form a mixture; disposing the mixture onto a surface to form a layer of the mixture; applying heat to form a paper fiber batt from the mixture having a fixed width and fixed length; and inserting the paper fiber batt within an interior of a corrugated box.

The invention provides a complex made up of consecutively stacked flat sheets configured for forming a package in a single run, wherein said complex comprises: at least a first die cut flat sheet configured for being folded and forming a wall of the package, comprising a continuous first rim demarcated by an outer contour and an inner contour, wherein said inner contour comprises a first portion and the outer contour comprises a second portion, wherein at least a first main flap extends along the first portion of the inner contour in the direction opposite the second portion of the outer contour; and an assembly comprising at least one additional flat sheet, wherein the perimeter of the at least one additional flat sheet is demarcated by the first rim of the first flat sheet. The invention furthermore provides a method for obtaining the complex, a method for manufacturing a package, and a method for packaging an item.

A method and system for producing an insulated mailer and an insulated box having an insulative paper fiber pad substructure with a density of less than about 10 pounds per cubic foot. The insulative paper fiber pad has entangled reinforcement fibers. A method of forming an insulative paper fiber pad using recycling-compatible or water soluble adhesive and paper layers is provided.