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 present disclosure describes methods of treating fibrous cellulosic materials with sucrose fatty acid ester containing particles (carrier systems) that allow for modifications of surfaces, including making such surfaces water resistance and/or oil/grease resistance. The methods as disclosed provide combining at least one saccharide fatty acid esters (SFAE) with a polymer (e.g., latexes) to form micellular particles and applying such particles to substrates including fibrous cellulose-based materials (e.g., pulp) to form, inter alia, molded products. Compositions comprising combinations of SFAE, a latex and optionally a mineral or other additives are also disclosed.

The present disclosure describes methods of treating fibrous cellulosic materials with sucrose fatty acid ester containing particles (carrier systems) that allow for modifications of surfaces, including making such surfaces water resistance and/or oil/grease resistance. The methods as disclosed provide combining at least one saccharide fatty acid esters (SFAE) with a polymer (e.g., latexes) to form micellular particles and applying such particles to substrates including fibrous cellulose-based materials (e.g., pulp) to form, inter alia, molded products. Compositions comprising combinations of SFAE, a latex and optionally a mineral or other additives are also disclosed.

There is disclosed a process of manufacturing a fibreboard from a waste material, for example from a corrugated waste material, wherein the process comprises: refining in a range of 5 to 30 percent of the waste material into micro-fibrillated cellulose (MFC), using a mechanical micro-fibrillation process; pulping in a range of 70 to 95 percent of the waste material with water to obtain a waste pulp; dispersing the micro-fibrillated cellulose (MFC) into the waste pulp to obtain a micro-fibrillated waste pulp; moulding the micro-fibrillated waste pulp by applying a pressure to obtain a moulded fibreboard, using a moulding process; and drying the moulded fibreboard at a temperature to obtain the fibreboard with a density in a range of 500 to 1000 kilograms per cubic metre (kg/m.sup.3), for example in a range of 650 to 850 kilograms per cubic metre (kg/m.sup.3).

There is disclosed a process of manufacturing a fibreboard from a waste material, for example from a corrugated waste material, wherein the process comprises: refining in a range of 5 to 30 percent of the waste material into micro-fibrillated cellulose (MFC), using a mechanical micro-fibrillation process; pulping in a range of 70 to 95 percent of the waste material with water to obtain a waste pulp; dispersing the micro-fibrillated cellulose (MFC) into the waste pulp to obtain a micro-fibrillated waste pulp; moulding the micro-fibrillated waste pulp by applying a pressure to obtain a moulded fibreboard, using a moulding process; and drying the moulded fibreboard at a temperature to obtain the fibreboard with a density in a range of 500 to 1000 kilograms per cubic metre (kg/m.sup.3), for example in a range of 650 to 850 kilograms per cubic metre (kg/m.sup.3).

Method of manufacturing a moulded pump product. The method includes activating a vacuum source, injecting an amount of pulp into the internal mould chamber through the mould opening, thereby forming a pulp preform on the internal mould surface, injecting a dewatering and heating fluid through the mould opening at gradually increasing pressure until a maximum pressure, thereby performing a dewatering and drying step whereby the pulp preform on the internal mould surface is dewatered and dried, deactivating the injection of dewatering and heating fluid, deactivating the vacuum source, and extracting the moulded pulp product. An option further step includes initiating rotation of the mould about the central axis thereof and increasing rotational speed gradually, maintaining a maximum rotational speed of the mould at least during a substantial part of the dewatering and drying step, decreasing rotational speed gradually until standstill of the mould.

Method of manufacturing a moulded pump product. The method includes activating a vacuum source, injecting an amount of pulp into the internal mould chamber through the mould opening, thereby forming a pulp preform on the internal mould surface, injecting a dewatering and heating fluid through the mould opening at gradually increasing pressure until a maximum pressure, thereby performing a dewatering and drying step whereby the pulp preform on the internal mould surface is dewatered and dried, deactivating the injection of dewatering and heating fluid, deactivating the vacuum source, and extracting the moulded pulp product. An option further step includes initiating rotation of the mould about the central axis thereof and increasing rotational speed gradually, maintaining a maximum rotational speed of the mould at least during a substantial part of the dewatering and drying step, decreasing rotational speed gradually until standstill of the mould.

Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes an embedded moisture barrier and/or vapor barrier, and the topical coating comprises an oil barrier comprising acrylate, rice bran wax, pectin, and pea protein.

Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes an embedded moisture barrier and/or vapor barrier, and the topical coating comprises an oil barrier comprising acrylate, rice bran wax, pectin, and pea protein.

Methods and apparatus for vacuum forming and subsequently applying topical coatings fiber-based food containers. The slurry includes an embedded moisture barrier and/or vapor barrier, and the topical coating comprises an oil barrier comprising acrylate, rice bran wax, pectin, and pea protein.