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.

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.

An egg carton and method and apparatus for forming an egg carton. A main body of the egg carton may be made of a single sheet of material and folded or otherwise bent to form the majority of the carton's interior space. Partition walls may be engaged with slots formed in the main body to define separate storage areas of the interior space as well as help hold the main body in the desired configuration. Hooks on the sides of the partition walls may engage with openings in the main body to secure the main body to the partition walls.

An egg carton and method and apparatus for forming an egg carton. A main body of the egg carton may be made of a single sheet of material and folded or otherwise bent to form the majority of the carton's interior space. Partition walls may be engaged with slots formed in the main body to define separate storage areas of the interior space as well as help hold the main body in the desired configuration. Hooks on the sides of the partition walls may engage with openings in the main body to secure the main body to the partition walls.

A process for the manufacture of lignocellulosic fiber-based insulation boards that includes: applying a binder composition to lignocellulosic fibers; forming a lignocellulosic fiber mat by compressing the lignocellulosic fibers impregnated with the binder composition; and heating the compressed lignocellulosic fiber mat so as to obtain a lignocellulosic fiberboard bound by an insoluble and infusible thermoset binder, where the binder composition is an emulsion of a poly(methylene diphenyl isocyanate) (pMDI) in an aqueous phase comprising water and a polyol in dissolved form.

A process for the manufacture of lignocellulosic fiber-based insulation boards that includes: applying a binder composition to lignocellulosic fibers; forming a lignocellulosic fiber mat by compressing the lignocellulosic fibers impregnated with the binder composition; and heating the compressed lignocellulosic fiber mat so as to obtain a lignocellulosic fiberboard bound by an insoluble and infusible thermoset binder, where the binder composition is an emulsion of a poly(methylene diphenyl isocyanate) (pMDI) in an aqueous phase comprising water and a polyol in dissolved form.