BIODEGRADABLE AND COMPOSTABLE FOOD PACKAGING UNIT FROM A MOULDED PULP MATERIAL, AND METHOD FOR MANUFACTURING SUCH FOOD PACKAGING UNIT

Abstract

The present invention relates to a biodegradable food packaging unit from a moulded pulp material and a method for manufacturing such biodegradable packaging unit. The packaging according to the invention comprises a food receiving or carrying compartment, wherein the moulded pulp material comprises an amount of a biodegradable aliphatic polyester, wherein the food packaging unit is a compostable food packaging unit. In a preferred embodiment the amount of biodegradable aliphatic polyester is in the range of 0.5-20 wt. %, more preferably in the range of 1-15 wt. %.

Claims

1. A food packaging unit from a moulded pulp material, the packaging unit comprising a food receiving or carrying compartment, wherein the moulded pulp material comprises an amount of a biodegradable aliphatic polyester, wherein the food packaging unit is a compostable food packaging unit.

2. The food packaging unit according to claim 1, wherein the amount of biodegradable aliphatic polyester is in the range of 0.5-20 wt. %.

3. The food packaging unit according to claim 2, wherein the amount of biodegradable aliphatic polyester is in the range of 2-10 wt. %.

4. The food packaging unit according to claim 1, further comprising one or more further agents from a biodegradable aliphatic polyester.

5. The food packaging unit according to claim 1, wherein the biodegradable aliphatic polyester comprises an amount of one or more of PBS, PHB, PHA, PCL, PLA, PGA, PHBH and PHBV.

6. The food packaging unit according to claim 1, wherein the unit is biodegradable at a temperature in the range of 5 to 60° C.

7. The food packaging unit according to claim 1, wherein the biodegradable aliphatic polyester is bio based.

8. The food packaging unit according to claim 1, further comprising an amount of natural and/or alternative fibers.

9. A method for manufacturing a food packaging unit from a moulded pulp material, the method comprising the steps of: preparing moulded pulp material; adding an amount of biodegradable aliphatic polyester; moulding the food packaging unit; and releasing the food packaging unit from the mould.

10. The method according to claim 9, wherein the biodegradable aliphatic polyester is in the range of 0.5-20 wt. %.

11. The method according to claim 9, wherein moulding the food packaging unit comprises connecting biodegradable aliphatic polyester to cellulose fibres of the moulded pulp material.

12. The method according to claim 9, further comprising the step of biodegrading the packaging unit.

13. The method according to claim 12, wherein biodegrading comprises decomposing the food packaging unit.

14. The method according to claim 13, wherein the decomposing is performed at a temperature in the range of 5 to 40° C.

15. The method according to claim 9, further comprising the step of adding one or more further agents in addition to the biodegradable aliphatic polyester, the agents comprising a biodegradable aliphatic polyester comprising an amount of one or more of PBS, PHB, PHA, PCL, PLA, PGA, PHBH and PHBV.

16. The method according to claim 9, further comprising the step of in-mould drying the packaging unit.

17. The method according to claim 9, further comprising the step of adding an amount of natural fibers.

18. The method according to claim 9, wherein the amount of biodegradable aliphatic polyester is in the range of 0.5-20 wt. %, wherein the biodegradable aliphatic polyester comprises an amount of one or more of PBS, PHB, PHA, PCL, PLA, PGA, PHBH and PHBV.

19. The method according to claim 18, further comprising the step of biodegrading the packaging unit.

20. A food packaging unit from a moulded pulp material, the packaging unit comprising a food receiving or carrying compartment, wherein the moulded pulp material comprises an amount of a biodegradable aliphatic polyester, wherein the food packaging unit is a compostable food packaging unit, wherein the amount of biodegradable aliphatic polyester is in the range of 0.5-20 wt. %, wherein the biodegradable aliphatic polyester comprises an amount of one or more of PBS, PHB, PHA, PCL, PLA, PGA, PHBH and PHBV.

Description

[0054] Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings, in which:

[0055] FIGS. 1A and 1B shows a packaging unit according to the invention comprising PBS and/or another biodegradable aliphatic polyester;

[0056] FIG. 2 shows an example of an alternative food packaging product according to the present invention;

[0057] FIGS. 3A and 3B shows an example of a further alternative food packaging product according to the present invention;

[0058] FIGS. 4A and B shows further packaging units for eggs according to the present invention; and

[0059] FIG. 5 shows a further packaging unit according to the invention for an ice cream product.

[0060] Packaging unit 2 (FIGS. 1A and B) carries or holds eggs and comprises cover part 4 and bottom part 6. Bottom part 6 is provided with back surface 8, sides 10 and front surface 12, and bottom surface 14. Cover part 4 is provided with back surface 16, side surfaces 18, front surface 20 and top surface 22. In the illustrated embodiment transition 24 is provided between top surface 22 and back and front surfaces 16, 20.

[0061] In the illustrated embodiment, top surface 22 of cover part 4 is provided with groove 26 comprising a number of openings 28. Openings 28 are defined by two adjacent arch-shaped edges 30, 32 having a larger thickness as compared to the average thickness of cover part 4. Side surfaces 18 of cover part 4 are provided with denest nocks or denest elements 34. In the illustrated embodiment, bottom part 6 is provided with similar elements 36 mirroring denest elements 34. Hinge 38 connects back surface 16 of cover part 4 with back surface 8 of bottom part 6. Lock 40 comprises nose-shaped lock element 42 that is connected to flap 44 of bottom part 6. Cover part 4 is provided with openings 46 that capture lock elements 42 therewith defining lock 40.

[0062] In the illustrated embodiment, bottom part 6 is provided with a number of product receiving compartments 48, cones 50 and separating walls 52. Cone 50 extends from the bottom of bottom part 6 in an upward direction. Cover part 4 comprises cone support 54. Inner surface 58 of packaging unit 2 comprises PBS and/or PLA material, optionally as film layer or alternatively blended and/or integrated with the fibres of the moulded pulp material.

[0063] In the illustrated embodiment, packaging unit 2 comprises twelve product receiving compartments 48 that are provided in two rows of six compartments 48. Individual compartments 48 are separated from each other by walls 52 and cones 50. It will be understood that other configurations can also be envisage in accordance to the invention.

[0064] Packaging unit 2 may also be configured to receive other products, such as tomatoes, kiwis.

[0065] It will be understood that other types of food packaging units can also be envisaged in accordance with the present invention. As a further example, bottle divider 101 (FIG. 2) is illustrated. Also, bottle divider 102 may comprise a film layer of PBS (and/or appropriate alternative biodegradable aliphatic polyester) and/or may comprise an amount of PBS that is blended into the moulded pulp.

[0066] A further example in accordance with the present invention is cover 202, for example for an ice cup. Another example of a packaging unit according to the invention is sip lid 302 (FIG. 3B). Cover 202 and sip lid 302 comprise a film layer of biodegradable aliphatic polyester and/or may comprise an amount of biodegradable aliphatic polyester that is blended into the moulded pulp. This renders cover 202 and sip lid 302 water or liquid repellent. One of the further advantages of the use of biodegradable aliphatic polyester is the reduction or prevention of the liquid entering or migrating into the sip lid material during use. Another advantage is the constancy of size or dimensional stability. In this specific case this prevents sip lid 302 loosening from a cup or beaker for hot beverages such as coffee, tea or soup, or cold beverages such as carbonated drinks, and cup 202 from loosing from an ice cup, for example. It will be understood that such lids 302 can also be applied to other food containers. For example, lids 302 can be applied to containers for milkshakes, for example. Further details and examples of lids 302 are disclosed in WO 2010/064899, including embodiments with specific flanges and notches.

[0067] Sip lid 302 is preferably coated with a biodegradable aliphatic polyester liner, such as a PBS liner. As mentioned, sip lids 302 can be used for cups and milkshakes. Also, sip lids can be applied to so-called ready meal trays (for example for pizza, wraps, fish, meat, lobster, pasta, ) and act as a (digital) printable and barrier seal, for example.

[0068] It will be understood that other designs for packaging units in accordance with the invention can be envisaged. For example, containers 402, 502 (FIGS. 4A and B) illustrate different designs for egg cartons capable of holding eggs P.

[0069] Other examples of food packaging products may relate to cup carriers, cups, plates and other table ware etc.

[0070] Packaging unit 602 (FIG. 5) comprises bottom part 604 and cover part 606. Unit 602 is provided with biodegradable aliphatic polyester, such as PBS and/or PLA, and is capable of holding an amount of ice cream. Cover part 606 comprises top seal 608 of a (paper) label whereon layer or film 610 of biodegradable aliphatic polyester(s) is provided. Optionally, fibers 612 are included in the cover part 606. This improves the possibilities for giving the unit a natural paper feel and/or look. This may also be applied to other type of packaging units. For example, in instant or ready-to-eat meals, such that conventional sleeves can be omitted from the packaging units. This enables a more cost-efficient packaging unit with a possible weight reduction.

[0071] When manufacturing a food packaging unit 2, 102, 202, 302, 402, 502, 602 a moulded pulp material is prepared. Optionally, an amount of biodegradable aliphatic polyester, such as PBS, is blended or mixed into the moulded pulp material and/or an amount of PBS is included in a separate layer that is provided in or on unit 2, 102, 202, 302, 402, 502, 602. Such separate layer may come into contact with a food product. Next, the raw unit is moulded. Optionally, the raw unit is dried in the mould applying an in-mould drying process. Finally the product is released from the mould. Several post-moulding operations may optionally be performed in relation to unit 2, 102, 202, 302, 402, 502, 602 optionally including, but not limited to, labelling including in-mould labelling, marking including printing and digital printing, testing. In several of the preferred embodiments, the compostable biofilm is at least arranged on the food contact area of the product containing part of the packaging unit. In preferred embodiments this film is capable of being used in a microwave or oven as a so-called ovenable film. Preferably, the biofilm is capable of withstanding temperatures up to 170° C., 190° C., or even higher. This biofilm preferably comprises an amount of PBS and/or MFC and/or biodegradable aliphatic polyester that may comprise an amount of one or more of PHB, PHA, PCL, PLA, PGA, PHBH and PHBV. Especially a combination of a compostable packaging unit involving in-mould drying further improves the sustainability as compared to conventional packaging units. The (digital) printable properties enable printing of packaging and/or food characteristics/information. This may obviate the use of separate sleeves, for example. In addition, it enables the application of prints, for example a fish & chips (newspaper) print on the packaging unit.

[0072] Experiments have been performed with one or more of the illustrated food packaging units. These experiments involved comparing the in-use characteristics of the food packaging units as compared to conventional packaging units, and also the compostable characteristics. An amount of a biodegradable aliphatic polyester was added to the moulded pulp material and a refining step was performed. Measurements were done at a temperature of about 23° C. and a relative humidity of about 50%. Measurements involved a compression test. This showed a significant improvement in compression value. For example, a packaging unit with 7.5% PLA and a refining step showed a compression value of 450-500 N, while for a similar conventional product under the same conditions this value is about 180 N. Even a sub-optimal conditions of RH about 90% the compression value for the packaging unit according to the invention was about 250-270 N, thereby still outperforming the conventional product at its optimal conditions.

[0073] Other tests were performed to show the dual ovenable (oven and microwave) performance of the packaging unit according to the invention. In the experiments a laminated product with a film of a biodegradable aliphatic polyester (PBS/PLA and/or PHBH) was heated to a temperature of about 190° C. for about 30 minutes. Results show that the film layer remains intact and does not melt. Furthermore, the strength and stability of the packaging unit were not significantly affected. As a further effect, the packaging unit was more stable in view of twisting when removing the packaging unit from the oven as is often the case with conventional packaging units. Furthermore, the packaging unit of the invention showed a limited temperature increase to about 50-70° C., while the conventional units reached a temperature of about 90-100° C. under similar conditions. Other experiments with a PHBH film that is laminated on the inside of a (food) tray shows an even improved heat resistance when heating the tray to a temperature of 180-200° C., and in addition shows (an improved) oil, acid and moisture resistance/repellence.

[0074] In still further tests other characteristics were examined. It was shown that wipeability of the packaging unit could be improved. Further improvements where shown by addition of further additives.

[0075] The present invention is by no means limited to the above described preferred embodiments thereof. The rights sought are defined by the following claims, within the scope of which many modifications can be envisaged.