Common Issues In The Production And Use Of Paper Pulp Molding Tableware And Their Possible Solutions
Mould design and raw materials for disposable paper pulp moulding still present some difficulties in terms of design of molds and the research of raw materials. The choice of raw materials significantly affects the quality of the final product; the design of molds must be maximized to fit various product forms and sizes. Among the solutions could be using more sophisticated mold design techniques and increasing study of raw material properties.
The quality and strength of the final product are much influenced by the post-processing operations of disposable paper pulp molding tableware including drying and shaping. Inappropriate post-processing could cause inadequate strength or product distortion. These issues can be resolved by bettering drying and shaping methods as well as by applying more powerful tools.
Brown deposits could develop during the hot pressing stage while manufacturing paper pulp molded dinnerware using raw materials including bagasse. These deposits could lower product quality, clog pipelines, and damage machinery. The main explanation, according to studies, is a high quantity of fine powder including water and oil repellents. Understanding the mechanism of deposit formation helps one to take related actions, such bettering raw material treatment and raising the frequency of equipment cleaning, thus addressing this issue.
The structural strength, heat resistance, and surface treatment of the products constitute further problems that could arise in the design and manufacturing of paper pulp molded dinnerware. Among the possible solutions could include bettering the manufacturing process, employing more appropriate raw materials and additives, and refining product design.
Usually produced with a 50% sugarcane fiber + 10%-50% bamboo pulp fiber ratio, conventional meal boxes Different tableware will add plant fibers such wheat straw, wheat grass, and reeds as needed and change the ratio of various fibers according on the form, angle, hardness, and stiffness of the product. All are composed entirely of plant fibers; chemical elements such PP and PET are not added.
Biodegradable plant fiber meal boxes comply with certifications such as ISO9001 quality management system certification, national “Paper Pulp Molding Tableware” quality inspection standards, FSC certification, and also pay attention to certifications from the U.S. Food and Drug Administration (FDA), Germany’s New Food and Dietary Products Act (LFGB), QS certification, SGS, FSC, BPI, ABA, OK COMPOST INDUSTRY, OK COMPOST HOME, DIN CERTCO, NO PLASTIC, PFAS-FREE, Little Seedling, etc. For medical paper pulp molding products, safety certifications such as FDA and CE are also required.
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Logos can be printed on biodegradable meal boxes. Products for printing are mostly the circumference, bottom, or top of the meal box, and products like cups and bowls are mostly printed on the outside of the product, requiring curved surface printing. According to the printing equipment, it can be divided into screen printing, silicone pad printing, laser printing, laser etching printing, and digital printing. Printed products will correspondingly increase the product cost.
The strength of disposable paper pulp molding tableware is usually lower than that of plastic or ceramic tableware and is prone to damage during use. This requires more care when using it to avoid heavy pressure or dropping. There are research institutions currently studying the improvement of the physical properties of paper pulp molding tableware by adding degradable additives. If the research and development is successful, it is expected to partially solve the above problems.
Paper pulp molding meal boxes will add a certain amount of food-grade additives, generally water repellent: 1.0%-2.5%, oil repellent: 0.5%-0.8%, to achieve water and oil resistance. The test is generally conducted with water at 100°C and oil at 120°C, with a test time of 30 minutes; special requirements can extend the oil temperature and test time. There are also surface coating techniques and surface lamination to improve the oil and water resistance of paper pulp molding products, which are handled according to customer needs.
Most of the oil repellents in plant fiber tableware on the market currently contain fluorine, while water-resistant and non-oil-resistant tableware does not contain fluorine. Currently, fluorine-free pulp addition is becoming more and more mature.
If degradable tableware is required to be fluorine-free and water and oil resistant, the current better alternative solutions are fluorine-free pulp addition, lamination, and surface coating, etc. Modified PLA, PBAT, and traditional plastics are currently the most widely used composite materials in paper pulp molding environmental tableware.
The laminated products can better maintain heat, reduce heat dissipation through the pores of the molded products, and at the same time can reduce the adhesion of food such as rice and dumplings, which can greatly reduce the use of water and oil repellents.
In the absence of any industrial decomposer, paper pulp molding environmental tableware takes about 45-90 days to fully decompose in a landfill in a natural state, without producing harmful substances, and will not cause harm to terrestrial organisms, corals, or marine life.
After degradation, 82% of the components are organic matter, which can be used as fertilizer for land use, sourced from nature and returning to nature.
Degradable paper pulp meal boxes can be microwaved and baked in the oven, and will not produce harmful chemical substances, with the highest temperature reaching 220°C. It can support refrigerator freezing and refrigeration, and the freezing can reach minus 18°C.
Unbleached plant fiber pulp is yellow due to the small amount of lignin and colored impurities it contains, and the fibers are also harder. Semi-bleached pulp contains a large amount of pentosans, and the color is light yellow, commonly known as the original color. The fibers of the bleached pulp are white, the texture is pure and soft, but because it has been bleached, the fiber strength is lower than that of the unbleached pulp. The bleaching agent generally uses hydrogen peroxide for bleaching, and chlorine bleaching is not allowed!
Regarding the cost issue of paper pulp molding tableware, compared with plastic tableware, the cost of paper pulp molding tableware is currently higher, mainly due to the difference in raw materials and production processes. With the increase in the use of paper pulp molding tableware and the continuous improvement of paper pulp molding production equipment and process technology, the cost of paper pulp molding tableware will become competitive with plastic tableware. Considering the impact of carbon neutrality and carbon peaking, with the rise of carbon prices and the popularization of plastic taxes, the comprehensive cost of paper pulp molding tableware will become more and more competitive compared to disposable plastic tableware.
Consumer acceptance of paper pulp molding tableware varies. European and American consumers have a high acceptance of paper pulp molding tableware because of the use of the scene, there is rarely high oil, high water (soup), so the user experience is quite good. Southeast Asian and Chinese consumers, including Hong Kong and Taiwan, have some poor user experience due to the high oil and high soup usage scene, and the water and oil resistance of paper pulp molding needs to be improved. Overall, consumers will choose to use it because of its environmental characteristics, but some consumers may also reserve because of its performance limitations.
Although paper pulp molding tableware is for single use, if the design process of paper pulp molding tableware is combined with the characteristics of the paper pulp molding process, and the tableware is made more artistic in the design process, it can make paper pulp molding tableware more favored by consumers and improve the artistic beauty of paper pulp molding.
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