Eco-friendly packaging such as moulded pulp products have gained commercial importance in the recent years. However, it remains a greatly under-researched area, and there is an arising need to consolidate the best practices from research and industry in order to increase its implementation. The goal of this paper is to give an overview of the main aspects involved in the manufacture of moulded pulp products. This includes a classification of moulded pulp products, historical and current applications, production processes, materials, mechanical properties and environmental sustainability. Moreover, based on the latest research in the field, an innovative drying technique that utilizes concepts derived from impulse drying is presented, and the implementation of this process technology is discussed. Copyright © 2017 John Wiley & Sons, Ltd. INTRODUCTIONMoulded pulp products, also referred to as moulded pulp or moulded fibre products, are primarily used for the packaging of manufactured products and for food-related carriers, such as food containers and serving trays. Because of form (geometry) and aesthetic limitations, moulded pulp products have mostly been limited to the egg tray market for many years. However, demand is now increasing because of their sustainable qualities.1 Environmental, social and economic concerns result in a growing search for more sustainable products and industrial processes. As it consists simply of water and wood fibres (i.e. primarily cellulose), moulded pulp is a renewable material and a biodegradable solution. The manufacturing process includes the recovery of discarded materials from manufactured and recycled products made of wood fibres, such as cardboard, newspapers and magazines. These qualities have enabled growing adoption within the packaging industry. Companies are eager to embrace alternatives to oil-based forms of packaging, because of government regulations and customer demands. Increasing R&D effort for standardizing design and testing practices is essential in order to meet the growing demand for eco-packaging with high-quality features.Reviews of the historical development in industrial applications of moulded pulp packaging, recent manufacturing innovations in the field and an overview of an industrial scenario in the UK are 5 While these articles give great insight into historical developments, they are outdated, and they report few of the recent innovations within the field. Consequently, not enough attention has been given to the different manufacturing processes, and there is a gap related to environmental considerations. By means of a comprehensive review, this paper fills the identified research gap by describing wide-ranging aspects of the manufacturing process of moulded pulp. The research method adopted in collecting and reviewing the publications focused the literature survey exclusively to moulded pulp. It excluded similar products used in the packaging industry, such as cardboard or honeycomb panels.The content has been organized to present the main aspects ...
Over the past years, eco‐friendly packaging solutions such as moulded pulp have resonated with a growing number of consumers. Among all of them, the thermoformed products make use of the most recent manufacturing approach that produces high‐quality, thin‐walled items. However, it remains an underresearched area, and the development of an efficient and precise manufacturing process is fundamental in order to increase the implementation of sustainable packaging. With the purpose of setting a step towards in the standardization of design and testing practices of eco‐friendly packaging, this work focused on the characterization of the thermoforming process of moulded pulp products and their characteristics. Three different analyses were carried out for this purpose, covering the dewatering efficiency of the process, a quantification of the moulding geometrical accuracy, and an analysis of the internal microstructure of the parts. Experimental results and statistical analysis show that the dewatering efficiency is mainly governed by the mould's temperature while the duration of the contact time is not influential. In the second investigation, the geometrical accuracy of the mouldability of microfeatures was assessed. The process appeared to be dependently related to the pulp type employed. Finally, the internal microstructure was documented using X‐ray computed tomography. The analysis shows an increase in the internal void fraction linked with an increase in the mould's temperature. The role of the water change of phase in the thermoforming process is also discussed by reference to the work conducted on impulse drying.
For an effective optimization of pulp thermoforming and of the moulded pulp products manufactured by this process, a full understanding of the process physics combined with full knowledge of the pressing equipment is necessary. For this reason, in this Addendum, we clarify how the process parameters "Holding time," "Vacuum time," "Cycle time," and "Temperature" were interpreted and subsequently defined for the analysis of the process and product-related outputs of the thermoforming experiments.
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