The effects of pretreatment and coating on the formability of extrusion‐coated multilayer paperboard–plastic composites

Franke, Wilken; Leminen, Ville; Groche, Peter; Varis, Juha

doi:10.1002/pts.2542

Cited by 10 publications

(17 citation statements)

References 21 publications

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“…Paperboard fibers and their bonds affect drying and consolidation of the tray geometry in its press-forming. Built-in compressive and tensile stresses of the formed geometry are derived from the forming, and the type of the material coating affects its forming behavior (Vishtal and Retulainen 2012;Franke et al 2021). Temperature and tray blank moisture in forming affect drying, softening, elastic recovery, and stress relaxation of the material fibers (Vishtal and Retulainen 2012).…”

Section: Optimal Press-forming Parametersmentioning

confidence: 99%

Effects of press-forming parameters on the dimensional stability of paperboard trays

Niini

Tanninen

Varis

et al. 2021

BioRes

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The dimensional stability of press-formed paperboard trays was investigated during heating and cooling of trays packed with oatmeal. Female mold tool temperature, dwell time, pressing force, and blank holding force were altered in the press-forming of the trays to observe their impacts on the dimensional stability. Dimensional measurements of the trays showed reduced tray width, and the trays exhibited distortions on the tray flange and outer wall. The results showed smaller effects on the tray length, parallel to the machine direction of the material. Improved dimensional stability of the trays was found with a 180 °C female mold tool temperature, a 600-ms dwell time, a 150-kN pressing force, and a 1.44-kN blank holding force. The optimal press-forming parameters were concluded to enhance bonding of the paperboard fibers during the press-forming. The optimization of the press-forming parameters was found necessary to reduce the observed negative response of the material to the challenging environmental conditions in the production of prepared food.

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Section: Optimal Press-forming Parametersmentioning

confidence: 99%

Effects of press-forming parameters on the dimensional stability of paperboard trays

Niini

Tanninen

Varis

et al. 2021

BioRes

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“…The effect of the polymer extruded on the paperboard blank before the tray forming operation could also be investigated. This coating may affect the upper ply allowing for higher failure strain 40 . Finally, the use of shell elements leaves the contribution of the out‐of‐plane (ZD) stress outside of the analysis.…”

Section: Resultsmentioning

confidence: 99%

Tray forming operation of paperboard: A case study using implicit finite element analysis

Lindberg

Kulachenko

2021

Packag Technol Sci

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The possibility to perform advanced forming operations of initially plane paperboard paves the way to making products like food trays, plates, cups and other containers as a part of shifting towards a circular bioeconomy. As a part of the ongoing efforts of expanding the product range using paperboard, we performed analyses of the forming operation using simulations. An implicit non‐linear finite element model is built to more accurately than previous studies simulate the tray forming process of paperboard. Two different commercial paperboards are investigated. The use of an implicit solver enabled the inclusion of the creasing pattern into the geometry of the paperboard blank resolving the formation of wrinkles during forming. The material data is extracted from tensile test curves of the investigated paperboards and was fitted accurately using Hill's plasticity with difference in tension and compression accounted for with subsequent failure evaluation. The results showed that the inclusion of the creases in the geometry is vital for getting a correct shape of the formed tray and important for decreasing the risk of failure. The results also showed that friction has a big impact on the formed shape and hence on the stress levels, and therefore supports the means of lowering friction between the blank holder and the blank during the tray forming operation. A stochastic approach is proposed to determine the probability of failure for the boards. The performed failure evaluation is consistent with the field observations. The developed approach enables more precise simulations of paperboard tray forming.

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“…The limited conversion capabilities of fibre‐based products hinder their market potential. Thus, extensive research has been conducted to increase the conversion capabilities of materials by altering fibres mechanically or chemically 1 or by including additives such as agar, gelatin, or soap to fibre materials 2–4 . In addition to the material development, updated manufacturing methods, machinery, and tools are required to handle these materials 5 …”

Section: Introductionmentioning

confidence: 99%

“…Thus, extensive research has been conducted to increase the conversion capabilities of materials by altering fibres mechanically or chemically 1 or by including additives such as agar, gelatin, or soap to fibre materials. [2][3][4] In addition to the material development, updated manufacturing methods, machinery, and tools are required to handle these materials. 5 In addition to advancements in materials, different forming processes of fibre-based materials, such as press forming, deep drawing, and hydroforming, have been examined for potential developments in their forming arrangements and tooling to improve the forming performance of such materials.…”

Section: Introductionmentioning

confidence: 99%

Effects of thermoforming operation and tooling on the thermoformability of plastic‐coated fibre‐based materials

et al. 2023

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Advances in the three‐dimensional (3D) forming of fibre‐based materials require the formulation of more formable materials and the development of process lines, machinery, and tools. Using a thermoforming process to convert fibre‐based materials into 3D forms is an emerging area of research which requires further investigation into the practicality of the process line and tooling in forming such materials. Accordingly, this study evaluated the impact of the thermoforming process operation and tooling on the thermoformability of plastic‐coated paperboards. The main objective was to provide design recommendations for the future development of thermoforming lines, followed by guidelines for tooling design to improve the performance of materials utilising the currently available machinery. This study examined the thermoforming behaviour of two different plastic‐coated paperboards in vacuum and pressure thermoforming by investigating their maximum acquired depth, shape accuracy, and damage mechanisms. The research findings, based on the depth and linear elongation achieved, indicate that the inferior performance of plastic‐coated paperboards in thermoforming cannot be wholly attributed to restrictions in the three‐dimensional formability of materials; the inability of the current process lines to utilise the maximum potential of materials can also lead to their inferior performance. Notably, the method of pressure supply and cooling of materials requires adjustment of these materials. From a tooling perspective, owing to the spring‐back effects, the enlargement of the mould dimensions should be considered during the design stage. Additionally, based on potential opportunities with the current unmodified machinery and materials, products in the size of standard food trays have a higher likelihood of being optimised with tooling design than smaller sized shapes, which still require additional developments in materials. Moreover, designing moulds without draft angles can reduce the risk of rupture owing to the prevention of localised stress formation in materials.

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The effects of pretreatment and coating on the formability of extrusion‐coated multilayer paperboard–plastic composites

Cited by 10 publications

References 21 publications

Effects of press-forming parameters on the dimensional stability of paperboard trays

Effects of press-forming parameters on the dimensional stability of paperboard trays

Tray forming operation of paperboard: A case study using implicit finite element analysis

Effects of thermoforming operation and tooling on the thermoformability of plastic‐coated fibre‐based materials

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