GB2588097A

GB2588097A - Packaging item

Info

Publication number: GB2588097A
Application number: GB1914332.0A
Authority: GB
Inventors: Jozef Hardej Daniel; Dohler Mischa; Guilera Ferré Gemma
Original assignee: Moving Beans Ltd
Current assignee: Moving Beans Ltd
Priority date: 2019-10-04
Filing date: 2019-10-04
Publication date: 2021-04-21
Also published as: WO2021064422A1; GB201914332D0

Abstract

A method and apparatus for producing an injection moulded, home compostable item of packaging (or portion thereof), for example a beverage capsule for coffee or tea. the method comprising: obtaining a feed material comprising of bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 µm; obtaining an injection moulding apparatus comprising a feed cylinder, a nozzle and a mould, in which the feed cylinder is in communication with the nozzle, and the nozzle is in communication with the mould; optionally mixing the bamboo powder with at least one binding material to produce a feed mixture; introducing the feed material or feed mixture into the feed cylinder; heating the feed cylinder and nozzle to a temperature of at least 120oc; and feeding the feed material or feed mixture from the feed cylinder, via the nozzle to the mould at a predetermined temperature and under an applied pressure. A coating to the packaging may be provided.

Description

PACKAGING ITEM

The present invention relates to a method and apparatus for producing an injection moulded, home compostable item of packaging, for example a home compostable beverage capsule, from bamboo powder, and an injection moulded, home compostable item of packaging, for example a beverage capsule, composed of bamboo powder. The invention relates to an injection moulded, home compostable item of packaging, for example a beverage capsule, for preparing or storing warm or hot beverages, in particular portions of coffee or tea.

BACKGROUND OF INVENTION

The consumption of single-use coffee capsules has increased significantly over the past decade due to convenience, cleanliness, the ability to consistently produce high-quality coffee and the relatively low cost. Nespresso, launched by Nestle in 1976, is one of the leading brands of coffee capsules. Over 27 billion Nespresso capsules have been sold since 2000 and the popularity of these capsules has been consistently increasing since their release. Unfortunately, these single-use coffee capsules generate an excessive amount of waste due to being consumed at increasingly high volumes globally.

A number of recycling schemes are available to recycle the single-use coffee capsules, however these recycling schemes are limited and are not available in all geographies. Furthermore, consumers have a tendency to throw the capsules out with general waste and as a result a significant proportion of the capsules are sent to landfill. Conventional capsules are typically made from a combination of materials, such as plastic and aluminium, and are contaminated by food waste (i.e. used coffee grounds), making it difficult to recycle the capsules.

There is therefore a need for packaging, for example a single-use beverage capsule, which is biodegradable and compostable in domestic or garden compost (i.e. home compostable) without requiring use of industrial compost facilities. There is a need for packaging, for example a single-use beverage capsule, which can be composted within a home environment. There is a need for packaging, for example a single-use beverage capsule, having a lower associated energy footprint.

There is also a need for packaging, for example a single-use beverage capsule, with reduced oxygen permeability (for example reduced oxygen permeability to achieve a hermetic seal) compared to conventional packaging.

The present invention seeks to address one or more of the above problems associated with conventional packaging, such as for example conventional single-use coffee capsules.

SUMMARY OF INVENTION

According to a first aspect of the invention, there is provided a method for producing an injection moulded, home compostable item of packaging or at least a portion of an item of packaging, the method comprising: obtaining a feed material comprising of bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 p.m; obtaining an injection moulding apparatus comprising a feed cylinder, a nozzle and a mould for an item of packaging (or at least a portion of an item of packaging), in which the feed cylinder is in communication with the nozzle, and the nozzle is in communication with the mould; optionally mixing the feed material with at least one binding material to produce a feed mixture; introducing the feed material or feed mixture into the feed cylinder; heating the feed cylinder and nozzle to a temperature of at least 120 °C; and feeding the feed material or feed mixture from the feed cylinder, via the nozzle to the mould at a predetermined temperature and under an applied pressure to produce an injection moulded, home compostable item of packaging (or portion thereof).

The bamboo powder has a maximum grain dimension of no more than 500 p.m to ensure that the bulk material bamboo powder within the feed material or feed mixture is capable of flowing like a fluid.

The method may further comprise coating the injection moulded, home compostable item of packaging (or portion thereof) with a coating. The coating may be applied to one or more surfaces of the item. For example, the item may have an inner surface (defining for example a cavity), and an opposed outer surface. The inner surface may be coated with the coating. Alternatively, or in addition, the outer surface of the item may be coated with the coating. The coating can be applied on the inner surface or the outer surface of the finished product. The coating is preferably composed of a natural material. Examples of coating materials include, but are not limited to, one or more of: starch, lignin, cellulose, chitosan, shellac, rosin, polyhydroxyalkanoates, furanone, alginate, bee wax, and vegetable oils, or any combination thereof. The coating is preferably applied in order to reduce the oxygen permeability of the item of packaging The item of packaging (or at least a portion of an item of packaging) of the present invention has been found to display reduced oxygen permeability compared to conventional packaging. In one embodiment, the item of packaging (or at least a portion of an item of packaging) of the present invention has been found to display reduced oxygen permeability to achieve a hermetic seal, for example to be substantially impervious to oxygen. The item of packaging (or at least a portion of an item of packaging) of the present invention may therefore be used to store substances within a cavity (surrounded by the packaging or at least a portion thereof) with a reduced risk of the substance deteriorating or degrading due to exposure to oxygen. For example, the item of packaging (or at least a portion of an item of packaging) may be a beverage capsule (for example a coffee capsule) comprising dried beverage powder, such as coffee powder, stored within an internal cavity. The substance, such as for example a beverage powder, may advantageously maintain its original, intended flavour, taste and freshness for a significant period of time as the item of packaging of the present invention (or portion thereof), such as for example a beverage capsule, may advantageously prevent or reduce the risk of the substance (e.g. beverage powder) stored therein from being exposed to oxygen prior to use, such as for example prior to preparation of the beverage.

The item of packaging (or at least a portion of an item of packaging) of the present invention has been found to display good structural integrity, particularly when subjected to high temperatures and/or pressures, as well as resistance to water saturation exposure to water at high temperature and/or pressure. The item of packaging (or at least a portion of an item of packaging) of the present invention has been found to have sufficient strength to be suitable for use such as for (but not to be limited to) food or beverage packaging. The item of packaging of the present invention has been found to be microwave-safe and/or dishwasher-safe.

According to a further aspect of the present invention, there is provided an injection moulding apparatus for producing an injection moulded, home compostable item of packaging (or at least a portion of an item of packaging), the apparatus comprising: a feed cylinder comprising: a feed material comprising bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 pm, or a feed mixture comprising bamboo powder feed comprising bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 pm mixed with at least one binding material; a nozzle providing an inlet, an outlet, and an injection passageway extends between the inlet and the outlet; a pressurized fluid passageway extending between the feed cylinder and the inlet of the nozzle; a pressure source configured to subject the feed material or feed mixture to a pressure within the pressurized fluid passageway to ensure a constant predetermined flow rate of the feed material source through the injection passageway and/or the outlet of the nozzle; a mould for an item of packaging (or at least a portion of an item of packaging) in which the mould is in communication with the outlet of the nozzle; and optionally containing a coating material source configured to provide a coating to the item of packaging (or at least a portion of an item of packaging).

In one embodiment, the apparatus comprises: a primary feed cylinder comprising bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 pm; and a secondary feed cylinder comprising at least one binding material, in which each of the primary feed cylinder and secondary feed cylinder are in communication with the feed cylinder.

The bamboo powder may be sourced from bamboo. The bamboo may be chopped or shaved to provide chippings or shavings of bamboo. The chippings or shavings are preferably subsequently milled to provide bamboo powder. The bamboo powder may then be filtered by passing the bamboo powder through a filter or screen comprising pores having predetermined dimensions to ensure that the filtered bamboo powder obtained has a maximum dimension of no more than 500 pm. The bamboo powder may have a maximum dimension of no more than 3001.1m. The bamboo powder may have a minimum dimension of at least 301.1m, preferably at least 501.1m, more preferably at least 75 pm. A maximum dimension of the grains of bamboo powder of 500 pm, preferably 300 pm, is essential for use with injection moulding apparatus in order to ensure a suitable predetermined flow rate of the feed material or feed mixture through the nozzle without the risk of the formation of blockages.

In one embodiment, the feed cylinder and/or nozzle, preferably the feed cylinder and the nozzle, are heated to an operating temperature of at least 120 °C, preferably at least 160 °C, more preferably at least 180 °C. In one embodiment, the feed cylinder and/or nozzle, preferably the feed cylinder and the nozzle, are heated to an operating temperature of no more than 220 °C, preferably no more than 200 °C. In one embodiment, the feed cylinder and/or nozzle, preferably the feed cylinder and the nozzle, are heated to an operating temperature in the range of from 120°C and to 220 °C, preferably in the range of from 160°C and to 200 °C, more preferably in the range of from 180°C and to 200 °C.

It has been found that by heating one or more of the feed cylinder and nozzle to a temperature as defined herein that the feed material or feed mixture flows through the injection moulding at a satisfactory rate.

In one embodiment, the item of packaging mould (for example a coffee capsule mould) may be heated to a predetermined temperature. For example, the item of packaging mould may be heated to a temperature which is less than the operating temperature of the feed cylinder and nozzle. The item of packaging mould may be heated to a temperature of at least SO °C, preferably at least 80 °C The item of packaging mould may be heated to a temperature of no more than 200 °C, preferably no more than 160 °C. Preferably, the item of packaging mould may be heated to a temperature within the range of from 50°C and to 200 °C, preferably from 80°C and to 160 °C.

The temperature of the item of packaging mould may be controlled so as to be homogenous across the entire mould to avoid the production of physical and mechanical defects within the resultant item of packaging formed therein.

The bamboo powder or bamboo powder feed material or feed mixture is preferably fed through the injection nozzle and into the item of packaging mould at a predetermined flow rate. The predetermined flow rate will depend on a number of factors including the size and geometry of the mould.

Flow rate is measured using either volumetric flow rate (in cubic meters per second) or mass flow rate (in kg/s).

The method may further comprise: steaming the feed material or feed mixture to produce a steamed feed material or a steamed feed mixture; and drying the steamed feed material or steamed feed mixture to produce a steamed and dried feed material or a steamed and dried feed mixture.

The steaming step preferably exposes the feed material or feed mixture to steam, for example super-heated steam. In one embodiment, the steaming step comprises exposing the feed material or feed mixture to saturated water vapour at a temperature of at least 100 °C, preferably at least 150 °C, more preferably at least 170°C, for example about 200 °C. In one embodiment, the steaming step comprises the use of a pressure vessel and subjecting the feed material or feed mixture to a predetermined pressure of at least atmospheric pressure.

The steaming step preferably increases the moisture content of the steamed feed material or steamed feed mixture compared to the initial moisture content of the feed material or feed mixture. Preferably, the steaming step increases the moisture content of the steamed feed material or steamed feed mixture by at least about 50%, preferably about 100%, more preferably about 150%, for example about 200%, compared to the initial moisture content of the feed material or feed mixture.

The drying step comprises drying at a temperature of around 30 °C and/or oven drying at a temperature of at least 70°C, preferably at least 100 °C, for example about 105 °C.

In one embodiment, the feed mixture or feed material consists essentially of plant based material.

The at least one binding material is a bio-plastic or plant based resin. The at least one binding material is preferably selected from, but are not limited to, one or more of: polylactic acid (PLA), polyhydroxyallcanoates (PHA/PHB), polyhydroxybutyrate (PHBV), cellulose acetate, sucrose, corn starch, plant resin, polybutylene succinate (PBS), polycaprolactone (PCL), thermoplastic starch-based plastics (TPS), hemp, pine resin, lignines, tannines, or any combination thereof. The at least one binding material is preferably present in an amount of at least 20% by weight, more preferably 30% by weight of the bamboo powder feed material. The at least one binding material is present in an amount of no more than 60% by weight, more preferably SO% by weight of the bamboo powder feed. The at least one binding material may be present in an amount of from 20% to 60% by weight, preferably from 20% to 50% by weight of the bamboo powder feeds.

In one embodiment, the bamboo powder is dried, for example dehydrated, prior to introduction of the at least one binding material.

The feed material or feed mixture may further comprise one or more of: water, steam, dye, paint, natural toner, or any combination thereof. Preferably, the feed material or feed mixture comprises one or more of: dye and/or paint are water-based food safe dye and/or paint.

Optimal flow temperature for injection moulding of the item of packaging (or portion thereof) was found to be dependent on the composition of the feed material and the amounts or ratios of the ingredients.

The thermal fluidity and injection mouldability of steamed and dried feed material or feed mixture was investigated while controlling the temperature. Thermal analysis, such as differential thermal analysis and thermogravimetry, indicated that the steam treated feed material or feed mixture can undergo degradation at low temperatures and the weight loss of the steam treated bamboo powder was larger than that for untreated feed material or feed mixture.

Thermal flow tests of the steam treated bamboo powder at several temperatures revealed that the flow rate of the feed material or feed mixture was optimal when heated to a temperature between 180 and 220 °C.

In a further aspect, the present invention provides an injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) comprising bamboo, optionally further comprising at least one binding material.

The item of packaging of the present invention, for example a beverage capsule, can be manufactured with little expenditure and in a short time. The term "home compostable" is used herein to refer to an item which is fully biodegradable (i.e. 100% biodegradable) in domestic compost. To this end, the item of packaging of the present invention, for example a beverage capsule, is composed of a fully biodegradable and natural material(s), and does not produce any harmful byproducts during manufacture, use, or after disposal, such as for example during biodegradation.

The presence of binding material within the feed mixture has been found to improve the structural integrity and mechanical strength of the resultant item of packaging. Furthermore, the presence of binding material within the feed mixture has been found to also reduce the oxygen permeability of the item of packaging, enabling the formation of a hermetic seal for any contents of the packaging item.

Preferably, the injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) is formed from bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 p.m Preferably, the injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) is formed from a bamboo powder feed comprising bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 5001.1m mixed with at least one binding material.

In one embodiment, the item of packaging (or at least a portion of an item of packaging) is not composed of any hydrocarbon or petroleum based materials. For example, the item of packaging (or at least a portion of an item of packaging) is substantially free of hydrocarbon or petroleum based materials.

In one embodiment, the item of packaging (or at least a portion of an item of packaging) does not comprise any adhesive. For example, the item of packaging (or at least a portion of an item of packaging) is substantially free of adhesive.

In one embodiment, the item of packaging (or at least a portion of an item of packaging) consists entirely of home compostable, natural materials. The item of packaging (or at least a portion of an item of packaging) of the present invention are environmentally friendly as the items of packaging (or at least a portion of an item of packaging) consists entirely of materials which do not produce any harmful greenhouse gases or harmful by-products during degradation.

The item of packaging (or at least a portion of an item of packaging) of the present invention have been found to display good resistance to high temperatures and/or high pressures. The phrase "resistant to high temperatures and/or high pressures" is used herein to mean that the item of packaging (or at least a portion of an item of packaging) does not deform or deteriorate (for example lose shape or structure) when subjected to high temperatures and/or high pressures. For example, the item of packaging (or at least a portion of an item of packaging) does not deform or deteriorate when subjected to temperatures and/or pressures associated with the production of hot beverages, such as for example temperatures and/or pressures associated with the operation of coffee or espresso machines to produce hot beverages. For example, the item of packaging (or at least a portion of an item of packaging) does not deform or deteriorate when subjected to temperatures in the range of from 80°C to 110°C and/or pressure of about 19 bar which are associated with the production of hot beverages.

In one embodiment, the of packaging (or at least a portion of an item of packaging) further comprises a coating material composed of a natural material. The coating material may be selected from, but not limited to, one or more of: starch, lignin, cellulose, chitosan, shellac, rosin, polyhydroxyalkanoates, furanone, alginate, bee wax, and vegetable oils, or any combination thereof.

The item of packaging (or at least a portion of an item of packaging) of the present invention has been found to display good structural integrity, particularly when subjected to high temperatures and/or pressures. The item of packaging (or at least a portion of an item of packaging) of the present invention has been found to have sufficient strength to be suitable for use such as for (but not to be limited to) food packaging. Examples of food packaging include containers or vessels for holding and/or storing a substance (such as for example a liquid and/or a solid), particularly a substance having a raised temperature and/or pressure, such as for example a hot beverage or material for use in producing a hot beverage. The item of packaging (or at least a portion of an item of packaging) may for example include containers, such as for example reusable beverage cups, or capsules such as for example beverage capsules, or at least a portion thereof. In one embodiment, the item of packaging may be a capsule for the preparation of hot drinks, such as for example servings (and in particular individual servings) of coffee or tea used in connection with a coffee machine, or a portion thereof.

The item of packaging (or at least a portion of an item of packaging) of the present invention has also been found to have suitable plasticity and elasticity for use as a beverage capsule (comprising a capsule body and a lid), such as for example capsules for use with known coffee or espresso machines. In particular, the item of packaging (or at least a portion of an item of packaging) of the present invention has been found to have sufficient structural integrity so that the item is capable of maintaining its original structural form at elevated temperatures and/or pressures, whilst also being capable of being pierced by for example one or more needles, without shattering or splintering. The piercings are required in order to enable hot water to flow into for example a beverage capsule at elevated temperatures and pressures to form a hot beverage.

The item of packaging (or at least a portion of an item of packaging) of the present invention has been found to be impervious to oxygen. The item of packaging (or at least a portion of an item of packaging) of the present invention may therefore be used to store substances within a cavity (surrounded by the packaging or at least a portion thereof) with a reduced risk of the substance deteriorating or degrading due to exposure to oxygen. For example, the item of packaging (or at least a portion of an item of packaging) may be a beverage capsule (for example a coffee capsule) comprising dried beverage powder, such as coffee powder, stored within an internal cavity. The substance, such as for example a beverage powder, may advantageously maintain its original, intended flavour, taste and freshness for a significant period of time as the item of packaging of the present invention (or portion thereof), such as for example a beverage capsule, may advantageously prevent or reduce the risk of the substance (e.g. beverage powder) stored therein from being exposed to oxygen prior to use, such as for example prior to preparation of the beverage.

In one embodiment, the item of packaging is a capsule, or a portion thereof. The item of packaging mould may have a predetermined shape of a desired item of packaging such as for example a capsule (e.g. a beverage capsule). The capsule may comprise a capsule body comprising first end providing an opening, an opposed rear end, and side portions extending therebetween. The capsule may further comprise a lid configured to extend across and substantially seal the opening provided by the first end of the capsule. The lid may be in the form of a substantially flat sheet configured to extend between opposing sides of the opening, and preferably seal the capsule body. In one embodiment, the side portions and the rear end of the capsule body form a domed or conical shape. The capsule body and the lid preferably together define a cavity extending therebetween. The cavity is preferably configured to store a substance such as for example a beverage material (such as for example coffee or tea) therein.

One or more of the capsule body and/or lid (or a portion thereof) is preferably formed from a feed material comprising: bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 pm or a bamboo powder feed comprising bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 pm mixed with at least one binding material. Preferably, each of the capsule body and lid (or a portion thereof) are formed from a feed material comprising: bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 pm or a bamboo powder feed comprising bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 pm mixed with at least one binding material.

The injection moulded, home compostable item of packaging as herein described is preferably a coffee capsule. The injection moulded, home compostable beverage capsule is preferably a single-use beverage capsule.

The injection moulded, home compostable item of packaging, such as for example a beverage capsule, as herein described preferably comprises an inner surface and an opposed outer surface, and in which the outer surface has a gloss finish.

In one embodiment, the item of packaging, for example a beverage capsule, further comprises one or more of: water, dye, paint, natural toner, or any combination thereof. Preferably, the item of packaging, for example a beverage capsule, comprises one or more of: dye and/or paint are water-based food safe dye and/or paint.

In one embodiment, the item of packaging (or portion thereof) comprises no more than 5% by weight, preferably no more than 2% by weight, more preferably no more than 1% by weight of total content of dye, paint and natural toner compared to the total weight of the item of packaging (or portion thereof).

In one embodiment, the item of packaging (or portion thereof) comprises no more than 15 % by weight, preferably no more than 10% by weight, more preferably no more than 6% by weight of total content of water compared to the total weight of the item of packaging (or portion thereof).

In one embodiment, the ratio of content (by weight %) of bamboo powder to binding material within the item of packaging (or portion thereof) is at least 1:1, preferably at least 1.5: 1, more preferably at least 1.75:1, for example at least 2:1. The ratio of bamboo to binding material within the item of packaging (or portion thereof)may be no more than 10:1, preferably no more than 7:1, more preferably no more than 5:1, for example no more than 3:1. The ratio of bamboo to binding material within the item of packaging (or portion thereof) may be from 1:1 to 10:1, preferably from 1.5:1 to 7:1, more preferably from 1.75:1 to 5:1, for example from 2:1 to 3:1.

DETAILED DESCRIPTION

Example 1 -Method for Producing a Beverage Container from Bamboo and Superheated Steam/Water Bamboo is introduced into an automatic feed planer to create bamboo shavings. The bamboo shavings are milled to obtain a fine bamboo powder. The bamboo powder is then passed through a filter with 300 pm pores to provide a powder having a maximum dimension of 300 pm.

The bamboo powder is then placed within a pressure vessel and subjected to a pressure of at least atmospheric pressure. The pressure vessel comprises a saturated water vapour and is heated to a temperature of around 200 °C. The moisture content (measured by mass relative to the initial feed material or feed mixture) of the bamboo powder is increased to approximately 200% of the initial dry bamboo powder (prior to steaming). The moisture content can be measured by use of moisture analysers such as: mass-base and sensor-base instruments. The methods for determining moisture content include, but are not limited to: calorimetric methods, thermogravimetric methods and spectroscopic methods. Once the moisture content of the bamboo powder has increased to approximately 200% of the initial dry bamboo powder, the steaming process continues for a further 20 minutes.

After steaming, the steamed bamboo powder is cooled and dried at a temperature of around 30 °C.

The bamboo powder is then oven dried at a temperature of at least 105°C to produce a steamed and dried bamboo powder.

The steamed and dried bamboo powder is placed within a feed cylinder of an injection moulding apparatus. The steamed and dried bamboo powder is heated to a temperature of between 180 °C and 200°C and subjected to an applied pressure. The feed cylinder and the injection nozzle are heated to a temperature of between 180°C and 200 °C. A flow test should be conducted in order to determine the flowability of the steamed bamboo powder. It has been found that the bamboo powder has good flowability characteristics at a temperature of between 160°C and 220 °C.

The powder flows from the feed cylinder, through an injection nozzle and into the capsule mould having a predetermined shape of the desired beverage capsule, i.e. the body of the capsule. The capsule mould is heated to a lower temperature than the feed cylinder and the injection nozzle. The capsule mould is heated to a temperature of between 80 °C and 160 °C. It is to be noted that the temperature of the capsule mould will depend on the specific geometry, exact size and wall thickness of the beverage capsule. The capsule mould temperature may also be a factor in determining the surface finish of the capsule. For example, a beverage capsule having a gloss outer surface may be produced by maintaining the capsule mould at a temperature of from 140°C and 160 °C.

Example 2-Method for Producing a Beverage Container from Bamboo and Binder Bamboo is introduced into an automatic feed planer to create bamboo shavings. The bamboo shavings are milled to obtain a fine bamboo powder. The bamboo powder is then passed through a filter with 300 -500 p.m pores to provide a powder having a maximum dimension of 500 Rm.

The bamboo powder is then dehydrated in a drying oven to remove moisture content.

Binding material (and distilled water if suitable, for example if using a water soluble binding material) is then mixed with the dehydrated bamboo powder to provide a bamboo powder feed. Excess water is exported until the desired flow properties (i.e. the ability for the material to flow easily enough to be used for injection moulding) are achieved. In the illustrated embodiment, the binder material is sucrose and present in an amount of 30% by weight compared to the total weight of the bamboo powder feed.

The bamboo powder feed is placed within a feed cylinder of an injection moulding apparatus. The bamboo powder feed is heated to a temperature of between 180°C and 200°C and subjected to an applied pressure. The feed cylinder and the nozzle are heated to a temperature of between 180 °C and 200 °C. A flow test should be conducted in order to determine the flowability of the steamed bamboo powder. It has been found that the bamboo powder feed has good flowability characteristics at a temperature of between 160°C and 220°C.

The plasticization temperature of the binder material within the powder feed may be determined by thermogravimetric or differential thermal analysis in order to determine the optimal thermal flow temperature of the powder feed. Optimal flow temperature of the powder feed will be dependent on the composition of the powder feed.

It was found that the flow behaviour and flow temperature tests showed that the plasticization point of the sucrose binder is typically around 176 °C, with a mass reduction onset at 200 °C due to decomposition to volatile products.

It was found that the bamboo powder feed mixture comprising sucrose flowed readily at temperatures above 180 °C, although flow was restricted at temperatures above 220 °C due to the effect of gases evolving from the sucrose. It was found that the minimum amount of binding material required to be present to achieve predetermined flow characteristics of the feed was at least 20% by weight compared to the total weight of the feed mixture.

The powder feed flows from the feed cylinder, through an injection nozzle and into the capsule mould having a predetermined shape of the desired beverage capsule. The capsule mould is heated to a lower temperature than the feed cylinder and the injection nozzle. The capsule mould is heated to a temperature of between 80°C and 160°C It is to be noted that the temperature of the capsule mould will depend on the specific geometry, exact size and wall thickness of the beverage capsule. The capsule mould temperature and homogeneity may also be a factor in determining the surface finish of the capsule. For example, a beverage capsule having a gloss outer surface may be produced by maintaining the capsule mould at a temperature of from 140°C and 160 °C.

Although the illustrated embodiment uses sucrose as the binder material, it is to be understood that the binding material may comprise one or more of: polylactic acid (PLA), polyhydroxyallcanoates (PHA/PHB), polyhydroxybutyrate (PHBV), cellulose acetate, sucrose, corn starch, plant resin, polybutylene succinate (PBS), polycaprolactone (PCL), thermoplastic starch-based plastics (TPS), hemp, pine resin, lignines, tannines, or any combination thereof.

Example 3 -Four Point Bending Strength and Rockwell Superficial Hardness The four point bending strength and Rockwell superficial hardness of the bamboo beverage capsules of the present invention were found to increase with both mould temperature and injection temperature up to approximately 200 C. Both bending strength and Rockwell hardness were high when the injection temperature was 180 °C, and the highest values obtained were 36 MPa and HR15w78 for bending strength and Rockwell hardness, respectively.

Observation of the fracture location of the bamboo coffee capsule confirmed that the fibre strength of the product moulded at an injection temperature of 180 °C was maintained, while fibre strength of those that were moulded at an injection temperature of 200 °C was not.

Flow behaviour of the mixture was evaluated for the temperature and the binder content by capillary flow tests. Based on these data, moulding test of wood powder with sucrose was conducted to evaluate the injection mouldability.

Example 4 -Beverage Capsule Lid A beverage capsule lid was formed following the methods of Examples 1 and 2. The mould provides a cavity with the predetermined shapes and dimensions of a lid for extending across (and substantially sealing) the opening provided at a first end of the beverage capsule body formed in Examples 1 and 2.

It is to be understood that the feed material or feed mixture used within Examples land 2 to form the capsule body of the beverage capsule may differ to the feed material or feed mixture used following the methods of Examples 1 and 2 to produce the lid of the beverage capsule. Alternatively, the feed material or feed mixture used within Examples 1 and 2 to form the capsule body of the beverage capsule may be the same as the feed material or feed mixture used following the methods of Examples land 2 to produce the lid of the beverage capsule.

Example 5 -Composition of Beverage Capsule An example of the composition of the bamboo beverage capsule of the present invention is as follows:

Material Percentage composition Description

Bamboo powder 63% Obtained from finely grinding down decommissioned/sterilised bamboo products, such as chopsticks, tablemats and scaffolding.

Organic plant resin 20% e.g. Mastic resin, Melamine resin, PLA resin, or tree/plant resin.

Corn-starch 10% Corn starch acts as a natural, food-safe binder for the bamboo fibres. It also aids biodegradability.

Water-based food-safe paint/dye 0.5% A natural, acrylic paint that is water based (or waterborne). Contains only natural resins and pigments that are certified food-safe according to ROHS, REACH and FDA standards.

Water 6% Improves flowability and malleability during the casting or injection moulding process when manufacturing the capsule.

Natural toner 0.5% An optional ingredient, organic toners or pigments can improve aesthetics of the capsules.

It is to be understood that this is one example of the item of packaging of the present invention. In one embodiment, the item of packaging (or portion thereof) may not contain paint and/or toner. In one embodiment, the item of packaging (or portion thereof) may contain a single binding material, or more than two binding materials. Furthermore, the item of packaging may not be a coffee capsule or beverage capsule. The item of packaging (or portion thereof) may include higher or lower proportions of bamboo powder and/or binder material. In one embodiment, the item of packaging (or portion thereof) may additionally comprise natural food coating, such as pectin polysaccharide.

Claims

CLAIMS1. A method for producing an injection moulded, home compostable item of packaging or at least a portion of an item of packaging, the method comprising: obtaining a feed material comprising of bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 ilm; obtaining an injection moulding apparatus comprising a feed cylinder, a nozzle and a mould for an item of packaging (or at least a portion of an item of packaging), in which the feed cylinder is in communication with the nozzle, and the nozzle is in communication with the mould; optionally mixing the bamboo powder with at least one binding material to produce a feed mixture; introducing the feed material or feed mixture into the feed cylinder; heating the feed cylinder and nozzle to a temperature of at least 120 °C; feeding the feed material or feed mixture from the feed cylinder, via the nozzle to the mould at a predetermined temperature and under an applied pressure to produce an item of packaging or at least a portion of an item of packaging.
2. A method as claimed in claim 1, further comprising mixing the bamboo powder with at least one binding material to produce a feed mixture.
3. A method as claimed in either of claims land 2, further comprising: steaming the feed material or feed mixture to produce a steamed feed material or a steamed feed mixture; and drying the steamed feed material or steamed feed mixture to produce a steamed and dried feed mixture or steamed and dried feed material.
4 A method as claimed in claim 3, in which the steaming step increases the moisture content of the steamed feed material or feed mixture by about 200% compared to the initial moisture content of the feed material or feed mixture.
5. A method as claimed in any preceding claim, in which the maximum dimension of grains of the bamboo powder has a maximum dimension of no more than 500
6. A method as claimed in any one of claims 1 to 5, in which the feed cylinder and/or nozzle are heated to a temperature of at least 120 °C, preferably at least 180 °C.
7. A method as claimed in any one of claims 1 to 6, further comprising heating the mould to a temperature of at least 50°C.
8. A method as claimed in either of claims 6 and 7, in which the mould is heated to a temperature of no more than 200 °C.
9 A method as claimed in any one of claims 1 to 8, in which the at least one binding material is selected from one or more of: polylactic acid (PLA), polyhydroxyallcanoates (PHA/PHB), polyhydroxybutyrate (PHBV), cellulose acetate, sucrose, corn starch, plant resin, polybutylene succinate (PBS), polycaprolactone (PCL), thermoplastic starch-based plastics, hemp, pine resin, lignines, tannines, or any combination thereof.
10. A method as claimed in any one of claims 1 to 9, in which the at least one binding material is present in an amount of at least 20% by weight or volume of the bamboo powder feed.
11. A method as claimed in any one of claims 1 to 10, in which the at least one binding material is resent in an amount of no more than 60% by weight or volume of the bamboo powder feed.
12. A method as claimed in any one of claims 1 to 11 further comprising coating the packaging or at least a portion of an item of packaging with a coating material composed of a natural material.
13. A method as claimed in claim 12, in which the coating material is selected from one or more of: starch, lignin, cellulose, chitosan, shellac, rosin, polyhydroxyalkanoates, furanone, alginate, bee wax, and vegetable oils, or any combination thereof.
14. An injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) comprising bamboo, optionally further comprising at least one binding material.
15. An injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) as claimed in claim 14, further comprising at least one binding material selected from one or more of: polylactic acid (PLA), polyhydroxyallcanoates (PHA/PHB), polyhydroxybutyrate (PHBV), cellulose acetate, sucrose, corn starch, plant resin, polybutylene succinate (PBS), polycaprolactone (PCL), thermoplastic starch-based plastics (TPS), hemp, pine resin, lignines, tannines, or any combination thereof.
16. An injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) as claimed in either of claims 14 and 15, in which the item of packaging is a beverage capsule.
17. An injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) as claimed in claim 15, in which the beverage capsule is a coffee capsule.
18. An injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) as claimed in either of claims 16 and 17, in which the capsule comprises a capsule body and a lid, and in which one or more of the capsule body and lid are formed from bamboo, optionally further comprising at least one binding material.
19. An injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) as claimed in any one of claims 14 to 18, in which the packaging (or at least a portion thereof) is free of non-renewable petroleum or hydrocarbon based materials.
20. An injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) as claimed in any one of claims 14 to 19, comprising or configured to form a hermetic seal.
21. An injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) as claimed in any one of claims 14 to 19, in which the item (or at least a portion thereof) is a lid for a beverage capsule.
22. An injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) as claimed in any one of claims 14 to 19, further comprising a coating material composed of a natural material
23. An injection moulded, home compostable item of packaging (or at least a portion of an item of packaging) as claimed in claim 22, in which the coating material is selected from one or more of: starch, lignin, cellulose, chitosan, shellac, rosin, polyhydroxyalkanoates, furanone, alginate, bee wax, and vegetable oils, or any combination thereof.
24. An injection moulding apparatus for producing an injection moulded, home compostable item of packaging (or at least a portion of an item of packaging), the apparatus comprising: a feed cylinder comprising: a feed material comprising bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 i_trn, or a feed mixture comprising bamboo powder feed comprising bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 pim mixed with at least one binding material; a nozzle providing an inlet, an outlet, and an injection passageway extends between the inlet and the outlet; a pressurized fluid passageway extending between the feed cylinder and the inlet of the nozzle; a pressure source configured to subject the feed material or feed mixture to a sufficient pressure within the pressurized fluid passageway to ensure a constant predetermined flow rate of the feed material source through the injection passageway and/or the outlet of the nozzle; a mould for an item of packaging (or at least a portion of an item of packaging) in which the mould is in communication with the outlet of the nozzle; and optionally containing a coating material source configured to provide a coating to the item of packaging (or at least a portion of an item of packaging).
25. An apparatus as claimed in claim 24, in which the apparatus comprises: a primary feed cylinder comprising bamboo powder in which the maximum dimension of grains of the bamboo powder is no more than 500 i_trn; and a secondary feed cylinder comprising at least one binding material, in which each of the primary feed cylinder and secondary feed cylinder are in communication with the feed source cylinder.