[go: up one dir, main page]

WO2003051980A1 - Procede de moulage d'un article biodegradable - Google Patents

Procede de moulage d'un article biodegradable Download PDF

Info

Publication number
WO2003051980A1
WO2003051980A1 PCT/CA2002/002005 CA0202005W WO03051980A1 WO 2003051980 A1 WO2003051980 A1 WO 2003051980A1 CA 0202005 W CA0202005 W CA 0202005W WO 03051980 A1 WO03051980 A1 WO 03051980A1
Authority
WO
WIPO (PCT)
Prior art keywords
amount
mixture
mold
grouping
weight
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CA2002/002005
Other languages
English (en)
Inventor
Doug Harle
Sunmin Wang
Richard C. Green
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to AU2002351622A priority Critical patent/AU2002351622A1/en
Publication of WO2003051980A1 publication Critical patent/WO2003051980A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D65/00—Wrappers or flexible covers; Packaging materials of special type or form
    • B65D65/38—Packaging materials of special type or form
    • B65D65/46—Applications of disintegrable, dissolvable or edible materials
    • B65D65/466—Bio- or photodegradable packaging materials
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L3/00—Compositions of starch, amylose or amylopectin or of their derivatives or degradation products
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A40/00—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production
    • Y02A40/90—Adaptation technologies in agriculture, forestry, livestock or agroalimentary production in food processing or handling, e.g. food conservation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W90/00—Enabling technologies or technologies with a potential or indirect contribution to greenhouse gas [GHG] emissions mitigation
    • Y02W90/10—Bio-packaging, e.g. packing containers made from renewable resources or bio-plastics

Definitions

  • the present invention relates to a biodegradable, disposable, thin walled, molded article and more particularly to a method of making an article using flour from an edible crop plant, for example wheat flour, as a main ingredient.
  • trays were prepared from a formula which comprised wheat starch, pre-gelatinized starch, starch acetate, water and ethanol. The mixture was molded at 250 °C to form a tray with a 1.5 mm thickness.
  • Biodegradable trays have also been made from protein-based materials, such as corn gluten meal which is a by-product of ethanol production (Wei et al., 1996- 1998). The trays were used for short term packaging of fresh food and seed planting cups for horticulture.
  • the use of biodegradable polymers to replace conventional synthetic materials reduces consumption of non-renewable resources and decreases waste through biological recycling to the bio-system. Enormous potentials exist for the development and marketing of environmental friendly and biodegradable products.
  • US Patent 6,461 ,549 to Meeuwsen describes a method of producing a biodegradable product in which an edible crop plant flour is mixed with wood flour, natural wax and water. The mixture is molded at elevated temperature and pressure to produce a molded product. While wood flour provides some structural integrity to the finished molded product, strength of the product is limited because cellulose in wood flour is already networked and bound with other wood components such as resin and hemicellulose which limits bonding of the various ingredients in the molded product. Furthermore, the complex mixture of aliphatic esters and aliphatic higher alcohols in the natural wax may migrate within the structure so that the emulsification and stabilization properties of the tray formulation would be limited.
  • a method of making a molded article comprising: providing a grouping of dry ingredients including an amount of plant flour, an amount of hydrocolloid, an amount of cellulose fibre, an amount of alcohol sugar and an amount of pre-gelatinised starch; providing an amount of water; mixing said grouping of dry ingredients with said amount of water to form a mixture; providing a mold; filling the mold with the mixture; heating the mold; applying pressure to the mixture within the mold so as to form a thin walled article from the mixture; and releasing the article from the mold after a prescribed cooking time has expired.
  • the amount of plant flour may have a weight in a range between 50% and 75% of a combined weight of said grouping of dry ingredients, but is preferably in a range between 50% and 60% of said grouping of dry ingredients, and is most preferred to be approximately 55% of a combined weight of said grouping of dry ingredients.
  • the plant flour preferably comprises flour derived from an edible crop plant, for example wheat flour.
  • the amount of hydrocolloid may have a weight in a range between 5% and 15% of a combined weight of said grouping of dry ingredients, but is preferably in a range between 7% and 13%, and is most preferred to be approximately 10% of a combined weight of said grouping of dry ingredients.
  • the hydrocolloid is preferably a long-chain, high molecular weight polymer, which may comprise a plant seed gum, for example guar gum.
  • the amount of cellulose fibre may have a weight in a range between 5% and 15% of a combined weight of said grouping of dry ingredients, but is preferably in a range between 7% and 13%, and is most preferred to be approximately 10% of a combined weight of said grouping of dry ingredients.
  • the cellulose fibre preferably comprises a dietary fibre which is a pure, refined cellulose, for example Solka-Floc.
  • the amount of alcohol sugar may have a weight in a range between 2% and 10% of a combined weight of said grouping of dry ingredients, but is preferably in a range between 3% and 7%, and is most preferred to be approximately 5% of a combined weight of said grouping of dry ingredients.
  • the alcohol sugar preferably comprises a sugar which does not undergo carmelization, and which includes a plurality of hydroxyl groups which are available for bonding.
  • the amount of pre-gelatinised starch may have a weight in a range between 10% and 30% of a combined weight of said grouping of dry ingredient, but preferably is in a range between 15% and 25%, and is most preferred to be approximately 20% of a combined weight of said grouping of dry ingredients.
  • the amount of water may have a weight in a range between 5% and 85% of a combined weight of said grouping of dry ingredients, but preferably is in a range between 10% and 20% of a combined weight of said grouping of dry ingredients, and is most preferred to be approximately 15% of a combined weight of said grouping of dry ingredients.
  • the method may include adding a preservative to the grouping of dry ingredients, for example sodium benzoate.
  • a preservative to the grouping of dry ingredients, for example sodium benzoate.
  • the amount of sodium benzoate may have a weight which is in a range between 0.1 % and 0.9% of a combined weight of said grouping of dry ingredients, but is preferred to be approximately 0.5% of a combined weight of said grouping of dry ingredients.
  • At least one of the amount of plant flour, the amount of hydrocolloid, the amount of cellulose fibre, the amount of alcohol sugar and the amount of pre-gelatinised starch preferably includes between 3 and 6 hydroxyl groups per molecule which are available for bonding.
  • the pressure is preferably applied to the mixture in the range of 59 psi to 946 psi.
  • An ideal pressure is between 236 and 355 psi, but variation within the preferred range still provides reasonable results.
  • the mold is preferably heated to a temperature in the range of 100 degrees Celsius to 150 degrees Celsius.
  • An ideal surface temperature of the dies of the mold is between 120-130 degrees Celsius.
  • the water in the mixture preferably has a combined weight which is less than 23% of the total weight of the mixture.
  • the weight of water noted herein preferably includes the water content of the wheat flour added to the mixture.
  • the mixture preferably has a powder like consistency when it is placed in the mold.
  • the water content added to the flour is sufficiently low to only slightly moisten the flour, thus producing a moistened powder consistency which is easily mixed and handled unlike dough when too much water is added.
  • the prescribed cooking time is preferably in the range of 6 minutes to 12 minutes.
  • the flour may comprise either whole wheat flour or white refined wheat flour, as well as a variation of other flours derived from edible crop plants which have similar characteristics.
  • the mold is preferably preheated before being filled with the mixture.
  • Water contained in the article released from the mold preferably has a combined weight which is substantially less than 23% of a combined weight of the article.
  • Pressure applied to the mixture preferably has a substantially constant magnitude throughout the prescribed cooking time. Variation of the pressure applied to the mixture may be required to accommodate for variation in the dimensions of the mixture as it is cooked.
  • the mold preferably comprises a pair of mating dies which are urged towards one another when applying pressure to the mixture.
  • the method may include moving the dies towards one another during the prescribed cooking time so as to apply a substantially constant pressure on the mixture as water is released from the mixture.
  • the powder like consistency of the mixture enables various powdered additives to be easily mixed into the mixture without extra water being required.
  • additives may include a powdered dye, a pre-gelatinised starch (preferably corn starch), a binding agent (preferably guar gum), a humectant (preferably D-Sorbitol), a cellulose fibre (preferably a dietary fibre) and/or a preservative (preferably Sodium Benzoate).
  • a method of making a molded article comprising: providing a grouping of dry ingredients including an amount of plant flour and an amount of hydrocolloid; providing an amount of water; mixing said grouping of dry ingredients with said amount of water to form a mixture; providing a mold; filling the mold with the mixture; heating the mold; applying pressure to the mixture within the mold so as to form a thin walled article from the mixture; and releasing the article from the mold after a prescribed cooking time has expired.
  • a method of making a molded article comprising: providing a grouping of dry ingredients including an amount of plant flour and an amount of cellulose fibre; providing an amount of water; mixing said grouping of dry ingredients with said amount of water to form a mixture; providing a mold; filling the mold with the mixture; heating the mold; applying pressure to the mixture within the mold so as to form a thin walled article from the mixture; and releasing the article from the mold after a prescribed cooking time has expired.
  • a method of making a molded article comprising: providing a grouping of dry ingredients including an amount of plant flour and an amount of alcohol sugar; providing an amount of water; mixing said grouping of dry ingredients with said amount of water to form a mixture; providing a mold; filling the mold with the mixture; heating the mold; applying pressure to the mixture within the mold so as to form a thin walled article from the mixture; and releasing the article from the mold after a prescribed cooking time has expired.
  • a method of making a molded article comprising: providing a grouping of dry ingredients including an amount of plant flour and an amount of pre-gelatinised starch; providing an amount of water; mixing said grouping of dry ingredients with said amount of water to form a mixture; providing a mold; filling the mold with the mixture; heating the mold; applying pressure to the mixture within the mold so as to form a thin walled article from the mixture; and releasing the article from the mold after a prescribed cooking time has expired.
  • a thin walled molded article formed of a mixture including an amount of plant flour, an amount of hydrocolloid, an amount of cellulose fibre, an amount of alcohol sugar, an amount of pre-gelatinised starch and water.
  • the article preferably has a thickness approximately in a range of 3 millimetres to 4 millimetres.
  • the low water content in a tray formed substantially of flour from an edible crop plant provides a biodegradable tray which maintains a reasonable consistency even when exposed to water for an given period of time. Trays produced from a high pressure molding process, even when formed substantially of wheat flour, have a high capacity to resist water absorption.
  • Figure 1 is a top plan view of a tray.
  • Figure 2 is a sectional view of the tray along the line 2-2 of Figure 1.
  • Figure 3 is a front elevational view of the hydraulic press and mold.
  • Figure 4 is a sectional view of the mold along the line 4-4 of Figure 3.
  • the tray 12 is a biodegradable, thin walled, molded article which can be formed using various ingredients in combination with flour from an edible crop plant as described herein.
  • the tray 12 illustrated herein in Figures 1 and 2 is only one example of a molded article which can be formed according to the present invention.
  • the tray 12 has a flat bottom 14 which is circular in shape with sides 16 extending at an incline upwardly and outwardly from a periphery of the bottom 14 to an annular upper flange 18 about a top end of the tray 12.
  • the bottom sides and upper flange have an even thickness of approximately 3 to 4 mm. The selection of the thickness depends upon the desirability of strength as well as the desirability of ease of manufacturing by reducing cooling time and raw materials used.
  • the tray 12 being molded has an even surface with a slight texture resulting from the texture of the particles used as ingredients, for example the particles in whole wheat flour.
  • the tray 12 is hard with a somewhat water resistant surface as a result of the processes to be described herein in which starches in the raw ingredients are partially gelantinized.
  • the tray 12 is formed from a mixture having the following ingredients:
  • Wheat flour and whole wheat flour The flours were used as main tray ingredients. Commercial all purpose refined wheat flour and whole wheat flour were purchased from a local supermarket. Wheat flour can be used to obtain reasonable results with water when using a thermo-molding process. The addition of few additives provides improved results. Other flours from edible crop plants having similar characteristics could be effectively used in place of wheat flour.
  • Pre-qelatinized corn starch was used as structure/strength builder. The pre-gelatinized starch assists in resisting cracks by adding strength and some flexibility to the finished tray. It was supplied by Charles Tennant & Company (Weston, Ontario, Canada).
  • D-Sorbitol is a humectant which was used as a softner or moisture holder. By retaining some moisture, the finished tray has reduced brittleness. It was supplied by Fisher Scientific (Fairlawn, NJ, USA).
  • Fibre A natural dietary fibre (Solka-Floc) was used as a structure/strength element to increase strength by providing some increased flexibility and thereby reduce brittleness. It was supplied by Canada Colors and Chemical Limited (Don Mills, Ontario, Canada).
  • Guar gum was used as a binder and water barrier for added strength and reduced flexibility. It was supplied by Hercules Inc. (Wilmington, DE, USA).
  • Sodium Benzoate Sodium benzoate was used as a preservative and applied at 0.5% in the tray formula.
  • Colorants Three food grade colorants (red, orange, and purple) were added separately to the tray formula at 0.14% (weight of colorant/ weight of dry ingredients, x100%).
  • Water was used to mix with tray ingredients. It was also used to dissolve colorants in some embodiments.
  • Pre-weighed dry ingredients were mixed with water in a Hobart Food Mixer (Model: N-50, Hobart Canada, Inc., Don Mills, Ontario, Canada) for 5 min.
  • the dough developed was allowed to sit for 1 h before it was manually sheeted to 3-4 mm in thickness.
  • the dough sheet was placed between two 9" pie pans, which were then clamped. Trays were baked at 110-170 °C for 1-2 h. After the baking, tray and the pans were cooled to room temperatures before the tray was released.
  • the tray formula was studied. Baked trays were evaluated for uniformity in shape and color, and surface smoothness. Baking temperatures (110-170 °C) and baking time (1-2 h) were investigated.
  • the baking study was designed to determine optimum tray formula and baking protocol. It formed a basis for development of press thermo-molding method.
  • thermo-molding method suits the purpose for low cost and mass production of trays with consistent quality.
  • the thermo-molding method uses a hydraulic press 30, as shown in Figures 3 and 4, for forming the trays 12 under heat and pressure.
  • the hydraulic press 30 includes a frame 32 having an upper support member 34 spanning laterally across a top end thereof and a lower support member 36 spanning laterally across the frame 32 spaced below the upper support member 34.
  • a mold is provided on the press 30 which includes a lower female die 38 and an upper male die 40.
  • the lower female die 38 is fixed on the lower support 36 of the frame and includes a recessed molding surface 42 in a top side thereof which mates with a lower surface of the molded article.
  • the upper male die 40 is mounted above the lower female die 38 for vertical sliding movement in relation to the lower female die.
  • the upper male die 40 is supported at respective corners on shafts 44 extending upwardly from the lower female die and slidably mounting the upper die thereon.
  • the upper male die 40 includes a protruding molding surface 46 in a bottom side thereof which is arranged to fit within the recessed molding surface 42 of the lower female die.
  • the protruding molding surface 46 is arranged to mate with the upper surface of the molded article.
  • a plurality of stops 48 are provided about a periphery of the male die 40 for engaging between the upper and lower dies to prevent the dies from moving closer than 3 mm away from one another.
  • the distance between the dies as prescribed by the stops 48 is predetermined based upon the desired final thickness of the molded article.
  • a series of three electric heating elements 50 are mounted within each of the dies 38 and 40 evenly spaced apart from one another so as to be arranged to heat the respective dies with a substantially even molding surface temperature.
  • Separate controls 52 including respective thermostats are provided for controlling the temperature of the respective dies within a preset range of temperatures or at a specific prescribed temperature for each die.
  • a hydraulic piston cylinder 54 is provided being coupled at a cylinder end on the upper support 34 of the frame and being coupled at a piston and on the upper male die 40 for controlling the relative position of the upper male die in relation to the lower female die as the hydraulic piston cylinder is extended and contracted. Extension of the hydraulic piston cylinder urges the upper male die 40 downwardly towards the lower female die for applying pressure to a mixture located between the dies.
  • a gauge 56 is coupled to the hydraulic piston cylinder 54 for determining the amount of pressure exerted on the mixture within the mold by the hydraulic piston cylinder.
  • a pressure control element 58 is provided for controlling the amount of pressure exerted on the mold in response to readings from the gauge 56.
  • the gauge 56 records the actual pressure of fluid within the hydraulic piston cylinder 54. Due to the difference in cross sectional area of the chamber within the piston cylinder and the cross sectional area of the upper and lower dies, the actual pressure on the mixture between the dies will only be a fraction of the pressure recorded by the gauge 56.
  • the cylinder has a radius of approximately 2.25 inches while the upper and lower dies have a radius of approximately 4.625 inches.
  • the dies are determined to have a cross sectional area which is approximately 4.23 times greater than that of the piston cylinder and thus the pressure of fluid in the piston cylinder as measured by the gauge will be 4.23 times greater than the actual pressure acting on the mixture between the dies.
  • the hydraulic press 30 (Princess Auto Ltd. Winnipeg, MB) used for the thermo-molding has a maximum 30 T force load.
  • the mold has a heating capability and was designed for use in the press 30.
  • the mold comprises basically of two parts, an upper male die and a lower female die, both of which are made from aluminum metal. Both dies are tray shaped, and measure 160-240 mm in diameter and 25 mm in depth.
  • the mold and associated connections for the press were manufactured at AJ Machine & Manufacturing Ltd. (Saskatoon, SK).
  • three electrical heaters each are housed in the upper and lower die, which allow die surface temperatures to reach 150 °C or higher. Die temperatures are displayed and can be adjusted through a control box.
  • the lower die is stationary, while the upper die is able to travel downward or upward. A minimum gap of 3 mm between the two dies is ensured when they are completely closed.
  • the tray preparation procedures are described as follows. Both dies were pre-heated to pre-determined surface temperatures, which were between 100-140 °C. A pre-determined amount of tray formula (275 g) was placed into the lower plate lined with an aluminum foil, and was spread evenly. Then another sheet of aluminum foil was placed on the top of the evenly spread formula. The use of aluminum foil was to prevent the tray from sticking to the dies when the tray was released after molding. The upper plate was then gradually lowered to compress the formula to a pre-determined pressure, which ranged from 59 to 473 psi. Simultaneous actions of compression, cooking and formation were thus exerted on the formula. Following 6-15 min holding period, the tray was released by slowly raising the upper die.
  • a sufficient amount of the mixture for forming the tray is placed within the mold so as to produce a tray having a thickness in the order of 3 to 4 millimeters. Thinner and thicker trays can be molded, however thinner trays will be less strong and thicker trays will require more cooling time and more raw material. 4. Characterization of Trays
  • a Texture Test System (model TMS-90, Food Technology Corp., Rockville, MD) was used. The flat bottom components of the trays were cut into four 7.5x4 cm rectangular pieces, which were then placed horizontally onto a cylinder-type round testing cell (diameter: 6.5 cm). A round plunger having 1.9 cm diameter travelled at a speed of 20 mm/min to hit the piece until it was broken. Maximum breaking forces were recorded, and a mean maximum breaking force, following four repetitive tests, was used to characterize the strength of trays.
  • Trays were floated in a sink filled with water at room temperature. Trays were evaluated for deformation for a period of 24 h. With another set of trays, 50 ml of water was poured into each tray. The trays were placed on the lab counter for a period of 24 h, during which trays were evaluated for deformation and water uptake.
  • Tests were carried out to determine appropriate levels of ingredients, water content, and baking conditions.
  • a Trays were made from whole wheat flour and water only. Tray thickness ranged from 3-4 mm. bdough water content was calculated by including initial water in whole wheat flour.
  • doughs made from whole wheat flour and water were sheeted and baked at 100, 140, 170 °C, for 1.0, 1.5, and 2.0 h, respectively.
  • high baking temperature (170 °C), and/or prolonged baking periods (2.0 h) resulted in over-cooked trays, which were partially burnt.
  • Baking temperatures at 140+10 °C, coupled with a baking period of 1.5 h were found to be optimum to produce trays with the best external appearance and uniformity.
  • a Tray formula was therefore proposed. It included 50-75% whole wheat flour, 10-30% pre-gelatinized starch, 5-10% guar gum, 5-10% D-sorbitol, 5-10% Solka- Floc, 0.1-0.5% sodium benzoate (as preservative), and an optimum amount of water. Following more baking tests, the optimum tray formula was determined as follows: whole wheat flour (55%), Pre-gelatinized starch (20%), Guar gum (10%), D-sorbitol (5%), Solka- Floc (10%), Sodium Benzoate (0.5%) and Water (85%). The weight of each ingredient is expressed in parentheses as a percentage of the total dry ingredients combined.
  • thermo-molding conditions were also designed to determine thermo-molding conditions, which included die temperature, pressure and cooking time.
  • thermo-molding method was determined to be as follows: whole wheat flour (55%), pre-gelatinized starch (20%), Guar gum (10%), D-sorbitol (5%), Solka- Floc (10%), Sodium Benzoate (0.5%) and Water (14.7%).
  • the weight of each ingredient is expressed in parentheses as a weight percentage of the total ingredients combined (excluding added water), on an as is basis.
  • the formula prepared for the molding method was essentially a moistened flour mixture. No sheeting and sheeting related equipment was necessary. The formula could be accurately weighed, divided and spread. 2.2. Effect of Thermo-molding Conditions
  • Thermo-molding conditions such as die temperatures, pressure, and cooking time would affect overall tray quality and appearance.
  • thermo-molding conditions were concluded as follows: die temperatures between 120 and 130 degrees Celsius, pressure between 118 and 355 psi and cooking time between 8 and 10 minutes.
  • Tray “A” is light brown in color compared to that of tray “C”. This is the result of replacing whole wheat flour with all purpose white wheat flour (Table 4). Color uniformity of the tray “C” would be improved if the bran in the commercial whole wheat flour were milled, instead of being blended as large pieces.
  • the current work has assessed the feasibility to produce biodegradable trays made from wheat flour based materials.
  • the press thermo-molding method requires fewer steps, which would include mixing, weighing and molding. It presents a much shorter and compact tray production cycle, thereby saving costs on labor and energy consumption.
  • a mixture is first prepared using wheat flour, either whole wheat flour or white refined wheat flour and water.
  • a low water content is included so as to achieve a moistened powder in which the mixture has a powder-like consistency.
  • the combined weight of the water content of the mixture including the water content in the flour used in the mixture is less than 23% of the total weight of the mixture.
  • Desired additives noted above including colourant can be mixed into the mixture as a dry powder so that the mixture is easy to mix and handle.
  • the use of each additive provides considerable improvements to the quality of the molded article as noted above but flour from an edible crop plant and water with only one or a few additives is sufficient to achieve reasonable results.
  • the dies of the mold are preheated and separated so that the mold may be filled with a prescribed amount of the prepared mixture which is spread evenly within the lower female die 38.
  • the thickness of the powder used as raw material is greater than the prescribed minimum separation of the dies before the cooking operation begins.
  • the dies are then urged together with pressure being applied to the mixture in the order of approximately 236 psi.
  • the dies are continued to be moved towards one another during the cooking process to maintain a consistent 236 psi pressure as the mixture is compressed during cooking.
  • the prescribed duration of the cooking time is between 8-10 minutes.
  • the cooking time Once the cooking time has expired pressure is gradually released over an elapsed period of time to allow steam to escape from the mold while maintaining the form of the molded article between the lower and upper dies. Once the dies are separated, the article may be released from the mold for cooling. After cooling, the molded article has a hard smooth surface with minimal texture and a water content which is less than the starting water content of the mixture which was less than 23% of the weight of the mixture.
  • the optimum water content for the trials using flour and water was determined to be a combined weight of water (including water content in the flour itself) which was between 20% and 23% of the combined weight of the overall mixture. Water content less than 20% resulted in trays that were too dry and therefore not completely integral, while water content greater than 23% resulted in air pockets formed in the trays due to excess steam being produced during the thermo-molding process. Greater than two thirds of the starch in the flour was determined to be gelatinized as a result of the molding conditions of temperature and pressure applied to the mixture. In further embodiments, the use of a mechanism to release steam while maintaining pressure on the mixture would permit more water to be added for greater gelatinization without the formation of pockets within the molded article.
  • cellulose fibre for example Solka-Floc
  • the purpose of cellulose fibre is to impart a structural integrity to the mixture.
  • the main advantage of using cellulose fibre is that it is a refined cellulose fibre which is pure and thus, will react more effectively with the starch and provide greater structural integrity to the mixture.
  • the hydroxyl ( H) groups on the cellulose molecule will form hydrogen bonds with the amylose fraction of the starch. This provides a stronger and more stable network in the tray.
  • Hydrocolloids or hydrophilic colloids which are used herein are more commonly referred to as gums and are long-chain, high-molecular-weight polymers that dissolve or disperse in water to give a thickening and sometimes gelling effect.
  • the hydrocolloids which are useful in the present formulation and which are intended to be designated generally herein by the term hydrocolloids include non-starch hydrocolloids including modified starches but not natural starches.
  • the particular hydrocolloid used in this patent formulation was guar gum but could be selected from a variety of natural and modified natural hydrocolloids as defined by Glicksman (1982).
  • the natural gums may include plant exudates such a gum Arabic, gum tragacanth and gum ghatti; seaweed extracts such as agar, carrageenan and alginates; plant seed gums such as guar gum, locust bean gum and psyllium and fermentation gums such as xanthan gum.
  • Modified natural gums may include carboxymethylcellulose, methylcellulose, modified starches and low methoxyl pectin.
  • different hydrocolloid gums may have different levels of association with starch due to the variation in carbohydrate composition and configuration of the gum molecules among the different gums, variations to the amounts used in the mixture can be used to obtain effective results with numerous different gums.
  • Functional properties that the hydrocolloids play in this formulation are adhesiveness and emulsifying properties, prevention of syneresis (loss of moisture due to re-association of the starch) and binding properties.
  • the incorporation of gums into the formulation may provide an environment that promotes stablility by hydrogen bonding of the carbohydrates of the hydrocolloid gum (ie. guar) with amylose in the starch (Glicksman, 1982; Miller, et al., 1973).
  • the result is the entanglement of the gum carbohydrates with the soluble starch and with the swollen starch granules and thus, a stable polymer network is formed.
  • the presence of gums in the formulation also provides stability to storage of the formulation by binding amylose and preventing retrogradation (re-forming of the starch granule and loss of water) of the starch that would lead to brittleness of the biodegradable tray.
  • Water proofing of the tray may occur as a result of the high heat and pressure applied to the surface of the tray during forming.
  • the heat causes drying and some carmelization of the carbohydrates on the surface of the tray.
  • Carmelized sugars are hardened and act as a water barrier for the carbohydrate polymer network in the tray.
  • Hydrogen bonding among the guar gum, starch, and cellulose carbohydrates results in effective emulsification of the tray ingredients.
  • Each of the guar gum, starch, cellulose and alcohol sugar include plural hydroxyl groups available for bonding, typically in the range of 3 to 6 available hydroxyl groups.
  • Sugar alcohol is a simple compound which will not migrate and thus, is relatively stable. Sorbitol is a humectant that helps stabilize the water content of the tray formulation. The sugar alcohols do not undergo Maillard browning and caramelization like other sugar substitutes.
  • Sorbitol is a sugar alcohol or acyclic polyol (Emodi, 1982).
  • the sugar alcohols are produced by reduction of sugars (glucose in the case of sorbitol).
  • Each of the dry ingredients added to the flour including the cellulose fibre (e.g. Solka-Floc) , the hydrocolloid (e.g. guar gum), the alcohol sugar (e.g. D-Sorbital) or the pre-gelatinised starch (e.g. corn starch) provides some improved quality over the use of flour and water alone, and accordingly can be used alone or in combination depending upon the desired results.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Biodiversity & Conservation Biology (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Wrappers (AREA)

Abstract

L'invention concerne un article à paroi mince, tel qu'un plateau biodégradable, formé au moyen d'un procédé utilisant un mélange constitué essentiellement de farine de blé. Le procédé consiste à soumettre le mélange à une pression dans un moule chauffé destiné à cuire ledit mélange sous pression en vue de produire l'article, à ajouter de l'eau au mélange, cette eau présentant un poids combiné inférieur à 23 % du poids total dudit mélange, lequel présente la consistance d'une poudre humidifiée avant son introduction dans le moule, puis à mélanger et traiter rapidement le mélange tout en permettant l'ajout de divers additifs dans ce mélange. Ces additifs peuvent comprendre un colorant en poudre, un amidon prégélatinisé, un agent de liaison (par ex., une gomme de guar), un humectant (par ex., du D-sorbitol), une fibre de cellulose (par ex., une fibre alimentaire naturelle) ou un agent de conservation (par ex., du benzoate de sodium).
PCT/CA2002/002005 2001-12-19 2002-12-19 Procede de moulage d'un article biodegradable Ceased WO2003051980A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2002351622A AU2002351622A1 (en) 2001-12-19 2002-12-19 Method of molding a biodegradable article

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CA 2365505 CA2365505A1 (fr) 2001-12-19 2001-12-19 Methode de fabrication d'articles a parois minces en utilisant de la farine de ble
CA2,365,505 2001-12-19

Publications (1)

Publication Number Publication Date
WO2003051980A1 true WO2003051980A1 (fr) 2003-06-26

Family

ID=4170887

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CA2002/002005 Ceased WO2003051980A1 (fr) 2001-12-19 2002-12-19 Procede de moulage d'un article biodegradable

Country Status (3)

Country Link
AU (1) AU2002351622A1 (fr)
CA (1) CA2365505A1 (fr)
WO (1) WO2003051980A1 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2379927A1 (es) * 2010-10-06 2012-05-07 Jose Oriol Tauler Procedimiento para fabricación de elementos biodegradables de relleno para protección en embalaje, y elemento biodegradable producido.
RU2651034C1 (ru) * 2017-05-19 2018-04-18 Общество с ограниченной ответственностью "Биотек" Биоразлагаемая полимерная композиция из вторичного крахмалсодержащего сырья
WO2020035462A1 (fr) * 2018-08-13 2020-02-20 Do Eat S.A. Appareil biodégradable pour contenir un aliment
KR20200057424A (ko) * 2018-11-16 2020-05-26 주식회사 마린이노베이션 해조류 펄프를 이용한 몰드 제조 방법
WO2022208367A1 (fr) * 2021-03-29 2022-10-06 Stephen Roland Cashmore Vaisselle biodégradable et/ou comestible
EP4070929A1 (fr) * 2021-04-08 2022-10-12 Titan Construct engineering s.r.o. Emballages alimentaires jetables biodégradables, procédé de production et moule pour la production d'emballages jetables biodégradables

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0474095A1 (fr) * 1990-09-03 1992-03-11 Bühler Ag Composition et procédé pour former des articles d'usage biodégradable
US5376320A (en) * 1990-02-06 1994-12-27 Biopac Biologische Verpackungssysteme Gesellschaft M.B.H. Process of producing rottable thin-walled shaped bodies made of starch
US5427614A (en) * 1992-02-14 1995-06-27 Warner-Lambert Company Starch based formulations
JPH1058412A (ja) * 1996-08-19 1998-03-03 Fukuoka Package Kk 成形体
WO2000039213A1 (fr) * 1998-12-24 2000-07-06 Apack AG für Biologische Verpackungen Procede de production d'un corps faconne en un materiau biodegradable

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5376320A (en) * 1990-02-06 1994-12-27 Biopac Biologische Verpackungssysteme Gesellschaft M.B.H. Process of producing rottable thin-walled shaped bodies made of starch
EP0474095A1 (fr) * 1990-09-03 1992-03-11 Bühler Ag Composition et procédé pour former des articles d'usage biodégradable
US5427614A (en) * 1992-02-14 1995-06-27 Warner-Lambert Company Starch based formulations
JPH1058412A (ja) * 1996-08-19 1998-03-03 Fukuoka Package Kk 成形体
WO2000039213A1 (fr) * 1998-12-24 2000-07-06 Apack AG für Biologische Verpackungen Procede de production d'un corps faconne en un materiau biodegradable

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Week 199819, Derwent World Patents Index; AN 1998-211509 *
PATENT ABSTRACTS OF JAPAN vol. 1998, no. 08 30 June 1998 (1998-06-30) *

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2379927A1 (es) * 2010-10-06 2012-05-07 Jose Oriol Tauler Procedimiento para fabricación de elementos biodegradables de relleno para protección en embalaje, y elemento biodegradable producido.
RU2651034C1 (ru) * 2017-05-19 2018-04-18 Общество с ограниченной ответственностью "Биотек" Биоразлагаемая полимерная композиция из вторичного крахмалсодержащего сырья
WO2020035462A1 (fr) * 2018-08-13 2020-02-20 Do Eat S.A. Appareil biodégradable pour contenir un aliment
KR20200057424A (ko) * 2018-11-16 2020-05-26 주식회사 마린이노베이션 해조류 펄프를 이용한 몰드 제조 방법
KR102141932B1 (ko) 2018-11-16 2020-08-06 주식회사 마린이노베이션 해조류 펄프를 이용한 몰드 제조 방법
WO2022208367A1 (fr) * 2021-03-29 2022-10-06 Stephen Roland Cashmore Vaisselle biodégradable et/ou comestible
AU2022247476B2 (en) * 2021-03-29 2023-10-12 Twiice New Zealand Limited Biodegradable and/or edible tableware
EP4070929A1 (fr) * 2021-04-08 2022-10-12 Titan Construct engineering s.r.o. Emballages alimentaires jetables biodégradables, procédé de production et moule pour la production d'emballages jetables biodégradables

Also Published As

Publication number Publication date
AU2002351622A1 (en) 2003-06-30
CA2365505A1 (fr) 2003-06-19

Similar Documents

Publication Publication Date Title
US5376320A (en) Process of producing rottable thin-walled shaped bodies made of starch
US6299907B1 (en) Reversibly swellable starch products
Dapčević Hadnađev et al. Rheological and breadmaking properties of wheat flours supplemented with octenyl succinic anhydride-modified waxy maize starches
JPH08510379A (ja) 複合ドゥからスナックを作る方法及び生成物
CA2084782A1 (fr) Procede pour aliments a cuire et produits ainsi obtenus
CA2392130A1 (fr) Materiau destine a la fabrication de moulages biodegradables a partir de son et procede associe
JP2002509969A (ja) 包装用の生分解性材料
JP4112182B2 (ja) アミロペクチンポテトフレークまたはグラニュールおよびスナック食品におけるそれらの使用
US20220325078A1 (en) Biodegradable, compostable molding mass compositions, molded articles and methods of manufacture
CA1067750A (fr) Produits d'amidon extrude utilise dans les poudings au tapioca
WO2003051980A1 (fr) Procede de moulage d'un article biodegradable
JP3766923B2 (ja) 油脂α化澱粉質およびこれを用いた食品
MXPA04006751A (es) Almidones modificados para uso en productos horneados libres de gluten.
DE69400210T2 (de) Verfahren zur Herstellung von Formkörpern auf Basis von einem Stärkeprodukt, sowie eine pulverförmige Mischung zur Verwendung darin
KR100758646B1 (ko) 생분해성 성형품 제조용 반죽물, 판상재 및 성형품의 각각의 제조방법
JP3618321B2 (ja) ベーカリー製品用ミックス及びそれを用いたベーカリー製品
DE69717111T2 (de) Vorgebackene geformte getreidenahrungsmittel und deren herstellung
Magabane Technologies for improving the quality of bread doughs made with barley spent grain and sorghum
Jalali et al. THE EFFECT OF BALANGU SHIRAZI (LALLEMANTIA ROYLEANA) GUM ON THE QUALITY OF GLUTEN-FREE PAN BREAD CONTAINING PRE-GELATINIZED SIMPLE CORN FLOUR WITH MICROWAVE.
JP2004248567A (ja) 菓子の製造方法並びに菓子用プレミックス
KR102276846B1 (ko) 액상 교반식 전자레인지 조리용 찰떡 프리믹스 조성물
KR100592166B1 (ko) 내수성 및 이형성이 우수한 생분해성 조성물
KR20190002230A (ko) 레토르트 점토의 제조방법
DE4234345C2 (de) Fertigknödel auf Stärkebasis und Verfahren zu seiner Herstellung
JP4932637B2 (ja) 人造米およびその製造方法

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EC EE ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NO NZ OM PH PL PT RO RU SC SD SE SG SK SL TJ TM TN TR TT TZ UA UG US UZ VC VN YU ZA ZM ZW

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): GH GM KE LS MW MZ SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE BG CH CY CZ DE DK EE ES FI FR GB GR IE IT LU MC NL PT SE SI SK TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG

121 Ep: the epo has been informed by wipo that ep was designated in this application
122 Ep: pct application non-entry in european phase
NENP Non-entry into the national phase

Ref country code: JP

WWW Wipo information: withdrawn in national office

Country of ref document: JP