UTENSÍLIOS E EMBALAGENS DESCARTÁVEIS E PROCESSO DE FABRICAÇÃO UTILIZANDO CAPIM BRAQUIARIA POR TERMOFORMAGEM

Description

5 Disposable utensils and packaging and manufacturing process using Brachiaria grass by thermoforming. Field of invention

[001] The present invention is situated in the field of biodegradable disposable utensils and packaging, including cutlery, plates, cups, lids, trays, containers and the like, produced from Brachiaria grass vegetable fibers, by a thermoforming process. Fundamentals of the invention

[002] Biodegradable disposable utensils and packaging are known, employing fibers from sugarcane bagasse, bamboo, corn starch, or recycled paper. However, the application of brachiaria grass, a fast-growing, abundant, and low-cost grass, remains limited. The present invention provides a sustainable solution with high potential for industrial application. Technical problem

[003] To obtain biodegradable disposable utensils and packaging with adequate mechanical and thermal resistance, using abundant and sustainable raw materials, in order to reduce the use of conventional plastics and mitigate environmental impacts. Proposed solution

[004] The invention provides a thermoforming process for brachiaria grass fibers, with the addition of biodegradable natural binders, Petition 870260048760, dated 05 / 21 / 2026, page 3 / 8 / 5 biodegradable plasticizers such as glycerol and optional additives, resulting in disposable products of multiple geometries, optionally includes natural antimicrobial additives and internal coatings of natural origin to increase thermal resistance, as well as reuse of process waste. Description of the invention

[005] The invention comprises a process for manufacturing disposable utensils and packaging, consisting mainly of vegetable fibers obtained from brachiaria grass (Brachiaria spp.) or equivalent vegetable fibers, combined with biodegradable natural binders, biodegradable plasticizers (e.g., glycerol) and, optionally, antimicrobial additives and natural coatings.

[006] Step 1 - Preparation of fibrous raw material: brachiaria grass is harvested and cut into fragments of 10 to 50 mm, the material is crushed in a knife mill or industrial defibrator until it reaches fibers with an average length of 0.5 mm to 3 mm.

[007] The fibers are washed in running water or a spray system with a flow of 5-10 L of water per kg of fiber, removing organic residues and impurities.

[008] Next, the fibers are subjected to drying in a forced-circulation oven at 80-100 °C for 1-2 hours, until they reach a moisture content of less than 10% by weight. Petition 870260048760, dated 05 / 21 / 2026, page 4 / 8 / 5

[009] Step 2 - Preparation of the binding mixture: in an industrial mixer or paddle mixer, the following are added: dry fibers (80-95% by mass); biodegradable natural binder (e.g., starch or vegetable resin), in a proportion of 5-20% by mass; biodegradable plasticizer (e.g., glycerol) of 5-25% in relation to the mass of the binder, when greater flexibility is desired; optional additives, such as natural antimicrobials (propolis, essential oils), the mixture is homogenized for 5-15 minutes until a uniform consistency is achieved.

[010] Step 3 - Formation of moldable pulp: the mixture is moistened with 5-10% water (depending on the final moisture content of the fibers) to obtain a pulp with a total moisture content of 10-20%, the pulp is fed into thermoforming equipment with an aluminum mold.

[011] Step 4 - Thermoforming: the moldable pulp prepared in the previous step is positioned inside a preheated aluminum mold made up of two parts (female and male).

[012] The mold must be at a controlled temperature of 170 °C ± 10 °C, with a heat source of at least 4 kW power, to allow partial fusion of the binder and structural fixation of the fibers.

[013] A pressure of 3 MPa is applied using a hydraulic or pneumatic press, ensuring uniform compaction of the material and the formation of the part in the desired geometry. Petition 870260048760, dated 05 / 21 / 2026, page 5 / 8 / 5

[014] The pressing time is 60 seconds, after the pressing time, the mold remains closed for 12 seconds before opening.

[015] The part is then unlocked and removed mechanically or manually, the product is then sent for natural cooling in a ventilated environment.

[016] Step 5 - Finishing and coating: (optional) the pieces can receive internal or external coating by immersion or spraying of biodegradable solutions (e.g., natural wax, gum or plasticized starch).

[017] Example: manufacturing an 80 mL cup, cup with the following dimensions; height 63.0 mm; upper diameter 68.1 mm; lower diameter 40.6 mm and average thickness 2.5 mm (wall and bottom).

[018] Brachiaria grass fibers 23.0 g; cassava starch 7.6 g; vegetable glycerol 1.9 mL (« 2.4 g) and distilled water (processing agent) 4.5 mL.

[019] Sizing notes: the solid volume of the cup (walls + bottom) is approximately 30.56 cm3, considering a typical density of the biocomposite between 1.05 and 1.15 g / cm3, the final mass of the piece is 32-35 g. Petition 870260048760, dated 05 / 21 / 2026, page 6 / 8 / 5

[020] The above formulation provides sufficient solid matter for one cup, with little margin for process and finishing losses.

[021] Water acts as a temporary plasticizer and some of it volatilizes, the glycerol remains in the piece, giving it toughness.

[022] Summary process (for one cup): pulp preparation; crush fibers; spray wash; dry at 90 °C until residual moisture <10%; homogenize fibers + starch + glycerol; add water (4.5 mL) and mix for 10-15 min until moldable pulp.

[023] Formation: Polished aluminum molds heated to 170 °C ± 10 °C (minimum recommended power 4 kW, electronic control), dose the pulp into the cavity (80 mL cup) and press at 3 MPa for 60 s.

[024] Thermal stabilization: keep the mold closed ~12 s after pressing for initial stabilization; eject mechanically and air cool in a ventilated environment to room temperature.

[025] Result: cup with an average thickness of 2.5 mm, suitable for hot and cold liquids, biodegradation <180 days under composting conditions. Petition 870260048760, dated 05 / 21 / 2026, page 7 / 8

Claims

1 / 2 CLAIMS 1. Biodegradable disposable product, characterized by being made of vegetable fibers of brachiaria grass (Brachiaria spp.) or equivalent vegetable fibers, bonded with resins or natural starches, molded by thermoforming under temperature and pressure, exhibiting adequate mechanical and thermal resistance for food, cosmetic, pharmaceutical, industrial or similar use.

2. A manufacturing process for disposable products according to claim 1, characterized by comprising the steps of: a) shredding brachiaria grass or equivalent vegetable fibers; b) washing and drying the fibers; c) mixing the fibers with a biodegradable natural binder; d) optional addition of biodegradable plasticizers such as glycerol; e) formation of fibrous pulp; f) shaping in metal molds under controlled heat and pressure; g) demolding and, optionally, cold pressing and / or application of a coating.

3. Product according to claim 1, characterized by comprising cutlery (spoons, forks, knives), plates, cups, lids, trays, containers or other disposable utensils obtained by the thermoforming process.

4. Product according to any of the preceding claims, characterized by including natural antimicrobial and / or bacteriostatic additives, selected from the group formed by propolis, citronella essential oil, rosemary essential oil, eucalyptus extract or similar. Petition 870260029926, dated 03 / 30 / 2026, page 8 / 11 2 / 2 5. A process according to any of the preceding claims, characterized by employing glycerol, vegetable glycerin, or equivalent biodegradable plasticizers, incorporated into the mixture of fibers and binders for the purpose of increasing flexibility and dimensional stability.

6. Product according to any of the preceding claims, characterized by exhibiting total degradation under industrial, domestic or natural composting conditions in a period of less than 180 days.

7. Process according to claim 2, characterized by allowing the reuse of waste and scraps from the production process without loss of mechanical or aesthetic properties.

8. Use of disposable products according to any of the preceding claims, characterized by packaging, transport, consumption or storage of food, cosmetics, pharmaceutical, chemical, veterinary or industrial products.

9. Product according to any of the preceding claims, characterized by having mechanical strength equivalent to or greater than that of conventional plastic products of the same application, proven by static load and impact tests.

10. Process according to claim 2, characterized by being compatible with existing industrial thermoforming lines and / or hydraulic presses, allowing adaptation without significant structural alteration of the equipment. Petition 870260029926, dated 03 / 30 / 2026, page 9 / 11