Automated hydropulping and shaping system for biodegradable mulberry bark containers
The MFCMS addresses the issues of plastic pots by producing biodegradable mulberry bark bags with controlled fiber processing and shaping, ensuring stability and nutrient-rich decomposition, offering a sustainable solution for horticulture.
Patent Information
- Application Number
- DE202025106775
- Authority / Receiving Office
- DE · DE
- Patent Type
- Utility models
- Current Assignee / Owner
- Filing Date
- 2025-11-06
- Publication Date
- 2026-01-15
- Estimated Expiration
- 2035-11-30
AI Technical Summary
The horticultural industry faces challenges with petroleum-based plastic plant pots contributing to landfill pollution and restricting root growth, while existing biodegradable alternatives often have complex sourcing, insufficient stability, or unsuitable degradation rates.
An automated manufacturing system (MFCMS) for biodegradable mulberry bark planting bags, utilizing an integrated hydropulping unit, thermal consolidation press, and multi-chamber forming matrix to control fiber length, density, and shape, achieving fiber bonding without chemical adhesives, ensuring optimal porosity and stability.
The system produces durable, porous planting bags that promote root aeration and moisture retention, decompose naturally to enrich soil with nutrients, and reduce environmental impact, providing a sustainable alternative to plastic pots.
Abstract
Description
Application area of the invention
[0001] The present invention relates to a device for the production of completely biodegradable plant containers made from mulberry bark fibers, which are intended to promote root growth and improve soil quality. Background of the invention
[0002] The global horticultural industry faces a major waste management challenge due to its reliance on petroleum-based plastic plant pots. These conventional containers contribute significantly to landfill pollution and often restrict root growth, potentially leading to root entanglement and transplant shock. While various biodegradable alternatives exist, they are frequently based on materials with complex sourcing or insufficient stability and degradation rate. Mulberry bark, a sustainable byproduct of silkworm breeding or tree care, offers an excellent fiber material. However, its conversion into durable yet rapidly biodegradable planting bags requires a specialized, standardized manufacturing process.There is an urgent need for a cost-effective, high-throughput plant that can reliably convert this agricultural waste stream into stable, porous, and nutrient-rich planting containers. This would promote a circular economy in horticulture and address pressing environmental problems. Summary of the invention
[0003] The present invention relates to a novel manufacturing system for mulberry bark planting bags (MFCMS). This system is designed for the automated production of fully biodegradable planting bags from raw mulberry bark fibers. It consists of an integrated hydropulping unit, a thermal consolidation press, and a multi-chamber forming matrix. The system controls each process step, from fiber preparation to the final container geometry, thus ensuring optimal density, porosity, and stability. As a result, the finished bag can effectively retain soil while simultaneously promoting the necessary root aeration and moisture retention.
[0004] The innovation of the MFCMS lies in its ability to precisely control fiber length and density distribution during hydropulping and shaping. By employing a thermopress with a specific pressure and temperature profile, the system achieves fiber bonding without chemical adhesives, thus preserving the natural biodegradability and nutrient profile of the mulberry wood. The resulting planting container decomposes naturally after planting, enriching the soil with organic matter and essential nutrients such as nitrogen. This effectively overcomes the disadvantages of plastic pots and creates a superior, sustainable solution for horticulture. Detailed description
[0005] The invention describes the manufacturing system for containers made from mulberry fibers; an integrated device for the mass production of biodegradable planting bags made from mulberry bark fibers.
[0006] The system begins with the hydro-pulping unit (HPU). The HPU processes raw, cleaned mulberry bark and separates the fibers using strong hydromechanical shear forces, ensuring optimal length distribution. This precise fiber length control is crucial to reconcile the strength required for pre-planting use with the desired rate of degradation after planting.
[0007] The resulting aqueous fiber suspension is then fed into the suspension delivery system (SDS). The SDS includes a mixing tank into which a small amount of non-toxic, bio-based binder (such as natural starch) can optionally be added to improve wet strength. However, the system is primarily designed to utilize the natural interlocking properties of the mulberry fibers.
[0008] The suspension, as specified in the Safety Data Sheet (SDS), is fed into the multi-chamber mold matrix (MCM) by gravity or pump. The MCM consists of a series of perforated molds that correspond to the shape of the finished planting bag. Simultaneously, a vacuum is applied to the molds to quickly remove the water. This draws the mulberry fibers to the mold surface, thus giving the original container shape with controlled wall thickness and a uniform surface.
[0009] The partially dried containers, still in their green state, are then transferred to the thermal consolidation press (TCP). The TCP applies a controlled temperature profile (e.g., 150 °C to 180 °C) and hydraulic pressure for a short period. This removes the residual moisture and thermally bonds the lignocellulosic fibers. The result is a durable, dimensionally stable, yet porous end product that requires no synthetic resins.
[0010] Crucially, the molds within the MCM and TCP are equipped with special micro-perforations. These perforations ensure that the finished bag structure maintains optimal porosity and aeration, promotes the necessary gas exchange, and prevents waterlogging. This is essential for healthy root development and simultaneously allows the roots to penetrate after planting.
[0011] The entire process is controlled by a central process control unit (PCU). Using sensors, the PCU monitors fiber consistency, sludge concentration, TCP temperature, and pressure. This active control loop ensures that every manufactured bag meets precise quality standards regarding structural integrity and decomposition time.
[0012] The use of mulberry bark, a common waste product, combined with the MFCMS's closed, low-waste design, makes the unit extremely cost-effective and sustainable. The resulting bags are designed to decompose completely after repotting, releasing organic nutrients and thus minimizing environmental impact.
[0013] In summary, the system offers an innovative, mechanized solution for the production of high-performance, environmentally friendly plant containers that effectively replace problematic plastic pots and establish a sustainable manufacturing standard for the horticultural industry.
Claims
[1] A system for the production of biodegradable plant containers, consisting of a hydropulping unit for processing raw mulberry bark fibers and a multi-chamber forming matrix for producing container shapes by means of vacuum dewatering. [2] System according to claim 1, further comprising a thermal consolidation press configured to apply a specific temperature and pressure profile to the formed container shapes to achieve a bond between the fibers without chemical adhesives. [3] System according to claim 1, wherein the form matrix has microperforations configured such that the finished container maintains optimized porosity for root aeration and water drainage. [4] System according to claim 2, wherein the thermal consolidation press operates between 150°C and 180°C to simultaneously dry the containers and adjust the final structural stiffness.