Dinnerware, in particular plates or bowls, for single use and methods for manufacturing them

Description

[0001] The invention relates to a disposable eating utensil, in particular a plate or bowl, with a top surface that faces the consumer during use and comes into contact with food, with a cardboard carrier layer, a paper protective layer on the top surface, and a color layer arranged at least partially between the carrier layer and the protective layer.

[0002] Such tableware, especially party plates and bowls, is well-known, but is increasingly criticized for its slow biodegradability in nature and water due to its plastic coating. This also applies to compostable plates and bowls with a protective layer of compostable polymers. Thinner protective coatings made of lacquer have the additional environmental disadvantage of breaking down into microplastics.

[0003] WO 2018 / 220070 A1 discloses a plate with a cardboard backing layer and a transparent, food-contacting protective layer made of biopolymer. In a packaging material disclosed in EP 0 542 143 A1, the food-contacting side consists of a laminate layer made of food-grade paper. EP 0 865 915 A1 describes a packaging laminate in which the food-contacting layer consists of food-grade, heat- and grease-resistant paper. A silicone layer is applied over this paper layer.

[0004] The problem with this type of tableware is to create a protective layer that, on the one hand, prevents direct contact between the food and the color of a decorative print due to abrasion from the use of cutlery or due to the penetration of components of the color caused by water and fat components in the food, but on the other hand, meets the requirements for rapid biodegradability of the tableware in nature and in water.

[0005] The invention is therefore based on the objective of creating a tableware that offers sufficient protection for food and is preferably readily biodegradable, in particular compostable.

[0006] This task is solved with a tableware set having the features of claim 1.

[0007] Preferred embodiments of the invention are the subject of the dependent claims.

[0008] The invention involves applying a protective layer, made of finely ground cellulose and a transparent paper, to a cardboard backing layer that is inherently harmless because it does not come into contact with food and is readily biodegradable. Such paper is commercially available under the name "parchment" and is used, for example, for window envelopes.

[0009] According to the invention, the protective layer has a water absorption rate with a COBB value ≤ 35 g / m². In particular, the protective layer has a water absorption rate with a COBB value of 20 g / m² to 35 g / m², particularly preferably 26 g / m² to 30 g / m², in 30 seconds according to DIN 53132.

[0010] Additionally, the protective layer exhibits grease resistance with a TAPPI value ≥ 25 sec. Preferably, the protective layer exhibits grease resistance with a TAPPI value of ≥ 30 sec, determined according to TAPPI T 454.

[0011] These value ranges and their combinations are used in the invention for a protective layer thickness of 20 µm to 40 µm and an areal weight greater than 20 g / m². Preferably, the protective layer has a thickness of 24 µm to 30 µm, in particular of about 27 µm, and / or an areal weight of 25 g / m² to 60 g / m², particularly preferably of 30.0 g / m² to 40.0 g / m², in particular of about 35 g / m².

[0012] These value ranges and combinations thereof meet current requirements and regulations for food safety and biodegradability, particularly compostability. Any combination of the aforementioned values ​​for water absorption and grease resistance, as well as material thickness and basis weight, including values ​​outside the specified ranges, is possible if special or changing requirements regarding the properties of the tableware, particularly from a food law perspective, need to be met.

[0013] In the combination of values ​​or value ranges, the transparency of the protective layer also plays a role, with the protective layer having a transparency value of 0.60 to 0.90 according to the invention. It is preferred that the protective layer has a transparency value of 0.80 to 0.86, particularly approximately 0.82, according to DIN 53147. The protective layer should have a transparency at which the color layer is perceived by the consumer as decorative and not as soiling.

[0014] Accordingly, the values ​​for water absorption and grease resistance, as well as the material thickness or basis weight, are preferably coordinated in such a way that the decorative pattern can be perceived attractively.

[0015] Although such a protective layer is not wet-resistant and not completely grease-resistant, it surprisingly exhibits sufficient mechanical strength and resistance to moisture and grease to meet the relevant food safety and food contact regulations. Since this type of paper is produced using highly refined cellulose fibers and a high degree of compaction, particularly of the surface, of the formed paper via a purely mechanical process ("supercalendering"), and no silicone layer or additional functional additives or polymers are used, it is also readily biodegradable and food-safe, thus permissible for direct contact with food.

[0016] In order to meet the requirements for biodegradability, the protective layer according to the invention is preferably free of wet strengtheners, wherein it further preferably contains less than 5%, in particular less than 3%, particularly preferably less than 1%, polymers, and wherein the polymers are uniformly distributed in the material of the protective layer.

[0017] In the case of plates and bowls, the deformations during the final shaping of the flat intermediate product, i.e., the layer structure consisting of the carrier layer and the applied protective layer, into the final shape are not so severe due to their shallower depth, so that the layer structure according to the invention can also be easily shaped into the final shape of the tableware.

[0018] In principle, recycled cardboard, virgin fiber cardboard (groundwood cardboard) and high-quality cellulose cardboard can be used for the production of the carrier layer of the tableware according to the invention, provided that these are approved for at least indirect contact, ideally even for direct contact, with food.

[0019] A water-based dispersion adhesive is preferably used to bond the protective layer to the substrate. Other adhesives can also be used, provided they are approved for indirect food contact.

[0020] In order to make the tableware easier to manufacture, the color layer in the invention is applied to the side of the protective layer facing the carrier layer, because the protective layer is particularly easy to print on.

[0021] Further features and advantages of the invention will become apparent from the following description of preferred embodiments of the invention, which do not limit the scope of protection, with reference to the accompanying drawings. These show: Fig. 1 an intermediate product for the manufacture of a plate according to the invention, Fig. 2 a schematic section through the intermediate product, Fig. 3 a plate according to the invention in top view, Fig. 4 the plate of Fig. 3 from the side, Fig. 5 a bowl according to the invention in top view, Fig. 6 the bowl of Fig. 5 from the side.

[0022] The Figs. 1 and 2 Figure 1 shows an intermediate product 1 used in the manufacture of a tableware set according to the invention. The intermediate product 1 consists of a flat or planar support layer 2 made of compostable cardboard, which has a thickness of, for example, 0.45 mm and a basis weight of, for example, 265 g / m².

[0023] A protective layer 4 is arranged on the user-facing side 3 of the substrate. This protective layer 4 has, for example, a thickness of 27 µm and a basis weight of, for example, 35 g / m² and is made of "glassine," a finely ground cellulose that forms a largely greaseproof and low-water-absorbing, but not wet-strength, transparent paper. The protective layer has, for example, a COBB value of 26 g / m² to 30 g / m² in 30 seconds and a grease resistance with a TAPPI value ≥ 30 seconds (TAPPI T 454).

[0024] On the side of the protective layer 4 facing the carrier layer 2, a color layer 5 was printed before the protective layer 4 was applied to the carrier layer 2. The color layer 5 forms a decorative print that is visible through the transparent protective layer 4 and can be applied to the entire surface of the protective layer 4, or, as in Fig. 2depicted, even if only partially printed.

[0025] If the color layer 5 is only present in certain areas, theoretically no protective layer 4 needs to be present in the exposed areas, which, however, presupposes that the carrier layer 2 is then suitable for direct food contact.

[0026] The protective layer 4 is bonded by means of an adhesive, for example a water-based dispersion adhesive approved for use in the food sector, which is in Fig. 2 (Not shown) it is bonded to the carrier layer 2 at a temperature of approximately 20°C to 35°C.

[0027] From the intermediate product 1 thus constructed, round or otherwise shaped blanks are subsequently cut or stamped, whereupon the blanks are formed in a manner known per se at a temperature of about 90°C to 110°C in a mold with a positive and a negative mold half into the final shape of the tableware, for example into the shape of a plate 6 according to Figs. 3 and 4 or in the shape of a bowl 7 according to Figs. 5 and 6 , are shaped or pressed.

[0028] After completion of this last manufacturing step, the eating utensil according to the invention has a user-facing surface 6 which comes into contact with the food and which has a decorative pattern and sufficient strength and durability to meet the relevant food safety regulations.

Claims

1. Crockery, in particular plate or dish, for single use, having an upper side, which, in use, is orientated towards the consumer and comes into contact with foodstuffs, having a carrier layer (2) made of cardboard, a protective layer (4) made of paper on the upper side (3) and a colored layer (5) which is printed onto the protective layer (4) at least in regions between the carrier layer (2) and the protective layer (4), characterized in that the protective layer (4) is a transparent paper produced from finely ground cellulose and in that the protective layer (4) has a thickness of 20 µm to 40 µm, a basis weight greater than 20 g / m2, a transparency value of 0.60 to 0.90, a water absorption with a COBB value ≤ 35 g / m2 and a fat resistance with a TAPPI value ≥ 25 sec.

2. Crockery according to claim 1, characterized in that the carrier layer (2) has a thickness of 0.3 mm to 0.6 mm, preferably of 0.4 mm to 0.5 mm, and / or in that the carrier layer (2) has a basis weight of 190 g / m2 to 350 g / m2, preferably of 250 g / m2 to 300 g / m2, in particular of approx. 265 g / m2.

3. Crockery according to claim 1 or 2, characterized in that the protective layer (4) has a thickness of 24 µm to 30 µm, in particular of approx. 27 µm, and / or in that the protective layer (4) has a basis weight of 25 g / m2 to 60 g / m2, particularly preferably of 30.0 g / m2 to 40.0 g / m2, in particular of approx. 35 g / m2.

4. Crockery according to one of claims 1 to 3, characterized in that the protective layer (4) has a transparency value of 0.80 to 0.86, in particular of approx. 0.82.

5. Crockery according to one of claims 1 to 4, characterized in that the protective layer (4) has a water absorption with a COBB value of 20 g / m2 to 35 g / m2, particularly preferably of 26 g / m2 to 30 g / m2, in 30 sec.

6. Crockery according to one of claims 1 to 5, characterized in that the protective layer (4) has a fat resistance with a TAPPI value ≥ 30 sec.

7. Crockery according to claim 1 to 6, characterized in that the protective layer (4) is free of water sealants.

8. Crockery according to one of claims 1 to 7, characterized in that the protective layer (4) includes ≤ 5%, in particular ≤ 3%, particularly preferably ≤ 1%, of polymers, and in that the polymers are uniformly distributed in the material of the protective layer (4).

9. Crockery according to one of claims 1 to 8, characterized in that the protective layer (4) is glued to the carrier layer (2) by means of a water-based dispersion glue.

10. Crockery according to one of claims 1 to 9, characterized in that the colored layer (5) is applied on the side of the protective layer (4) which is orientated towards the carrier layer (2).

11. Crockery according to one of claims 1 to 10, characterized in that it is biologically degradable, in particular compostable, by both the cardboard and the protective layer (4) consisting of biologically degradable, in particular compostable, materials.