Bottle divider from a moulded pulp material with reduced surface roughness, and method for manufacturing such bottle divider

Abstract

The present invention relates to a bottle divider made of moulded pulp and a method for manufacturing such bottle divider. The bottle divider according to the present invention comprises: - a number of bottle receiving compartments; and bottle positioning elements configured for maintaining the bottle that is placed in one of the compartments in a desired position, wherein the bottle positioning elements comprise bottle neck positioners configured for engaging the bottle neck.

Description

[0001] The present invention relates to bottle dividers that are made of moulded pulp. Such bottle dividers are used in the transport or storage of bottles, specifically including wine bottles.

[0002] Bottle dividers are known in practice. Such conventional bottle dividers are often made from moulded pulp originating from paper material. These bottle dividers comprise a sheet or layer made from a moulded pulp material separating different layers of bottles, and preferably separating bottles adjacent bottles in the same layer. This enables transport and storage of bottles, such as wine bottles.

[0003] A problem with conventional bottle dividers is that labels or markings are damaged. When transporting and handling bottles with the bottle divider, for example in cartons, boxes, crates and the like, such labels or markings can be damaged, thereby reducing the quality perception of a consumer.

[0004] US 5 950 829 A discloses a packaging for at least one bottle having first and second parts that have bottle receiving recesses with a first portion to receive the cylindrical base portion of the bottle and a second portion to receive the neck portion of the bottle.

[0005] US 1960 279 A discloses a packing tray such as a bottle divider.

[0006] Also these conventional packaging units for bottles are subjected to damaged labels or markings. This reduces the quality perception of a consumer.

[0007] The present invention has for its object to obviate or at least reduce the above stated problems in conventional bottle dividers and to provide a bottle divider that preferably maintains or even improves the quality perception of the consumer.

[0008] For this purpose the present invention provides a bottle divider from a moulded pulp material, according to claim 1.

[0009] The bottle divider comprises a number of bottle receiving compartments, for example three or six compartments, wherein each compartment is preferably capable of receiving one bottle, such as a wine bottle. It will be understood that another number of compartments can also be envisaged in accordance with the present invention.

[0010] The bottle divider further comprises bottle positioning elements that maintain the bottle in the desired position in the respective compartment. These bottle positioning elements may comprise nocks, embossments, protrusions, edges, compartment walls, chambers and the like. These positioning elements maintain a bottle that is placed in the compartment in its position and prevent adjacent bottles engaging each other.

[0011] Bottles are preferably maintained in a substantially horizontal position. This specifically applies to wine bottles. Also, bottles including wine bottles are sometimes stored and transported in a substantially vertical position. In preferred embodiments of the present invention the bottle divider can be used both in a preferred horizontal, a vertical, or other position.

[0012] According to the invention the bottle positioning elements of the bottle divider engage the bottle neck. More specifically the bottle neck positioners of the bottle positioning elements engage the bottle neck. By engaging the bottle neck the bottle positioning elements clearly define the position of the bottle in the bottle receiving compartment. This prevents a bottle moving in the compartment during transport or handling of the bottle. These positioning elements may comprise one or more of cams, nocks, ridges or other positioning elements. The actual size or number of bottle positioning elements may depend on the size and shape of the bottle. Conventional bottle dividers allow for relative movement between the bottle neck and the bottle divider. In fact, conventional bottle dividers have a contact point or contact line with the bottle neck. According to the invention, the bottle divider preferably has a contact surface that engages the bottle neck. This may require a little force to push the bottle into the bottle divider such that the positioning elements engaging the bottle neck. This prevents or at least reduces relative movement between the bottle and the bottle divider, thereby preventing or at least reducing damaging a label, for example. In addition, the bottle is preferably maintained in its desired orientation, for example involving a so-called form closure or interlock.

[0013] Preferably, the bottle neck positioners engage the bottle neck over a substantial part of the bottle neck perimeter (also referred to as bottle neck circumference). In presently preferred embodiments of the invention the bottle neck positioners engage the bottle neck perimeter over 20% of the total perimeter, preferably over 25%, and most preferably over 30%.

[0014] Engaging a bottle neck over a substantial part of its perimeter stabilises the bottle and more specifically the bottle neck in a fixed position, preferably with a form closure or interlock. This prevents the bottle from moving relatively to the bottle divider. This reduces the risk of damaging the label of the bottle, for example. Furthermore, this improves maintaining the bottle position in a desired orientation during transport, storage and handling. For example, this maintains a label visible to a consumer, thereby maintaining the quality appearance of the bottles and its contents.

[0015] In a further preferred embodiment according to the present invention the bottle divider further comprises a marking area.

[0016] Providing the bottle divider with a marking area that comprises a marking of the origin of the intended bottle in the compartment, or other marking, contributes to the quality perception of a consumer.

[0017] The bottle divider according to the invention further preferably comprises a number of denesting elements, such as nocks, protrusions, edges, stops, cams, and ridges. These elements are configured to enable denesting of a bottle divider from a stack of bottle dividers. This enables easy handling of the bottle dividers and packing of bottles.

[0018] In a further preferred embodiment according to the invention at least some of the denesting elements are positioned in a first configuration or in a second configuration, wherein the first and second configurations have different positions for at least some of the denesting elements, and the positions are such that the denesting elements are alternately positioned in the first and second configurations to enable denesting of a stack of bottle dividers.

[0019] By providing at least two different configurations for the position of denesting elements the overall stability of a stack of bottle dividers is significantly improved. For example, this reduces or prevents deflection or deforming of the bottle dividers when stacked.

[0020] According to the invention the moulded pulp material comprises an amount of non-wood biomass material of plant origin.

[0021] As a further effect of manufacturing moulded fiber products, particularly a bottle divider, from a biomass material of plant origin improves the flexibility of incorporating (possible raw) materials in such products, thereby providing additional or alternative raw material sources. In addition, the use of biomass of plant origin improves the natural feel for the consumer. Also, especially in case the biomass of plant origin originates from a rest flow, the sustainability of the packaging unit manufactured with the method according to the invention is further enhanced. As a further effect of using biomass material of plant origin is the reduction of the amount of mineral oils in the resulting moulded fiber product. These mineral oils are used in printing ink of recycled paper material involving components like MOSH (Mineral Oil Saturated HydroCarbon) and MOAH (Mineral Oil Aromatic HydroCarbon). More specifically, these mineral oils are used as solvent in printing inks used for printing paper and board packaging and end up in recycled paper grades that are used by the paper industry and moulded fiber industry.

[0022] According to the invention the biomass of plant origin is responsible of 10 wt% of the moulded pulp fiber product, this biomass of plant origin comprises so-called non-wood biomass in the form of non-wood lignocellulosic biomass. This further improves the natural feel and sustainability of the resulting packaging unit. In a preferred embodiment the biomass of plant origin is responsible of at least 20 wt% of the moulded pulp fiber product, more preferably at least 50wt%, even more preferably at least 80 wt%, even more preferably at least 85 wt%, and most preferably at least 92.5 wt.%.

[0023] The biomass of plant origin may involve plants from the order of Poales including grass, sugar cane, bamboo and cereals including barley and rice. Other examples of biomass of plant origin are plants of the order Solanales including tomato plants of which the leaves and / or stems could be used, for example plants from the Order Arecales including palm oil plants of which leaves could be used, for example plants from the Order Maphighiales including flax, plants from the Order of Rosales including hemp and ramie, plants from the Order of Malvales including cotton, kenaf and jute. Alternatively, or in addition, biomass of plant origin involves so-called herbaceous plants including, besides grass type plants and some of the aforementioned plants, also jute, Musa including banana, Amarantha, hemp, cannabis etcetera, preferably, the (lignocellulosic) biomass of plant origin comprises biomass originating from plants of the Family of Poaceae (to which is also referred to as Gramineae). This family includes grass type of plants including grass and barley, maize, rice, wheat, oats, rye, reed grass, bamboo, sugar cane (of which residue from the sugar processing can be used that is also referred to as bagasse), maize (corn), sorghum, rape seed, other cereals, etc. Especially the use of so-called nature grass provides good results when manufacturing packaging units such as egg packages. Such nature grass may originate from a natural landscape, for example. This family of plants has shown good manufacturing possibilities in combination with providing a sustainable product to the consumer.

[0024] According to the invention the invention, the moulded pulp material comprises an amount of a surface roughness reducing agent.

[0025] Thus, the moulded material of the bottle divider comprises an amount of a surface roughness reducing agent. By providing an amount of surface roughness reducing agent in the moulded pulp material for the bottle divider, the overall surface roughness on a substantial part of the contact surface of the bottle divider with a bottle is reduced. This further prevents or at least reduces damaging a label or marking on the bottle. This increases the quality perception of a consumer. Surface roughness can be measured with the so-called Bendtsen measurement process. The surface roughness reducing measures of embodiments of the present invention reduce the Bendtsen measurement value (in ml / min). For example, a conventional rough moulded fiber material may have a Bendtsen value of about 2000 ml / min, while a material for the bottle divider may have a value of 200 ml / min or even less. It will be understood that other values can also be envisaged depending on a number of parameters.

[0026] Furthermore, the reduced surface roughness improves the opportunity to provide markings or signs in the bottle divider with a good quality. This further increases the quality perception of a consumer.

[0027] According to the invention the invention the surface roughness reducing agent comprises a biodegradable aliphatic polyester.

[0028] The use of a surface roughness reducing agent comprising a biodegradable aliphatic polyester provides a bottle divider with a further reduced surface roughness. This further enhances preventing damage to a label or marking of the bottle. This contributes to the overall quality perception by a consumer of the bottles.

[0029] In a presently preferred embodiment of the invention the biodegradable aliphatic polyester comprises an amount of one or more of PHB, PHA, PCL, PLA, PGA, PBS and PHBV. It is shown that these components effectively reduce the surface roughness of the bottle divider. In presently preferred embodiments the weight percentage of one or more of the aforementioned components is in the range of 0.5-20%, more preferably in the range of 1-15%.

[0030] The present invention further relates to a method for manufacturing a bottle divider from a moulded pulp material, according to claim 12.

[0031] Such method provides the same effects and advantages as described with respect to the bottle divider. The method preferably manufactures a bottle divider in one of the earlier described embodiments. This method therefore reduces damage to the label or other marking during transport or handling of the bottles.

[0032] In a presently preferred embodiment the bottle divider is first moulded in moulds, where after the raw bottle divider is transferred to drying moulds to perform the in-mould drying. After drying the bottle divider is released and a high quality bottle divider is achieved with a significantly lower surface roughness as compared to conventional bottle dividers. As already mentioned the surface roughness can be measured using the Bendtsen measurement process, for example.

[0033] In a further preferred embodiment of the invention, the method for manufacturing the bottle divider further comprises the step for providing the bottle divider with a marking. This further contributes to the overall quality perception of the consumer. Such marking is preferably achieved by placing an insert in the in-mould drying mould. This achieves a marking on the bottle divider in an effective manner without requiring additional efforts. Alternatively, or in addition thereto, a label can be placed in the in-mould drying mould to render the overall manufacturing process efficient and effective.

[0034] Preferably, in the manufacturing process a number of bottle positioning elements are provided that are configured for maintaining a bottle that is placed in one of the compartments in its desired position. This prevents movement of the bottle inside the compartment due to transport and / or handling of the bottles.

[0035] In a presently preferred embodiment the method further comprises the step of preparing a slurry comprising the biomass fibers, as described earlier in relation to the bottle divider, and preferably adding an amount of enzymes to the slurry and performing enzymatic fibrillation of the fibers and / or protein removal. Preferably, the enzymes comprise a hydrolase, preferably protease, and / or cellulose and / or pectinase.

[0036] The use of a hydrolase catalyses the hydrolysis of a chemical bond of the biomass fibers. The hydrolases that are added to the slurry act upon these bonds of the fibers, thereby improving the characteristics of the material for a moulding operation.

[0037] Preferably, the hydrolases comprise proteases that are an enzyme capable of performing proteolysis. The proteases may comprise so-called serine proteases, threonine proteases, cysteine proteases, aspartate proteases, flumatic acid proteases, and metalloproteases. Proteases cut proteins in amino acids and / or peptides, thereby obviating the negative effects of the protein on the moulding operation and not hindering the dewatering.

[0038] Cellulases further de-fiber the biomass involving enzymatic fibrillation, thereby further increasing the bonding surface achieving an improved strength of the end products. Cellulases may involve endo-cellulase, exo-cellulase with optimally cellobiase, for example. Preferably, the enzymes comprise both proteases and cellulases.

[0039] Pectinases break down pectin. Pectin is typically found in cell walls. These pectic enzymes may include one or more of the following enzymes, pectolyase, pectozyme and polygalacturonase. Preferably, the enzymes comprise proteases, cellulases and optionally pectinases. Such mixture provides optimal results for the manufacturing process of the moulded fiber product.

[0040] The enzymes preferably act on the cell wall and further preferably remove protein and produce peptides and amino acids, for example. These components positively influence dewatering in the manufacturing process.

[0041] According to the invention the surface roughness is further reduced by providing an amount of a surface roughness reducing agent, the agent comprising a biodegradable aliphatic polyester.

[0042] Further advantages, features and details of the invention are elucidated on the basis of preferred embodiments thereof, wherein reference is made to the accompanying drawings, in which: figure 1A-C a first embodiment of a bottle divider according to the present invention; figure 2A-C a second embodiment of a bottle divider according to the present invention; figure 3A-C a third embodiment of a bottle divider according to the present invention; figure 4A-B a fourth embodiment of a bottle divider according to the present invention; figure 5A-B a fifth embodiment of a bottle divider according to the present invention; figure 6A-C an embodiment of an insert for a marking according to an embodiment of the present invention; and figure 7 a schematic overview of the manufacturing process according to the present invention.

[0043] Bottle divider 2 (figures 1A-C) is provided with three bottle receiving compartments 4, 6, 8. Bottle divider 2 is provided with marking area 10 and a number of denesting elements 12.

[0044] In the illustrated embodiment height H 1 is about 42.6 mm, width W 1 is about 241 mm, length L 1 is about 287 mm.

[0045] Bottle divider 2 is further provided with edge or area 14 having a thickness d 1 of about 0.8 mm. In the illustrated embodiment edge or wall d 2 extends over a height of about 4.1 mm. These elements 16 act as bottle neck positioners and engage a neck of a bottle that is placed in one of the bottle receiving compartments 4, 6, 8 over a part of the bottle neck perimeter. A second marking area 18 is provided in or on bottle divider 2. Further support elements 20 may also act as denesting elements. Stops 21 also act as denesting elements. In the illustrated embodiment stop 21 is provided with height d 0 of about 4.1 mm.

[0046] In the illustrated embodiment elements 20 and / or stops 21 are shown in a first configuration. It will be understood that in an optional second configuration, elements 20 and / or stops 21 are differently positioned in or on bottle divider 2 to provide an improved support for a stack of bottle dividers. In such stack bottle dividers of different configurations are provided adjacently. Walls 22 separate adjacent compartments 4, 6, 8. In the illustrated embodiment the overall roughness of contact surface 24 of compartment 4, 6, 8 is provided with a reduced roughness as compared to conventional bottle dividers.

[0047] Similar elements are provided in bottle divider 102 (figures 2A-C). In the illustrated embodiment length L 2 of bottle divider 102 is about 295 mm, height H 2 is about 43 mm, width W 2 is about 251 mm and the height of wall elements 104 d 3 is about 4.1 mm and the thickness d 4 of area 106 is about 0.8 mm. Bottle divider 102 is provided with marking areas 108, and in the illustrated embodiment with three bottle receiving compartments 110, 112, 114. Denesting nocks 116 are provided and an additional marking area 118. Also in this illustrated embodiment stops 120 and bottle neck positioners 122 are provided.

[0048] A third embodiment 202 (figures 3A-C) of a bottle divider having a different outer shape is provided with length L 3 of about 310.7 mm, width W 3 of about 255.1 mm, height H 3 of about 46.4 mm, a thickness d 5 of about 0.8 mm, and distance W 0 of about 81 mm. Bottle divider 202 comprises a number of denesting elements 204 with a thickness d 6 of about 10 mm. Further denesting elements 206 are provided at a distance d 7 in the range of 110.7 mm. In the illustrated embodiment bottle divider 202 is provided with three bottle receiving compartments 208, 210, 212. Bottle divider 202 is further provided with marking areas 214, 216. In the illustrated embodiment stop 218 is provided at a small distance from the centreline of bottle divider 202 and bottle neck positioner 220 is provided.

[0049] A fourth embodiment of bottle divider 302 (figures 4A-B) comprises six bottle receiving compartments 304, 306, 308, 310, 312. Denesting nocks 314 are provided with height d 8 of about 6.2 mm. Thickness d 9 of area 316 is about 0.8 mm. Length L 4 is about 288 mm and width W 4 is about 469 mm, height H 4 is about 37.7 mm. Height h 1 of bottle receiving compartments 304, 306, 308, 310, 312 is about 34 mm and edge 318 is provided with height h 2 of about 24.2 mm. Bottle divider 302 in the illustrated embodiment is provided with first part 320 and second part 322 that are connected by perforated line 324 enabling separating or splitting both parts 320, 322. Marking areas 326, 328, 330 are provided.

[0050] A fifth embodiment of bottle divider 402 (figures 5A-B) is also provided with six compartments 504, 506, 508, 510, 512, 514. Bottle divider 502 further comprises denesting elements 516 having a height d 10 of about 6.2 mm. Edge area 518 has a thickness d 11 of about 0.8 mm. Bottle divider 502 further comprises marking areas 520, 522. Bottle divider 502 has a length L 5 of about 281.6 mm and a width W 5 of about 495 mm, a height H 5 of about 41.8 mm. In the illustrated embodiment bottle divider 502 is provided with a sort of embossment or having a extension depth d 12 of about 3 mm. Bottle neck positioners 524 maintain the bottle neck in a stable position.

[0051] It will be understood that the dimensions that are mentioned for the different illustrated embodiments are examples and other configurations and / or dimensions of a bottle divider can be envisaged in accordance with the invention. In preferred embodiments bottle neck positioners achieve a form closure or interlock between bottle divider and bottle (neck).

[0052] In a preferred embodiment a marking is introduced into a bottle divider 602 (figures 6A-C) introducing insert 604 into a mould. Part 606 of insert 604 extends over the product edge 608 over a distance d 13 of about 10 mm. In the illustrated embodiment a smaller edge 610 is provided.

[0053] When manufacturing a bottle divider 2, 102, 202, 302, 402, 502 in manufacturing process 702 (figure 7) in first preparation step 704 the moulded pulp is prepared including an amount of surface roughness reducing agent and non-wood biomass material with or without additional enzymes. In moulding step 706 the bottle divider in its raw embodiment is moulded. After transferring the divider in transfer step 708 to the drying mould a drying step 710 is performed. Alternatively or in addition, a separate drying step is performed. After terminating drying step 710, the releasing step 712 releases bottle divider 2, 102, 202, 302, 402, 502 from the drying mould. Optionally, insert 604 can be provided and / or labels can be provided. Optionally, drying step 710 is performed in a conventional manner or with the bottle divider remaining in the mould that is used in the moulding step.

[0054] The present invention is by no means limited to the above described preferred embodiments thereof. The rights sought are defined by the following claims within the scope of which many modifications can be envisaged.

Claims

1. Bottle divider (2, 102, 202, 302, 402, 502, 602) from a moulded pulp material, the bottle divider comprising: - a number of bottle receiving compartments (4, 6, 8); and - bottle positioning elements (16) configured for maintaining the bottle that is placed in one of the compartments in a desired position, wherein the bottle positioning elements comprise bottle neck positioners configured for engaging the bottle neck, wherein the moulded pulp material comprising an amount of non-wood biomass material of plant origin, wherein the moulded pulp comprises at least 10 wt.% non-wood lignocellulosic biomass, wherein the moulded pulp material comprises an amount of a surface roughness reducing agent, wherein the surface roughness reducing agent comprises a biodegradable aliphatic polyester.

2. Bottle divider according to claim 1, wherein the bottle neck positioners engage the bottle neck over a substantial part of the bottle neck perimeter.

3. Bottle divider according to claim 2, wherein the bottle neck positioners engage the bottle neck perimeter over 20% of the total perimeter, preferably over 25%, and most preferably over 30%.

4. Bottle divider according to claim 1, 2 or 3, wherein the bottle positioning elements comprises a number of bottle engaging cam, nock or edges.

5. Bottle divider according to one or more of the foregoing claims, wherein the bottle positioning elements define a form closure or interlock.

6. Bottle divider according to one or more of the foregoing claims, further comprising a marking area (10, 18).

7. Bottle divider according to one or more of the foregoing claims, the bottle divider further comprising a number of denesting elements (20, 21).

8. Bottle divider accroding to claim 7, wherein at least some of the denesting elements are positioned in a first configuration or in a second configuration, wherein the first and second configurations have different positions for at least some of the denesting elements and the positions are such that the denesting elements are alternately positioned in the first and second configurations to enable denesting of a stack of bottle dividers.

9. Bottle divider according to one or more of the foregoing claims, wherein the moulded pulp comprises at least 50 wt.% non-wood lignocellulosic biomass, preferably at least 80 wt.% non-wood biomass, more preferably at least 85 wt.% non-wood biomass, and most preferably at least 92.5 wt.% non-wood biomass.

10. Bottle divider according to one or more of the foregoing claims, wherein the non-wood biomass comprises biomass originating from plants of the Order Poales, the Order Solanales, the Order Arecales, the Order Malphighiales, the Order of Rosales, the Order of Malvales and / or herbaceous plants, wherein the non-wood biomass preferably comprises biomass originating from plants of the Family of Poaceae.

11. Bottle divider according to one or more of the foregoing claims, wherein the biodegradable aliphatic polyester comprises an amount of one or more of PHB, PHA, PCL, PLA, PGA, PBS and PHBV.

12. Method for manufacturing (702) a bottle divider (2, 102, 202, 302, 402, 502, 602) from a moulded pulp material, the method comprising the steps of: - preparing moulded pulp material (704); - moulding the bottle divider (706); - providing bottle positioning elements (16) configured for maintaining the bottle that is placed in one of the compartments in a desired position, wherein the bottle positioning elements engage the bottle neck; and - releasing (712) the bottle divider from the mould, further comprising the step of adding non-wood biomass material of plant origin, wherein preparing moulded pulp material comprises at least 10 wt.% non-wood lignocellulosic biomass, wherein preparing moulded pulp further comprises providing an amount of a surface roughness reducing agent, wherein providing the surface roughness reducing agent comprises providing a biodegradable aliphatic polyester.

13. Method according to claim 12, further comprising the step of in-mould drying the bottle divider.

14. Method according to claim 12 or 13, further comprising the step of preparing a slurry comprising the biomass fibers and adding an amount of enzymes to the slurry and performing enzymatic fibrillation of the fibers and / or protein removal.

15. Method according to claim 14, wherein the enzymes comprise a hydrolase, preferably protease, and / or cellulose and / or pectinase.

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