SYSTEM AND METHOD FOR MANUFACTURING 3-DIMENSIONALLY SHAPED PACKAGING UNITS FROM DRY MOULDABLE FIBRE MATERIAL

Abstract

The present invention relates to system and method for manufacturing 3-dimensionally shaped packaging unit from dry mouldable fibre material. The system comprises: - a feeding device for providing separated fibres of the fibre material; - a rotary drum unit having a rotary drum configured for receiving the separated fibres of the fibre material from the feeding device at a material receiving position, and comprising a number of drum mould parts; - a forming unit configured for forming and / or pre-forming a packaging unit in co-operation With the rotary drum at a forming and / or pre-forming position, wherein the forming unit comprises a number of forming mould parts that are configured for co-operating With the drum mould parts; and - a release station for releasing the formed or pre-formed packaging unit from the rotary drum at a release position.

Description

The present invention relates to a system for manufacturing packaging units from fibre material, more specifically from dry mouldable fibre material. Packaging units from such dry mouldable fibre material, and specifically three-dimensionally shaped packaging units, are used to contain, store, transport and / or display a range of products, such as meat, cereals, eggs, snacks, fruits, vegetables, and other products including liquids and beverages. The three-dimensionally shaped packaging units may relate to containers, carriers, cases, cups, plates, boxes, trays, dividers et cetera. Conventional systems for manufacturing packaging units from dry mouldable fibre material involve preparing the fibre material in a hammer mill, whereafter the fibres are provided in a layer or sheet or pad or web or blanket, or more specifically in a non-woven-like blanket as a uff pulp layer. This layer is then provided in a mould or press wherein the pressed (shaped) parts are removed from the layer. These conventional systems limit the freedom of design for the packaging units. In fact, complex shapes ofthe packaging units cannot be manufactured effectively with these conventional systems. This is especially problematic when high volume / high speeds in the manufacturing process are required. Especially at relatively high speeds, the fibre material can be incorrectly stretched such that the products are incorrectly formed. Also, conventional systems (and methods) produce a relatively high amount ofwaste material. Often, in conventional systems and methods, the waste material is fed back into the process. However, due to the presence of additives this may result in manufacturing difficulties. Performing high volume / high speed manufacturing results an even higher amount of waste, thereby increasing the manufacturing difficulties. The present invention has for its object to obviate or at least reduce one or more of the above- stated problems in conventional systems and methods for manufacturing three-dimensionally shaped packaging units from dry mouldable fibre material. For this purpose, the present invention provides a system for manufacturing 3-dimensionally shaped packaging units from dry mouldable fibre material, the system comprising: a feeding device for providing separated fibres of the fibre material; a rotary drum unit having a rotary drum configured for receiving the separated fibres of the fibre material from the feeding device at a material receiving position, and comprising a number ofdrum mould parts; a forming unit configured for forming and / or pre-forming a packaging unit in co-operation with the rotary drum at a forming and / or pre-forming position, wherein the forming unit comprises a number offorming mould parts that are configured for co-operating with the drum mould parts; and a release station for releasing the formed or pre-formed packaging unit from the rotary drum at a release position. Preparing and providing dry mouldable fibre material typically involves providing an amount of fibre material as starting material. This fibre material may have different origin, such as wood and / or non-wood fibre material, optionally from a recycling process such as from recycled paper material. Alternatively, or in addition to such paper material, the fibre material may also comprise an amount ofnon-wood fibre material to which is also referred to as natural and / or alternative fibres. Such fibres may involve biomass fibres from plant origin, examples ofwhich are described inWO 2021 / 145764 A1. The three-dimensionally shaped packaging units from dry mouldable fibre material relate to packaging units having relevant sizes in three dimensions, i.e. having a width, a depth, and a (significant) height. This may involve the presence of a compartment thatmay contain a product such as an egg, fruit, vegetable, beverage etcetera. Such three-dimensionally shaped packaging units are therefore different from layer or blanket type material that are essentially two-dimensional and only having a certain (limited) thickness in the third dimension and is not shaped in this third (height) dimension. Manufacturing three-dimensionally shaped packaging units from a dry mouldable fibre material involves providing such fibre material as a first step. Typically, in such dry laid process involving dry mouldable fibre material, the fibre pulp matrix can be supplied as sheets or reels that can be fed into a hammer mill, or other similar device, to which can also be referred as a defibrator. Such hammer mill or similar device separates compressed rolls or sheets of the fibre pulp into individual loose fibres which are then transported to a feeding device for providing separated fibres of the fibre material to the rotary drum unit. It is noted that in addition to, or as an alternative to, providing the raw fibre material as sheets or reels, also loose fibres can be provided. According to the present invention the feeding device provides the separated fibres to a rotary drum unit, more specifically to a rotary drum thereof that can receive these separated fibres at a material receiving position of the rotary drum. The rotary drum ofthe system according to the invention comprises a number ofdrum mould parts. The system further comprises a forming unit that can form and / or pre-form the packaging unit in cooperation with the rotary drum at a forming / pre-forming position of the rotary drum. Such forming unit also comprises a number offorming mould parts that are capable of co-operating with the drum mould parts. Depending on the actual design these forming mould parts and drum mould parts may relate to male or female mould parts. The fibres are effectively compacted / pressed with the respective co-operating mould parts, and the material is typically compacted to a thickness between 0.5 to 5 mm. The pressing may be done using heated tools at temperatures in a range between 50 °C and 130 °C. Pressure is preferably similar to conventional dry moulded fibre processing. It will be understood that other thicknesses and / or temperatures can be envisaged and may depend on the actual 3-dimensional design, for example. The position of the forming unit or units can be optimized, for example depending on the process and product characteristics. For example, a forming unit can be positioned relative to the rotary drum at a position below and / or above the rotary drum and / or at any intermediate position. Also, it will be understood that the other units can be positioned depending on process and product characteristics, for example. The system further comprises a release station for releasing the formed or pre-formed packaging unit from the rotary drum at a release position. This enables release or removal of the formed packaging unit from the rotary drum to storage, use, further processing et cetera. Optionally, a(n) (intermediate) mixing drum may be used to homogenize the fibres, with the mixing drum preferably being provided between the hammer mill and the rotary drum. At this stage, binders (such as starch, MFC, NFC, or other bio-based materials) may be added to improve interfibre adhesion. When in use, the (forming) rotary drum is rotating and the fibre material goes through various stations or positions where different operations of the fibre materialmay take place. First, the fibre material is provided to the rotary drum at a receiving position. Then, the fibre material is transferred from a receiving position to one or more forming positions on which the packaging unit is formed with the use of the mould parts. Finally, the formed units reach the release position at which the formed packaging unit leaves the rotary drum. It will be understood that additional operations can be included in the system. For example, a spraying section can be provided that co- operates with the different stages ofthe rotary drum to allow for deposition of additives such as binders, for example. The rotary drum may receive the separated fibres by using an under-pressure, also referred to as vacuum, or other pressure difference, such that the fibre material is directed towards the rotary drum surface. In addition, or as an alternative, to the application of an under-pressure or vacuum involving vacuum means, the separated fibres can also be guided or directed to the drum surface using one or more blower units and / or other suitable means, such as pipes and blowers. In some ofthe presently preferred embodiments of the invention, the rotary drum may have a diameter in the range of 1 to 4 metres and may have a height or length in the range of 1 to 3 metres. The drum may rotate at different speeds, preferably in a range of 10 to 80 rpms. It will be understood that other values can be envisaged in accordance with the present invention and may depend on the actual 3-dimensional design, for example. An advantage ofthe system for manufacturing three-dimensionally shaped packaging units from dry moulded fibre material using a rotary drum is that no transport of a sheet, web, blanket, pad or layer is required. This renders the manufacturing process and associated system with its components relatively straightforward and less complex. As a further effect, the system for manufacturing three-dimensionally shaped packaging units may operate at high volume / high speed as compared to conventional systems, while having a minimum ofwaste material. Also, there is no need for manufacturing of intermediate products such as the aforementioned blanket thereby providing an effective system and method. Also, the application of a rotary drum in the system according to the present invention provides an increased freedom for design ofthe packaging unit as compared to the use ofconventional blankets that typically limit the depth of a formed packaging unit to about 15 mm. This use of a rotary drum in the system according to the present invention renders complex shapes for the packaging unit possible, such as the shape ofegg packages having a significant depth. While the application of blankets typically results in 60 to70% ofwaste or material feedback into the process, the use of a rotary drum significantly reduces the amount ofwaste material. This improves the energy efficiency ofthe overall system and method and accordingly increases the overall capacity of the system and method. As a further effect, tests have shown that packaging units having a broader range of fibre densities can be handled with the system according to the present invention. Such broader range of fibre densities can be provided in an individual packaging unit and / or between different designs of such packaging units. In a presently preferred embodiment of the invention, the rotary drum comprises a number of openings configured for attracting the separated fibres of the fibre material towards a surface of the rotary drum. Providing openings in the surface of the rotary drum enables an effective positioning of the separated fibres onto the rotary drum surface. For example, vacuum means (also referred to as pressure means) enable providing an under-pressure on the inside of the rotary drum such that the separated fibres are guided or directed towards the rotary drum surface. This provides an effective means for feeding the separated fibres to the rotary drum surface at a material receiving position. Preferably, in such embodiment, the drum mould parts of the rotary drum are porous. The loose fibres land on or in the mould part(s) as the fibres are sucked onto the rotary drum surface due to the vacuum / under-pressure force. In one of the presently preferred embodiments of the invention, the actual porosity of the surface of the rotary drum, and more specifically the drum mould parts thereof, involves a distribution of openings. Such distribution may result in a variation of the fibre density in the packaging unit. For example, this can be achieved by adjusting the size and / or number of the openings or pores at a specific cross-section of the mould such that the amount of fibres deposited can be manipulated and varied, and, accordingly, a formed or pre-formed packaging unit having a non-uniform fibre distribution may be created. This could then be used to manufacture a packaging unit having different fibre densities at different areas of the packaging unit. In a presently preferred embodiment of the invention, the rotary drum comprises a honeycomb structure. Providing the rotary drum surface with a honeycomb structure reduces clogging, which is a significant problem ofconventional systems and methods. In presently preferred embodiments of the invention, such honeycomb structure is used in combination with a so-called filter or membrane sheet. Application of such membrane or sheetmay enable a laminarow of air that further reduces the risk of clogging. Such sheet ormembrane is also referred to as a filter element. As a further effect, the use of a honeycomb structure increases the exibility for applying different shapes / designs for the packaging unit that can be manufactured with the system and method according to the present invention. In a further preferred embodiment of the invention, the rotary drum comprises one or more protrusions extending from the surface to provide openings and / or shaped elements in the packaging unit. Providing protrusions in the drum mould parts directly provides the desired shape of the packaging unit. Therefore, there is no need to cut out material from the (roughly) formed packaging unit, for example. This obviates the need for a separate post-treatment process, and additionally reduces the amount ofwaste material, so that an effective and efficient system and manufacturing method is provided. In a further preferred embodiment of the present invention the system further comprises one or more blower units. The application ofone or more blower units enables guiding the separated fibres towards the drum surface. As mentioned earlier, the one or more blower units can be applied in co-operation with vacuum means to provide an under-pressure. In a further preferred embodiment of the invention the system comprises a further forming unit. Providing a further forming unit, such as a second or further forming unit, enables a multi- stage forming of the packaging unit, such as a two-stage forming. For example, at a first forming position, a first forming unit presses the fibre material into a desired shape having a wall thickness of2 to 2.5 mm. At a second forming position, preferably on the same rotary drum, the second forming unit further brings the fibre material into a desired shape of the packaging unit while reducing the wall thickness to 1.5 mm, for example. The mentioned wall thicknesses are average thicknesses of a wall part or bottom part of the packaging unit. In addition to, or as an alternative to a further rotary drum, a further hammermill is optionally provided to enable deposition at various positions of the rotary drum. Optionally, using multiple hammermills / forming heads enables depositing different fibres one after the other to form a packaging unit. This may be used to build a multilayer structure wherein each layer may contribute to a specific function (for example, barrier layer, strength layer, low-cost material or recycled material, decoration layer, etc.). In a further preferred embodiment of the present invention the system further comprises a feeding station configured for adding additives. Such feeding station may involve a spraying unit and can be positioned at the desired location relative to the rotary drum. For example, such feeding station can be provided between a first and a second forming unit. Additives that can be provided to the rotary drum can be provided as particles, fibres and / or layers. The additives may include binders, barriers, pigments for coloring the packaging unit and other additives to increase strength and stability of the resulting packaging unit, for example. In several of the presently preferred embodiments of the invention, a feeding station involves an additional spraying station / step that is optionally provided / performed between the first and second forming steps. In such embodiment, an additional spraying unit may add additives and / or a specific layer to the fibre material such that the second forming step provides better results. In a further preferred embodiment of the present invention the system further comprises a charging station configured for charging fibres. Providing a charging stationmay result in an improved positioning of the separated fibres in the packaging unit. Optionally, fibres can be provided with a charge, positive or negative, in the hammer mill. Preferably, by providing an opposite charge on the rotary drum, the fibres may adhere better to the drum surface. Optionally, such charging station is applied in combination with vacuum means and / or blower unit(s). In a further preferred embodiment of the invention, the system comprises a further rotary drum unit configured for providing a second or further layer to the packaging unit. Providing a system with two or more rotary drum units provides additional design freedom for the packaging unit. For example, the design may include multiple layers by having the first and the second rotary drum unit co-operating with each other and adhering two layers to each other, thereby forming the desired packaging unit. For example, in a (pre)forming stage, two co-operating drums may be run in unison to form a single preform article where two separate preforms are combined and compressed together at the compression stage and then removed as a single preformed or formed packaging unit. As a further effect of the application of a second or further rotary drum unit, the resulting packaging unit has two smooth surfaces having reduced surface roughness. In a further preferred embodiment of the present invention, the system has a rotary drum that comprises a longitudinal axis and two or more segments that are positioned along the longitudinal axis, and further comprising positioning means configured for positioning at least one of the two or more segments in a production line. Providing different sections to the rotary drum enables providing several designs for the desired packaging unit on a single rotary drum. This enables relatively fast switching between different product designs or product shapes without requiring a (substantial) standstill of the manufacturing line, for example. Preferably, the separated fibres ofthe mouldable pulp material comprise alternative fibres. Such alternative fibres may involve biomass fibres from plant origin, examples ofwhich are described inWO 2021 / 145764 A1. In one of the presently preferred embodiments the alternative fibres comprise wheat straw, optionally the wheat straw is provided as wheat straw powder. It will be understood that other alternative fiber material may also be applied, optionally in different combinations. In a further preferred embodiment of the present invention the system further comprises a sensor system configured to determine pressure difference over the surface of the rotary drum. Providing a sensor system improves the overall control of the manufacturing process with the system according to the present invention. The sensor system has been shown to be especially effective in case a distribution or variation of fibres over the drum mould part is intended to have a fibre density variation in the resulting packaging unit. The invention further relates to a manufacturing line and / or method for manufacturing 3- dimensionally shaped packaging units from dry mouldable fibre material that comprise and / or use a system in one ofthe aforementioned embodiments. The manufacturing methodmay further comprise the steps ofpreparing an amount of separated fibres of the mouldable fibre material and forming the fibres into a packaging unit with the rotary drum. Such manufacturing line and / or method provide the same or similar effects and / or advantages as described in relation to the system. Such method and / or manufacturing line typically have a reduced complexity as compared to conventional manufacturing processes. For example, a separate transport of a blanket or other layer is not required. Furthermore, by the reduction ofwaste material production, the entire process can be performed effectively and more efficiently as compared to conventional processes. At the same time, the freedom of design for the packaging units is significantly increased thereby widening the range ofproducts that can be manufactured with such manufacturing line and method. 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 1 shows a schematic overview of the manufacturing process involving the system and method of the present invention; Figure 2A-B shows different embodiments of the rotary drum that can be applied in the manufacturing process offigure 1; Figure 3A-B shows alternative embodiments of the rotary drum; Figure 4 shows a honeycomb structure with filter element in accordance with an embodiment ofthe present invention; and Figures 5A-I show different examples ofpackaging units that can be manufactured with a system and method according to the invention. Manufacturing process 2 (figure 1) comprises preparation step 4 wherein fibres are prepared. This may involve the production of sheets or reels, for example. In loosening step 6, loose fibres are processed and formed, optionally using a hammer mill. Optionally, charging step 8 enables charging of fibre material. In depositing step 10, the loose fibres are provided to the surface of the rotary drum using vacuum means and / or blowing means and / or other suitable means. In positioning step 12, fibres are positioned in or on drum mould parts. Optionally, adding step 14 provides additional material to the fibres thatmay involve suitable additives, for example. In forming step 16, the fibre material is shaped with the drum mould part after which a second forming step 18 is optionally performed. Optionally, a further adding step 14 (not shown) can be performed between first and second forming step 16, 18. Preferably, stabilizing step 20 is performed when rotating the rotary drum from a forming position to a further position. Optionally, a further material layer is provided in multi-layer step 22, preferably involving a second rotary drum. After further rotation of the rotary, drum a packaging unit is released from the rotary drum in releasing step 24. Optionally, further processing steps 26 can be performed, whereafter the packaging unit is ready for use 28. System 102 (figure 2A) comprises rotary drum unit 104 with rotary drum 106. In this illustrated embodiment, rotary drum 6 is capable of rotating in direction A. At surface 108 ofrotary drum 106 there are provided a number ofdrum mould parts 110. Drum mould parts 110 can be shaped as male parts 110a or female parts 110b (figure 2B). Supply system 112 provides fibres 114 towards hammer mill 116. In the illustrated embodiment, optional charging station 118 is provided that is capable ofproviding a charge to fibres 114. Fibres 114 are guided or directed towards drum surface 108 in direction B. Optionally, sensor system 120 is provided to measure a pressure difference over surface 108 that is generated through vacuum means 120. Feeding device 111 comprises supply system 112 and hammer mill 116, and optionally other suitable components. Feeding device 111 deposits fibres 114 on and / or in drum mould parts 110 at depositing position 124. After rotating rotary drum 106, fibre material arrives at first forming position 126 having first forming unit 128 that is moved in directionC towards drum surface 108 to shape or press or compress or compact or perform other suitable operation of the fibre material to shape fibre material 114 into a desired packaging unit. In the illustrated embodiment, after further rotation ofrotary drum 106, the shaped fibre material arrives at a further feeding or spraying position 130 where feeding or spraying unit 132 provides additional material to the fibres. It will be understood that this feeding or spraying unit 132 is optional. In this illustrated embodiment, after further rotation ofrotary drum 106, the material arrives at second forming position 134. Second forming unit 136 having forming mould parts 129 can be moved in directionD towards the surface 108 ofrotary drum 106 to perform a second pressing step. In the illustrated embodiment, after further rotation ofrotary drum 106, the fibre material arrives at a further feeding or spraying position 138 having feeding / spraying unit 140, or other suitable unit, to provide further material to the packaging unit. After further rotation ofrotary drum 106, release position 142 is reached with release station 144 that releases the formed or preformed packaging unit P from rotary drum 106. It will be understood that different embodiments of rotary drum 106 and system 102 can be envisaged in accordance with the present invention. In addition to the already mentioned example ofmale or female mould parts 110, 110a, 110b, also protrusions 146 (schematically illustrated in figure 2B) can be provided that provide additional shapes, such as openings or cones ofegg packages, in the design ofpackaging unit P. Other alternative embodiments involve system 202 (figure 3A) with first rotary drum 106 and second rotary drum 204. As mentioned earlier, such system 202 provides possibilities for combining two pre-formed shapes to a single packaging unit. The second rotary drum 204 can optionally be provided with separate hammer mill 206 and / or other units, ormay use these units in combination with first rotary drum 106. Also, it is possible to provide a first hammer mill 116a and second hammer mill 116b in combination with a single rotary drum 106, optionally with individual supply units 112a, 112b. In a further alternative embodiment rotary drum unit 302 (figure 3B) comprises multiple sections 304, 306, 308 along surface 310 ofrotary drum 302 as seen in longitudinal directionE of rotary drum 310. Translation drive 312 enables movement or positioning of an individual section 304, 306, 308 in directionE relative to manufacturing line 314 to enable fast switching between different designs 304a, 306a and 308a of the respective sections 304, 306, 308 ofrotary drum 310. In illustrated embodiments the position of the forming unit or units 128, 136 can be optimized depending on the process and product characteristics. For example, a forming unit 128, 136 can be positioned relative to rotary drum 106 at a position below (e.g. figure 2A) and / or above rotary drum 106 and / or at any intermediate position. Also, it will be understood that the other units can be positioned depending on process and product characteristics, for example. In a possible embodiment ofrotary drum surface 108a (figure 4), honeycomb structure 402 is provided in cooperation with filter element404 having distribution 406 ofopenings 408 (schematically illustrated in figure 4). It will be understood that the distribution ofopening 408 and / or the actual design of the honeycomb structure 402 can be adapted as a function of the desired designs of the packaging units. Process 2 enables the design ofpackaging units having three-dimensional and complex shapes. Next, some examples of such packaging units will be provided. It will be understood that other designs can also be envisaged in accordance with the present invention. An example ofpackaging unit P having a complex shape is egg package 502 (figure 5A). Such egg package 502 comprises bottom part 504 and cover part 506 that are preferably connected with hinge 508. Egg compartments 510 are designed to receive individual eggs. Cones 512 can be provided with the use ofprotrusions 146 (see also figure 2B). Alternative egg packages such as twin package 514 (figure 5B) are capable ofreceiving eggs G, and cup 516 (figure 5C) can also be envisaged in accordance with the present invention. Alternative designs for further packaging units can be manufactured with a process 2 according to the present invention and may relate to bottle dividers 602 (figure 5D), (meat) trays 702 having compartments 704 (figure 5E), plate 802 having compartment 804 (figure 5F), small cup 902 having container part 904 with product receiving compartment 906, and seal or lid 908 (figure 5G), sip lid 1002 (figure SH), and cup 1012 (figure 51). Other designs that can be manufactured with process 2 according to the present invention include drinking cups, yoghurt cups, Butter tuns, trays for ready-to-eat meals, etc. 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 ofwhich many modifications can be envisaged. CLAUSES 1. System for manufacturing 3-dimensionally shaped packaging units from dry mouldable fibre material, the system comprising: a feeding device for providing separated fibres of the fibre material; a rotary drum unit having a rotary drum configured for receiving the separated fibres of the fibre material from the feeding device at a material receiving position, and comprising a number ofdrum mould parts; a forming unit configured for forming and / or pre-forming the packaging unit in co- operation with the rotary drum at a forming and / or pre-forming position, wherein the forming unit comprises a number offorming mould parts that are configured for co- operating with the drum mould parts; and a release station for releasing the formed or pre-formed packaging unit from the rotary drum at a release position. 2. System according to clause 1, wherein the rotary drum comprises a number ofopenings configured for attracting the separate fibres of the fibre material towards a surface of the rotary drum. 3. System according to the foregoing clause, wherein the rotary drum comprises a distribution of the openings to manipulate distribution of the separate fibres of the fibre material. 4. System according to any of the foregoing clauses, wherein the rotary drum comprises a honeycomb structure. 5. System according to the foregoing clause, wherein the honeycomb structure is provided with a filter element. 6. System according to any of the foregoing clauses, wherein the rotary drum comprises protrusions extending from the surface to provide openings and / or shaped elements in the packaging unit. 7. System according to any of the foregoing clauses, wherein the feeding device comprises one or more blower units. 8. System according to any of the foregoing clauses, further comprising a further forming unit. 9. System according to any of the foregoing clauses, further comprising a feeding station configured for adding additives. 10. System according to any of the foregoing clauses, further comprising a charging station configured for charging fibres. 11. System according to any of the foregoing clauses, further comprising a further rotary drum unit configured for providing a second or further layer to the packaging unit. 12. System according to any of the foregoing clauses, wherein the rotary drum comprising a longitudinal axis and two or more segments that are positioned along the longitudinal axis, and further comprising positioning means configured for positioning at least one of the two or more segments in a production line. 13. System according to any of the foregoing clauses, wherein the separate fibres of the mouldable fibre material comprise alternative fibres. 14. System according to the foregoing clause, wherein the alternative fibres comprise wheat straw. 15. System according to any of the foregoing clauses, further comprising a sensor system configured to determine a pressure difference over the surface of the rotary drum. 16. Manufacturing line for manufacturing 3-dimensionally shaped packaging units from dry mouldable fibre material, comprising a system according to one of the foregoing clauses. 17. Method for manufacturing a 3-dimensionally shaped packaging unit from dry mouldable fibre material, comprising the steps of: providing a system or manufacturing line according to any of the foregoing clauses; preparing an amount of separated fibres of the mouldable fibre material; and forming the separated fibres into a packaging unit.

Claims

1. System for manufacturing 3-dimensionally formed packaging units from dry formable fiber material, where the system comprises: a feeding device for supplying separated fibers from the fiber material; a rotating drum unit with a rotating drum designed for the feeding device receiving the separated fibers from the fiber material on a material receiving position, and includes a number of drum mold parts; a forming unit designed for forming and / or pre-forming the packaging unit in conjunction with the rotating drum on a form and / or preform position, where the mold unit comprises a number of mold parts that are configured for cooperation with the drum mold parts; and an unloading station for unloading the formed or pre-formed packaging unit of the rotating drum at a discharge position.

2. System within the meaning of claim 1, where the rotating drum comprises a number of openings which is designed to attract the individual fibers of the fiber material to a surface of the rotating drum.

3. System in accordance with the preceding conclusion, where the rotating drum has a distribution of includes the openings to the distribution of the individual fibers of the fiber material achieve.

4. System in accordance with one of the preceding claims, where the rotating drum a includes honeycomb structure 5. System in accordance with the preceding conclusion, where the honeycomb structure is provided with a filter element.

6. System in accordance with one of the preceding claims, where the rotating drum includes protrusions extending from the surface around openings and / or shaped to provide elements in the packaging unit.

7. System pursuant to one of the preceding claims, where the feeding device is one or includes more blowing units.

8. System pursuant to one of the preceding claims, further comprising a further formal unit 9. System pursuant to one of the preceding claims, further comprising a supply station that is designed for the addition of additives.

10. System pursuant to one of the preceding claims, further comprising a charging station that is configured to supply a fiber load.

11. System pursuant to one of the preceding claims, further comprising a further rotating drum unit configured for delivering a second or further layer to the packaging unit.

12. System in accordance with one of the preceding claims, where the rotating drum a longitudinal axis and comprises two or more segments that are along the longitudinal axis positioned, and further comprising positioning means that are designed for the positioning of at least one of the two or more segments in a production line.

13. System according to one of the preceding conclusions, whereby the separated fibers of the moldable fiber material includes alternative fibers.

14. System in accordance with the preceding conclusion, whereby the alternative fibers are wheat straw include.

15. System pursuant to one of the preceding claims, further comprising a sensor system that is designed to determine a pressure difference across the surface of the rotating drum.

16. Production line for producing 3-dimensionally formed packaging units from dry formable fibre material, comprising a system according to one of the preceding claims.

17. Method for producing a 3-dimensionally shaped packaging unit from dry formable fiber material, comprising the steps of: - providing a system or production line in accordance with one of the preceding claims; - the preparation of a quantity of separated fibers from the formable fiber material; and - forming the separated fibers into a packaging unit.

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