Recyclable container and method for producing a recyclable container

Abstract

Disclosed is a recyclable container (300) comprising a biofoam body (100) with a side wall (102), a floor (104) and a biofilm layer (302), wherein inner surfaces of the side wall and the floor are adapted to provide an inner volume (106) of the biofoam body for retaining an object, an outer surface of the biofoam body is adapted to provide an external face for supporting the biofilm layer, wherein the biofilm layer provides an impermeable layer to the outer surface (108) of the biofoam body.

Description

[0001] RECYCLABLE CONTAINER

[0002] TECHNICAL FIELD

[0003] The present disclosure relates to recyclable containers for retaining objects for packaging. Moreover, the present disclosure related to methods for producing recyclable containers.

[0004] BACKGROUND

[0005] The packing industry is versatile and generates large amount waste material, compared to many other industries. For example, materials used for packaging of products are discarded after usage as waste. Conventionally, packaging industry, specifically, food packaging industries, use materials such as expanded polystyrene (EPS), polyethylene (PE), polypropylene (PP) based packaging. Such conventional materials are preferred for packaging as they are lightweight, durable, and have insulating properties. However, the conventional materials are non-biodegradable and detrimental to the environment. Moreover, specifically for packaging food products, there is a potential risk of contamination, particularly when packaging materials are exposed to bio-contaminants. For example, seafood, fish, cooked food and so on when packaged, may release biological contaminants such as oil, bio-sludge, and so on. The packaging in such cases are rendered unsuitable for recycling and are either used for landfill or for energy production by incineration, which causes soil pollution, air pollution or may end up in an ocean or waterbody causing water pollution, may be degraded into micro-plastic causing severe health challenges to living beings. Furthermore, such conventional packaging materials are prone to damage during transport, warehouse storage, or handling.As a solution to all possible biohazards and environmental pollutions from the conventional packaging materials, biodegradable material-based packaging means are being adopted. However, the biodegradable material-based packaging means still fail in terms of tensile strength to withstand accidental and natural damages during transport, warehouse storage, or handling. Moreover, the biodegradable material-based packaging means are prone to moisture damage which causes degradation of the packaged product therein.

[0006] Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks.

[0007] SUMMARY

[0008] The aim of the present disclosure is to provide a recyclable container and a method to produce recyclable and single-use packaging solutions for applications such as food (particularly fish), medical, and defense packaging. The aim of the present disclosure is achieved by a recyclable container comprising a biofoam body with a side wall, a floor and a biofilm layer, wherein inner surfaces of the side wall and the floor are adapted to provide an inner volume of the biofoam body for retaining an object and a method method for producing a recyclable container comprising a biofoam body with a side wall, a floor and a biofilm layer; wherein the inner surfaces of the side wall and the floor are adapted to provide an inner volume of the biofoam body for retaining an object, as defined in the appended independent claims to which reference is made to. Advantageous features and additional implementations are set out in the appended dependent claims.

[0009] Throughout the description and claims of this specification, the words "comprise" , "include", "have", and "contain" and variations of these words, for example "comprising" and "comprises" , mean "including but not limited to" , and do not exclude other components, items, integers orsteps not explicitly disclosed also to be present. Moreover, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

[0010] BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an upper perspective illustration of a biofoam body of a recyclable container, in accordance with an embodiment of the present disclosure;

[0011] FIG. 2 is a bottom perspective illustration of a a recyclable lid member of a recyclable container, in accordance with an embodiment of the present disclosure; and

[0012] FIG. 3 is a schematic illustration of a cross-sectional view of a recyclable container in an assembled configuration, in accordance with an embodiment of the present disclosure.

[0013] DETAILED DESCRIPTION OF EMBODIMENTS

[0014] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practising the present disclosure are also possible.

[0015] In a first aspect, the present disclosure provides a recyclable container comprising a biofoam body with a side wall, a floor and a biofilm layer, wherein inner surfaces of the side wall and the floor are adapted to provide an inner volume of the biofoam body for retaining an object, characterised in thatan outer surface of the biofoam body is adapted to provide an external face for supporting the biofilm layer, wherein the biofilm layer provides an impermeable layer to the outer surface of the biofoam body. According to the first aspect of the present disclosure, the aforementioned recyclable container provides a sustainable, versatile, and efficient solution for packaging needs across various industries such as food (particularly fish) industry, medical industry and defense industry. Moreover, biofoam body and biofilm layer of the recyclable container is entirely biodegradable, compostable and recyclable that reduces long-term environmental pollution compared to conventional EPS packaging. Furthermore, the biofilm layer acts as a protective barrier and prevents contamination (for example, fish oil or waste) of the biofoam body. This ensures that the biofoam body remains recyclable or reusable even after contact with substances like fish oil or medical residues. The outer biofilm layer adds tensile strength to the biofoam body, reinforciing its load-bearing capacity and impact resistance. The reinforcement makes the recyclable container more robust and better suited for the safe transport or fragile or perishable goods. Furthermore, the biofilm layer is impermeable that prevents water, oil and other contaminants from penetrating the biofoam body that increases its usability. Furthermore, the biofilm layer can be replaced, allowing the recyclable container to be reused multiple times without compromising hygiene or food-contact safety that extends the lifespan of the recyclable container and reduces waste which further reduces carbon emission.

[0016] In a second aspect, the present disclosure provides a method for producing a recyclable container comprising a biofoam body with a side wall, a floor and a biofilm layer; wherein the inner surfaces of the side wall and the floor are adapted to provide an inner volume of the biofoam body for retaining an object, the method comprising the steps of:

[0017] receiving a biofoam body in a suitable shape;applying a biofilm layer to an outer surface of the biofoam body, wherein the biofilm layer provides an impermeable layer to the outer surface of the biofoam body.

[0018] According to the second aspect of the present disclosure, the aforementioned method provides a sustainable, versatile, and efficient solution for packaging needs across various industries such as food (particularly fish) industry, medical industry and defense industry. Moreover, biofoam body and biofilm layer of the recyclable container is entirely biodegradable, compostable and recyclable that reduces longterm environmental pollution compared to conventional EPS packaging. Furthermore, the method uses renewable materials like seaweed for the biofoam and the biofilm that reduces reliance on petroleum-based products. Furthermore, applying the biofilm layer acts as a protective barrier and prevents contamination (for example, fish oil or waste) of the biofoam body. This ensures that the biofoam body remains recyclable or reusable even after contact with substances like fish oil or medical residues. By applying the biofilm layer on the outer surface of the biofoam body adds tensile strength to the biofoam body that reinforces its loadbearing capacity and impact resistance. The reinforcement makes the recyclable container more robust and better suited for the safe transport or fragile or perishable goods. Furthermore, the biofilm layer is impermeable that prevents water, oil and other contaminants from penetrating the biofoam body that increases its usability. Furthermore, the biofilm layer can be replaced, allowing the recyclable container to be reused multiple times without compromising hygiene or food-contact safety that extends the lifespan of the recyclable container and reduces waste which further reduces carbon emission.

[0019] Throughout the present disclosure, the term "recyclable container" refers to a volumetric storage and packaging arrangement made out of recyclable materials, for storing / retaining goods or an object therein. Theterm "goods" or "object" as herein refers to products that are either directly used, or processed before use, and that are required to be transferred from one location to another. The goods or object may be any of dry goods, moist goods, edible goods, inedible goods. For example, the object may be fruits, vegetables, prepared meals, baked goods, frozen foods, fish, seafood, rice, grains, nuts, seeds, toys, cleaning products, cosmetic products and the like. It may be appreciated that preferably, the recyclable container is used for storage

[0020] The recyclable container comprises the biofoam body comprising the side wall and the floor. Throughout the present disclosure, the term "biofoam body" refers to a main structure of the recyclable container, made from biofoam material. Notably, biofoam refers to a foam-like solid yet lightweight material manufactured using suitable biological raw materials, utilizing a predefined manufacturing process. It may be appreciated that the biofoam body is biodegradable and eco-friendly, making it a sustainable choice for the recyclable container. Throughout the present disclosure, the term "floor" refers to a base of the recyclable container. Throughout the present disclosure, the term "side wall" refers to a vertical or an inclined surface that forms a boundary or sides of the recyclable container. Notably, the side wall is arranged along a circumference of the floor. It may be appreciated that the side wall and floor are molded as a single piece (monolithically) or assembled together to form the biofoam body of the recyclable container. In this regard, the side wall may comprise a first end adjacent to the floor's inner surface when the biofoam body is constructed and a second end opposite the first end defining an opening of the biofoam body via which the goods / objects may be loaded into the inner volume. It may be appreciated that biofoam body may be dimensioned in a required manner, where optionally a thickness of the floor and a thickness of the side wall may be same or different depending on load-bearing capacity required, strength ofbiofoam, thermal insulation required, production feasibility, costeffectiveness and so on.

[0021] Moreover, the biofoam body also comprises an outer surface and inner surfaces of the side wall. The term "outer surface" as used herein refers to a surface of the biofoam body that is exposed to the environment and external factors thereof, such as dust, humidity, contaminants and the likes. The outer surface forms outer parts of the side wall and the floor. The term "inner surface" as used herein refers to a surface of the side wall opposite the outer surface, that comes in contact with the goods / object packaged within the biofoam body. Optionally, the inner surfaces are designed to be smooth and dimensioned to define an inner volume capable of retaining objects therein. Throughout the present disclosure, the term "inner volume" refers to a space enclosed and defined by the floor, and the inner surfaces of the side wall and is adapted to accommodate the goods or object that needs to be packaged in the recyclable container. In other words, the side wall and the floor together form the inner volume of the recyclable container to hold / store the objects therein. Notably, the inner volume of the biofoam body is adapted to resist degradation upon contact with stored objects (e.g., semi-fluidic goods / objects, sludge, oil or acidic liquids that may be secreted from the packaged goods / objects). It may be appreciated that the inner volume of the biofoam body is also adapted to provide thermal insulation, ensuring the biofoam's inherent properties are utilized.

[0022] In an embodiment, the biofoam body comprises

[0023] one or more drainage channels on the floor of the biofoam body; and

[0024] one or more drainage holes, connected to the one or more drainage channels, on the sidewall of the biofoam body.In this regard, the one or more drainage channels refer to grooves or depressions integrated into the floor of the biofoam body. The one or more drainage channels are adapted to guide liquid from melting of preservation ice, sludge and other discharged wastes from packaged goods / objects (for example, watery discharge from wet products, fish generated over time) to specific locations, preventing pooling, thereby minimizing damages to the biofoam body. Optionally, the one or more drainage channels are designed to have different depth, width, length and shape depending on the material and size of the biofoam body. For example, the one or more drainage channels may be 2-5 mm wide and 1-3 mm deep, designed to allow liquid flow without compromising structural integrity. It may be appreciated that the one or more drainage channels may have varying shapes (e.g., linear, radial, or grid-like) depending on requirements. For an example, the one or more drainage channels can be arranged radially from the center of the floor or in a parallel fashion, depending on liquid collection points. The one or more drainage holes refer to openings on the side wall connected to the one or more drainage channels, allowing the liquid from melting of preservation ice, the sludge and other discharged wastes from packaged goods / objects, to exit the recyclable container. Notably, the one or more drainage holes are arranged at the endpoints of the one or more drainage channels on the side wall. Optionally, the one or more drainage holes are positioned above or at a base of the side wall (at the first end), for efficient liquid removal. It may be appreciated that the one or more drainage channels ensure the liquid from melting of preservation ice, the sludge and other discharged wastes from packaged goods / objects, move efficiently toward the one or more drainage holes, avoiding pooling or stagnation. Optionally, the one or more drainage holes are designed to pass through the thickness of the side wall to direct the liquid from melting of preservation ice, the sludge and other discharged wastes from packaged goods / objects outward without compromising the floor of thebiofoam body. Optionally, the one or more drainage holes allow the biofoam body to absorb the liquid from melting of preservation ice, the sludge and other discharged wastes from packaged goods / objects. The biofoam body have properties of absorption of liquid, and the biofoam body may absorb the liquid from melting of preservation ice, the sludge and other discharged wastes from packaged goods / objects via the one or more drainage holes. Optionally, the one or more drainage holes may have variable shapes, and sizes. For example, the one or more drainage holes may be circular, elliptical, or slot-shaped. Optionally, the one or more drainage holes may have diameters ranging from 2-4 mm, depending on the requirement. For example, the diameter of the one or more drainage holes may be from 2, 2.1, 2.2, 2.3, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, or 3.9 mm up to 2.1, 2.2, 2.3, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4 mm. Notably, the number and arrangement of one or more drainage channels and the one or more drainage holes can be tailored for specific applications. The technical advantage of the one or more drainage channels and the one or more drainage holes is to provide a path for the liquid from melting of preservation ice, the sludge and other discharged wastes from packaged goods / objects to exit the container, preventing accumulation and ensuring dry storage conditions, thereby preventing sogginess or contamination for packaged goods / objects (like fresh produce or seafood).

[0025] Notably, the outer surface of the biofoam body is enveloped, or covered with the biofilm layer. Throughout the present disclosure, the term "biofilm layer" refers to a thin sheet made up of a suitable biological raw materials to exhibit hydrophobic properties. It may be appreciated that the biofilm layer is biodegradable and eco-friendly. For example, the biofilm layer may be prepared from plant-based polymers (e.g., polyhydroxyalkanoates, or PHAs) or cellulose derivatives (e.g., cellulose acetate), which have naturally low degradation period and disintegratenaturally. Notably, the biofilm layer is impermeable and does not allow the passage of particulates (such as moisture, gaseous substances) through it. The biofilm layer compensates for any potential porosity of the biofoam body. Therefore, the outer surface of the recyclable container is enveloped or layered with the biofilm layer to prevent external contaminants such as moisture, dust, foreign particles, lifeforms, and the likes from entering the recyclable container. Optionally, the outer surface is pre-treated to allow firm adhesion of the biofilm layer. The pretreatment may involve any of biodegradable adhesive coating, chemical priming, plasma treatment or such suitable pre-treatment. The technical advantage is better adhesion of the biofilm layer.

[0026] In an embodiment, the biofilm layer is produced from a biodegradable material selected from: seaweed, plant derived starch, polylactic acid (PLA), bagasse, mycelium, under a second set of processing conditions. In this regard, the phrase "second set of processing conditions" refers to specific manufacturing parameters, methods, and environmental factors employed to transform the biodegradable material into the biofilm layer. The second set of processing conditions are tailored to the biodegradable material's physical and chemical properties and are distinct from the first set of processing conditions used for the biofoam body. It will be appreciated that the second set of processing conditions such as temperature, pressure, time duration, moisture content, chemical additives, processing techniques and the like varies according to the biodegradable material. Beneficially, the biodegradable material is selected from different aforementioned materials to reduce dependency on synthetic plastics, offering a sustainable alternative that breaks down naturally without harming ecosystems. The selected materials possess inherent qualities (for example, flexibility, impermeability, moisture resistance) suitable for creating a durable yet eco-friendly biofilm layer. The range of the biodegradable materials ensures adaptability to different recyclable container use cases, such as food packaging (requiringmoisture barriers) or storage of organic materials (requiring compostability). Moreover, the biodegradable material is chosen based on the specific functional requirements of the biofilm layer, such as gas impermeability, strength, or flexibility. A technical effect is that the biofilm layer decomposes naturally in composting environments or landfills, reducing long-term environmental impact. The biodegradable materials complement the biofoam body, ensuring the entire container can be recycled or composted as a unit.

[0027] In an embodiment, the biofilm layer is formed from a chitosan material. In this regard, the term "chitosan material" refers to a natural, biodegradable polymer derived from chitin that is found in the exoskeletons of crustaceans (such as shrimp, crabs, and lobsters) and in the cell walls of fungi. Notably, the chitosan material is used as the primary component in forming the biofilm layer for the packaging recyclable container. A technical effect is that the chitosan material enhances the barrier properties of the biofilm, such as water resistance and impact protection and prevents external moisture, oil, or contaminants from affecting the biofoam body, while ensuring that the recyclable container remains biodegradable and compostable. Additionally, the chitosan material provides antimicrobial benefits that contributes to the protection of food and other sensitive contents during the storage and transportation.

[0028] In an embodiment, the biofilm layer is replaceable. In this regard, the biofilm layer of the recyclable container is designed to be detachable and exchangeable without compromising the structural integrity or functionality of the underlying biofoam body. The replaceable biofilm layer allows for removal and substitution with a new layer when the biofilm layer becomes damaged, degraded, or contaminated. Beneficially, by replacing only the biofilm layer rather than the entire container, the overall lifespan of the recyclable container is increased. This reduceswaste and promotes reuse. Moreover, the ability to replace the biofilm layer ensures that the recyclable container can maintain sanitary conditions, particularly for applications involving food, medicine, or sensitive materials.

[0029] In an embodiment, the recyclable container further comprising a recyclable lid member, formed from a biofoam material used to form the biofoam body, which is adapted to provide a lid inner surface that cooperates with the inner volume of the biofoam body. In this regard, the term "recyclable lid member" refers to a component of the recyclable container that is complementary to the biofoam body and when in use forms a closed space sealing the object in the inner volume of the biofoam body. The term "lid inner surface" as used herein refers to a surface of the recyclable lid member that is adapted to face the inner volume of the biofoam body. It may be appreciated that the recyclable lid member is shaped and sized to create a secure seal with the biofoam body of the recyclable container. In other words, the lid inner surface is designed to fit and seal against an opening of the biofoam body ensuring that the lid stays securely in place and helps maintain the integrity of the recyclable container's contents (i.e., objects packaged therein). The technical advantage of using the same biofoam material for the recyclable lid member ensures that the entire recyclable container, i.e., the biofoam body and the recyclable lid member can be recycled together without needing to separate different material.

[0030] In an embodiment, the biofoam material is produced from a biodegradable material selected from: seaweed, plant derived starch, polylactic acid (PLA), bagasse, mycelium, under a first set of processing conditions. Herein, the term "seaweed" refers to a type of marine plant that grows in coastal areas and bodies of water. The seaweed serves as a raw material for the biofoam production due to its biodegradability, flexibility in forming films or foams, and low environmental footprint. Theterm "plant derived starch" refers to carbohydrate polymers extracted from plants like corn, potatoes, wheat, or cassava. Starch is a natural biopolymer that can be processed into thermoplastics or foams for packaging and other uses. The plant derived starch is included as a biodegradable material due to its ability to be molded and shaped under specific processing conditions. The term "polylactic acid" refers to a biodegradable polymer derived from renewable resources like cornstarch or sugarcane through a fermentation process. The polylactic acid (PLA) contributes to the production of durable and heat-resistant biofoam materials. The PLA's biodegradability and compatibility with industrial composting makes it a preferred choice for creating eco-friendly products. The term "bagasse" refers to a fibrous byproduct of sugarcane or sorghum after the juice has been extracted. The bagasse is a renewable and biodegradable material that is commonly used in eco-friendly packaging and disposable products. The bagasse is used as the biofoam material due to its strong fibrous properties, which provide structural integrity and moisture resistance. The term "mycelium" refers to a dense network of thread-like structures that can be grown in molds to create biofoams or composites that serve as packaging and insulation materials. The mycelium is utilized in the biofoam production for its ability to grow rapidly, adapt to specific shapes, and provide durable, compostable materials.

[0031] In an embodiment, the biofoam material is co-polymerised with a plant derived elastomer. In this regard, the term "plant derived elastomer" refers to a flexible, plant-based polymer that enhances the mechanical properties of the biofoam material when co-polymerized. The plant based elastomer exhibits high flexibility, resilience and the ability to recover to its original shape after deformation. The plant derived elastomer is blended at the molecular level with the base material of the biofoam (for example, seaweed-based biofoam) through co-polymerization. The copolymerization of the biofoam material with the plant derived elastomeradds flexibility, impact resistance and durability to the biofoam material. Additionally, the co-polymerization enhances the structural integrity and shock-absorption capabilities of the biofoam material, making it more suitable for high-stress applications.

[0032] In an embodiment, the biofoam body is recycled as a fertilizer material. Herein, the term "fertilizer materia!" refers to a material that is incorporated into the soil to enhances its fertility by providing essential nutrients to promote plant growth and agricultural productivity. In this regard, the biofoam body is made form biodegradable and organic materials like seaweed that inherently contains beneficial nutrients such as nitrogen, potassium and phosphorus that enhances soil fertility. The biofoam body is processed to break down into smaller pieces to facilitate decomposition, gradually releasing nutrients over time, reducing the risk of nutrient leaching and providing long-term benefits to plants. The biofoam, when shredded and ploughed into the soil enhances soil structure and water retention capability of the soil, further promoting healthy plant growth. A technical effect of recycling the biofoam body as the fertilizer material is to reduce the waste by the repurposing the biofoam body into a valuable agricultural input. Additionally, the slow-release nature of the biofoam minimizes leaching of nutrients into water bodies, preventing environmental pollution. It also offers an eco-friendly and potentially cost-efficient alternative to synthetic fertilizers.

[0033] In an embodiment, the biofoam body is recycled as a compostable material. Herein, the term "compostable materia!" refers to a material that can naturally break down into organic components through a biological process (i.e. composting). The biofoam body under proper environmental conditions (for example, appropriate temperature, moisture and microbial activity) decomposes into harmless organic matter such as carbon dioxide, water and humus. The recycling of the biofoam body into the compostable material promotes sustainable wastemanagement practices by converting the waste into a valuable resource. The recycling of the biofoam into the compostable material encourages a circular lifecycle for packaging materials, ensuring that the waste is reintegrated into the ecosystem rather than polluting it. Moreover, the used biofoam body is collected and separated for composting. The biofoam body is introduced into a composting system, either industrial or domestic, where the biofoam body decomposes under the controlled conditions. The composted material is mixed into soil to enhance the organic content of the soil, improving fertility and water retention capability of the soil. A technical effect of recycling the biofoam body is to avoid incineration or landfill disposal, reducing greenhouse gas emissions associated with conventional waste management.

[0034] In an embodiment, the recyclable lid member further comprises a lid outer surface that is adapted to provide an external face for supporting a biofilm layer, wherein the biofilm layer provides an impermeable layer to the outer surface of the biofoam material of the recyclable lid member. In this regard, the term "lid outer surface" used herein refers to a surface of the recyclable lid member that is opposite the lid inner surface and is exposed to the environment when the recyclable lid member is placed on the recyclable container. Notably, the lid outer surface is adapted to be layered with the biofilm layer forming the external face of the recyclable container. Optionally, the biofilm layer may be layered upon the lid outer surface after the recyclable lid member is coupled with the biofoam body, thereby ensuring tension wrapping of the biofilm layer to achieve a cease-free, air gap free layering of the biofilm layer. The technical advantage is the prevention of the external contaminants form entering the inner volume of the recyclable container.

[0035] In an embodiment, the lid inner surface of the recyclable lid member further comprises a stepped peripheral edge, which when in use, cooperates with a top surface of the side wall having a continuousdepression portion complimentary to the stepped peripheral edge to provide an impermeable seal between the biofoam body and the recyclable lid member. It may be appreciated that the term "stepped peripheral edge" refers to a structure that includes at least one protrusion and an adjacent recess. In this regard, the stepped peripheral edge comprises raised and recessed profile along a circumference of the lid inner surface of the recyclable lid member. The term "top surface" refers to a surface at a second end of the side wall opposite to the first end and that is designed to engage with the stepped peripheral edge of the recyclable lid member. The top surface comprises the continuous depression portion complimentary to the stepped peripheral edge. The continuous depression portion may be a groove-like structure designed to match and engage the stepped peripheral edge of the recyclable lid member. The complementary geometry of the stepped peripheral edge and the continuous depression portion of top surface are precisely designed to lock together, preventing slippage or misalignment. Notably, the stepped peripheral edge compresses against the continuous depression portion, filling gaps and forming a barrier. When the recyclable lid member and biofoam body are assembled, the interaction between the stepped peripheral edge and the complementary depression creates an air-tight, impermeable seal. The technical advantages of formation of air-tight seal between the biofoam body and the recyclable lid member of the recyclable container is ensuring safety of the packaged goods / objects therein, by preventing leakage of the packaged goods / objects from the recyclable container or entry / passage of external contaminants such as air, moisture, or other liquids.

[0036] In an embodiment, the one or more drainage channels are sloped towards the sidewall of the biofoam body, wherein a slope of the one or more drainage channels in a range of XX to YY degrees, with respect to the floor of the biofoam body.In an embodiment, the biofilm layer is recycled as a fertilizer material. In this regard, the recyclization process describes an end-of-life application for the biofilm layer, where the biofilm layer is repurposed as the fertilizer material. After use, the biofilm layer is collected separately, and the biofilm is shredded into smaller pieces to facilitate easier decomposition and integration into the soil. Microorganism present in the soil break down the biofilm into simpler compounds, releasing nutrients such as nitrogen, potassium and phosphorus that enhances soil fertility and are beneficial for the plant growth. A technical effect of recycling the biofilm layer as the fertilizer material is to ensure that the biofilm layer, like the biofoam body, decomposes safely and effectively without polluting the environment.

[0037] In an embodiment, the biofilm layer is recycled as compostable material. In this regard, the biofilm layer under proper environmental conditions (for example, appropriate temperature, moisture and microbial activity) decomposes into harmless organic matter such as carbon dioxide, water and humus. The recycling of the biofilm layer into the compostable material promotes sustainable waste management practices by converting the waste into a valuable resource. Moreover, the recycled compostable material addresses the growing need for sustainable and environmentally friendly packaging materials by ensuring that the biofilm layer fails to contribute to landfill waste or pollution. The recycling of the biofilm layer into the compostable material encourages a circular lifecycle for packaging materials, ensuring that the waste is reintegrated into the ecosystem rather than polluting it. Moreover, the used biofilm layer is collected and separated for composting. The biofilm layer is introduced into a composting system, either industrial or domestic, where the biofilm layer decomposes under the controlled conditions. The composted material is mixed into soil to enhance the organic content of the soil, improving fertility and water retention capability of the soil. A technical effect of recycling the biofilm layer is to avoid incineration or landfilldisposal, reducing greenhouse gas emissions associated with conventional waste management.

[0038] In an embodiment, the recyclable container further comprises a sensor configured to monitor at least one of: the temperature within the inner volume of the recyclable container, the location of the recyclable container and gas content of the recyclable container. In this regard, the term "sensor" refers to a device that is designed to detect and measure specific physical, chemical, or environmental parameters, and convert them into signals that can be interpreted and utilized for monitoring or controlling purposes. The sensor is a temperature sensor (such as thermistors, thermocouples, infrared (IR) sensors) that monitors the temperature within the inner volume of the recyclable container. The monitoring of the temperature within the inner volume of the recyclable container by the sensor ensures that the stored object remains within an optimal temperature range, such as for food preservation or temperature-sensitive goods like medicines. Optionally, the sensor is a location sensor (such as GPS modules, RFID tags) that tracks the geographic location of the recyclable container. The monitoring of the location of the recyclable container enables real-time tracking of the recyclable container for logistics, inventory management, theft prevention and the like activities. Optionally, the sensor is a gas content sensor (such as CO2Sensors, VOC Sensors and the like) that ensures that the atmosphere inside the recyclable container is suitable for the specific object (such as fish) for preserving food quality or maintaining sterility. A technical effect is that the sensor improves the product quality and safety by ensuring proper environmental conditions, facilitates traceability and monitoring in the supply chain and supports automation and data-driven decision-making in logistics and storage.

[0039] The present disclosure also relates to the method as described above. Various embodiments and variants disclosed above, with respect to theaforementioned the recyclable container, apply mutatis mutandis to the method.

[0040] In an embodiment, the method comprises a further step of receiving a recyclable lid member formed from a biofoam material used to form the biofoam body, which is adapted to provide:

[0041] a lid inner surface that cooperates with the inner volume of the biofoam body; and

[0042] a lid outer surface that is adapted to provide an external face for supporting a biofilm layer, wherein the biofilm layer provides an impermeable layer to the outer surface of the biofoam material of the recyclable lid member.

[0043] In an embodiment, the method comprises a further step of providing the inner surface of the recyclable lid member with a stepped peripheral edge comprising an elevated continuous portion, which when in use, cooperates with a top edge surface of the side wall having a continuous depressed portion complimentary to the elevated continuous portion of the recyclable lid member and thereby providing an impermeable seal between the biofoam body and the recyclable lid member.

[0044] In an embodiment, the method comprises a further step of draining fluid accumulated on the floor of the biofoam body by means of

[0045] one or more drainage channels on the floor of the biofoam body; and

[0046] one or more drainage holes, connected to the one or more drainage channels, on the sidewall of the biofoam body.

[0047] In an embodiment, the one or more drainage channels sloped towards the sidewall of the biofoam body, wherein a slope of the one or moredrainage channels in a range of XX to YY degrees, with respect to the floor of the biofoam body.

[0048] In an embodiment, the method comprises a further step of producing at least one of: the biofoam material, the biofilm layer, from a biodegradable material selected from: seaweed, plant derived starch, polylactic acid (PLA), bagasse, mycelium, under a first set of processing conditions and a second set of processing conditions, respectively.

[0049] In an embodiment, the method comprises a further step of recycling at least one of: the biofoam body, the biofilm layer, as at least one of: a fertilizer material, a compostable material.

[0050] In an embodiment, the method comprises a further step of spraying a chitosan material as the biofilm layer over the outer surface of the biofoam body.

[0051] In an embodiment, the method comprises a further step of copolymerising the biofoam material with a plant derived elastomer.

[0052] In an embodiment, the method comprises further steps of: extracting the biopolymer material from one or more raw materials; processing the biopolymer material extracted to produce at least one of: the biofoam material, the biofilm layer; and

[0053] molding the biofoam material to produce the biofoam body and the recyclable lid member of the recyclable container.

[0054] In an embodiment, the method comprises a further step of producing the recyclable lid member adapted to seal the recyclable container by engaging with the biofoam body, wherein the recyclable lid member is fabricated from the biofoam material that is layered with the biofilm layer.In an embodiment, the method comprises a further step of arranging a sensor on at least one of: the biofoam body, the recyclable lid member, for monitoring at least one of: the temperature within the inner volume of the recyclable container, the location of the recyclable container and gas content of the recyclable container.

[0055] DETAILED DESCRIPTION OF THE DRAWINGS

[0056] Referring to FIG. 1A, illustrated is a schematic illustration of a biofoam body 100 of a recyclable container, in accordance with an embodiment of the present disclosure. As shown, the biofoam body 100 comprises a side wall 102, a floor 104 and a biofilm layer. Inner surfaces of the side wall 102 and the floor 104 are adapted to provide an inner volume 106 of the biofoam body for retaining an object. An outer surface 108 of the biofoam body is adapted to provide an external face for supporting the biofilm layer, wherein the biofilm layer provides an impermeable layer to the outer surface 108 of the biofoam body 102. The side wall 104 of the biofoam body 100 also comprises a top surface 110. The biofoam body 100 also comprises one or more drainage channels 112 on the floor 104 of the biofoam body 100 and one or more drainage holes 114 connected to the one or more drainage channels 112, on the side wall 102 of the biofoam body 100.

[0057] It may be appreciated that FIG. 1 is merely an example, which should not unduly limit the scope of the claims herein. A person skilled in the art will recognize many variations, alternatives, and modifications of embodiments of the present disclosure.

[0058] Referring to FIG. 2, illustrated is a schematic illustration of a recyclable lid member 200 of a recyclable container, in accordance with an embodiment of the present disclosure. As shown, the recyclable lid member 200 comprises a lid inner surface 202 which further comprises a stepped peripheral edge 204, which when in use, cooperates with a top surface 110 of the side wall having a continuous depression portioncomplimentary to the stepped peripheral edge 204 to provide an impermeable seal between a biofoam body 100 and the recyclable lid member 200.

[0059] It may be appreciated that FIG. 2 is merely an example, which should not unduly limit the scope of the claims herein. A person skilled in the art will recognize many variations, alternatives, and modifications of embodiments of the present disclosure.

[0060] Referring to FIG. 3, illustrated is a schematic illustration of a cross-sectional view of a recyclable container 300 in an assembled configuration, in accordance with an embodiment of the present disclosure. As shown, a biofoam body 100 and a recyclable lid member 200 are assembled together. Notably, the recyclable lid member 200 having inner lid surface 202 seals an inner volume 106 adapted for retaining objects therein. One or more drainage holes 114 are arranged on a side wall 102 of the biofoam body 100 to allow exit of waste fluid generated in the inner volume 106. As shown, the recyclable container 300 also comprises a biofilm layer 302 layering the assembled configuration. Moreover, as shown, the recyclable container 300 also comprises a sensor arrangement 304 configured to monitor the objects in the inner volume 106.

[0061] It may be appreciated that FIG. 3 is merely an example, which should not unduly limit the scope of the claims herein. A person skilled in the art will recognize many variations, alternatives, and modifications of embodiments of the present disclosure.

Claims

CLAIMS1. A recyclable container (300) comprising a biofoam body (100) with a side wall (102), a floor (104) and a biofilm layer (302), wherein inner surfaces of the side wall and the floor are adapted to provide an inner volume (106) of the biofoam body for retaining an object, characterised in thatan outer surface (108) of the biofoam body is adapted to provide an external face for supporting the biofilm layer, wherein the biofilm layer provides an impermeable layer to the outer surface of the biofoam body.

2. A recyclable container (300) according to claim 1, further comprising a recyclable lid member (200), formed from a biofoam material used to form the biofoam body (100), which is adapted to provide an inner surface (202) that cooperates with the inner volume (106) of the biofoam body.

3. A recyclable container (300) according to claim 2, wherein the recyclable lid member (200) further comprises an outer surface that is adapted to provide an external face for supporting the biofilm layer (302), wherein the biofilm layer provides an impermeable layer to the outer surface of the biofoam material of the recyclable lid member.

4. A recyclable container (300) according to any of the preceding claims, wherein the inner surface (202) of the recyclable lid member (200) further comprises a stepped peripheral edge (204), which when in use, cooperates with a top surface (110) of the side wall (102) having a continuous depression portion complimentary to the stepped peripheral edge to provide an impermeable seal between the biofoam body (100) and the recyclable lid member.

5. A recyclable container (300) according to any of the preceding claims 2 to 4, wherein the biofoam body (100) comprisesone or more drainage channels (112) on the floor (104) of the biofoam body; andone or more drainage holes (114), connected to the one or more drainage channels, on the sidewall (102) of the biofoam body.

6. A recyclable container (300) according to claim 5, wherein the one or more drainage channels (112) are sloped towards the sidewall (102) of the biofoam body (100), wherein a slope of the one or more drainage channels in a range of XX to YY degrees, with respect to the floor (104) of the biofoam body.

7. A recyclable container (300) according to any of the preceding claims 2 to 5, wherein the biofoam material is produced from a biodegradable material selected from: seaweed, plant derived starch, polylactic acid (PLA), bagasse, mycelium, under a first set of processing conditions.

8. A recyclable container (300) according to any of the preceding claims, wherein the biofoam body (100) is recycled as a fertilizer material.

9. A recyclable container (300) according to any of the preceding claims, wherein the biofoam body (100) is recycled as a compostable material.

10. A recyclable container (300) according to any of the preceding claims, wherein the biofilm layer (302) is recycled as a fertilizer material.

11. A recyclable container (300) according to any of the preceding claims, wherein biofilm layer (302) is recycled as compostable material.

12. A recyclable container (300) according to any of the preceding claims, wherein the biofilm layer (302) is produced from a biodegradable material selected from: seaweed, plant derived starch, polylactic acid (PLA), bagasse, mycelium, under a second set of processing conditions.

13. A recyclable container (300) according to any of the preceding claims 1 to 9, wherein the biofilm layer (302) is formed from a chitosan material.

14. A recyclable container (300) according to any of the preceding claims 2 to 11, wherein the biofoam material is co-polymerised with a plant derived elastomer.

15. A recyclable container (300) according to any of the preceding claims, further comprises a sensor (304) configured to monitor at least one of: the temperature within the inner volume of the recyclable container, the location of the recyclable container and gas content of the recyclable container.

16. A recyclable container (300) according to any of the preceding claims, wherein the biofilm layer (302) is replaceable.

17. A method for producing a recyclable container (300) comprising a biofoam body (100) with a side wall (102), a floor (104) and a biofilm layer (302); wherein the inner surfaces of the side wall and the floor are adapted to provide an inner volume (106) of the biofoam body for retaining an object, the method comprising the steps of:receiving a biofoam body in a suitable shape;applying a biofilm layer to an outer surface (108) of the biofoam body, wherein the biofilm layer provides an impermeable layer to the outer surface of the biofoam body.

18. A method according to claim 17, comprising a further step of receiving a recyclable lid member (200) formed from a biofoam material used to form the biofoam body (100), which is adapted to provide:an inner surface (202) that cooperates with the inner volume (106) of the biofoam body; andan outer surface that is adapted to provide an external face for supporting a biofilm layer (302), wherein the biofilm layer provides an impermeable layer to the outer surface of the biofoam material of the recyclable lid member.

19. A method according to claim 17 or 18, comprising a further step of providing the inner surface (202) of the recyclable lid member (200) with a stepped peripheral edge (204) comprising an elevated continuous portion, which when in use, cooperates with a top edge (110) surface of the side wall (102) having a continuous depressed portion complimentary to the elevated continuous portion of the recyclable lid member and thereby providing an impermeable seal between the biofoam body (100) and the recyclable lid member.

20. A method according to claims 17 to 19, comprising a further step of draining fluid accumulated on the floor (104) of the biofoam body (100) by means ofone or more drainage channels (112) on the floor of the biofoam body; andone or more drainage holes (114), connected to the one or more drainage channels, on the sidewall (102) of the biofoam body.

21. A method according to claim 20, wherein the one or more drainage channels (114) sloped towards the sidewall (102) of the biofoam body (100), wherein a slope of the one or more drainage channels in a range of XX to YY degrees, with respect to the floor (104) of the biofoam body.

22. A method according to claims 18 to 20, comprising a further step of producing at least one of: the biofoam material, the biofilm layer (302), from a biodegradable material selected from: seaweed, plant derived starch, polylactic acid (PLA), bagasse, mycelium, under a first set of processing conditions and a second set of processing conditions, respectively.

23. A method according to claims 17 to 22, comprising a further step of recycling at least one of: the biofoam body (100), the biofilm layer (302), as at least one of: a fertilizer material, a compostable material.

24. A method according to claim 17 to 21, comprising a further step of spraying a chitosan material as the biofilm layer (302) over the outer surface (108) of the biofoam body (100).

25. A method according to claim 18 to 23, comprising a further step of co-polymerising the biofoam material with a plant derived elastomer.

26. A method according to claim 21 to 24, comprising further steps of:extracting the biopolymer material from one or more raw materials; processing the biopolymer material extracted to produce at least one of: the biofoam material, the biofilm layer (302); andmolding the biofoam material to produce the biofoam body (100) and the recyclable lid member (200) of the recyclable container (300).

27. A method according to claim 17 to 26, comprising a further step of producing the recyclable lid member (200) adapted to seal the recyclable container (300) by engaging with the biofoam body (100), wherein the recyclable lid member is fabricated from the biofoam material that is layered with the biofilm layer (302).

28. A method according to claim 17 to 27, comprising a further step of arranging a sensor (304) on at least one of: the biofoam body (100), therecyclable lid member (200), for monitoring at least one of: the temperature within the inner volume (106) of the recyclable container (300), the location of the recyclable container and gas content of the recyclable container.

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