A method for manufacturing packaging material

Abstract

NOT VISIBLE DUE TO STATUS OF PATENT

Description

[0001] A METHOD FOR MANUFACTURING PACKAGING MATERIAL

[0002] TECHNICAL FIELD

[0003] This invention relates to a method for manufacturing packaging material. In particular, the invention relates to a method for manufacturing packaging material from brewers spent grain.

[0004] SUMMARY OF THE INVENTION

[0005] According to the invention, there is provided a method for manufacturing packaging material including: - collecting residual grain from a brewing process; breaking down fibres contained in the grain; creating a pulp from the broken-down fibres; preparing the pulp for article formation, including adding biodegradable additives to the pulp; and forming an article from the pulp suitable for use as packaging.

[0006] The residual grain may be collected from a beer brewing process. In particular, the residual grain may be in the form of BSG (brewers spent grain). It is to be appreciated that BSG is a byproduct of the beer brewing process, typically being formed after malted grains are mashed, wherein starches in the grain are broken down by enzymes, and a liquid known as wort is formed and removed.

[0007] The method may include drying the grain after being collected. It is to be appreciated that BSG is a wet substance having a high moisture content, and drying may be necessary to reduce the likelihood of spoiling during transportation and / or storage. The method may include grinding and / or milling the grain to create a finer consistency before breaking down the fibres. It is to be appreciated that drying and / or milling the grain before breaking down the fibres and / or pulping may serve to improve even cooking and / or chemical treatment of the grain.

[0008] The method may include a thermal treatment before breaking down the fibres.

[0009] Breaking down the fibres contained in the grain may be carried out via a mechanical process. The mechanical process may include any one or more of the group including refining, grinding, beating, stamping, pressing, flattening, rolling, and blending. During blending, a liquid may be added to the grain for facilitating blending, the liquid preferably being in the form of water. The amount of water added may be dependent on the amount of grain to be blended, preferably adding in the range of 200ml to 300ml of water for every 400g to 600g of grain. It is to be appreciated that the amount of water to be added may be dependent on the strength of the blender being used, typically adding more water to the grain for a weaker blender. It is to be appreciated further that it is desirable to add as little water as possible. It is to be appreciated yet even further that such processing is done to break down the grains sufficiently to ensure a finer grained article. In addition, such processing may improve bond quality between remaining fibres during article formation. The mechanical process may further include flattening out with a weight, preferably using a mortar and pestle.

[0010] The mechanical process may be carried out using a mill or a high-shear mixer. The mill may be in the form of a colloidal mill. The mill may be configured to break down the grain into a homogenous solution. The mill may be configured to break down the grain into small sizes in the range of 2 to 5 microns. It is to be appreciated that the benefit of breaking down the grains to such a size is that the surface area available for bonding is increased, which is in turn believed to increase the strength of a product to which the grain has been added. It is to be appreciated that mechanical breakdown of the grain in the presence of fluid would create a pulp, however, this particular pulp may not have the required characteristics for certain articles to be formed.

[0011] In one form of the invention, the method may include removing undesired material from the grain after mechanical fibre breakdown. The undesired material may be utilised as a source of energy, typically by burning. Removal of undesired material may be carried out by sieving through a mesh with mesh sizes smaller than the undesired material, or through a flotation process in which the undesired material floats to a surface of a flotation medium. The undesired material may be in the form of husks of the grain. It is to be appreciated that this step is optional and the inclusion of the husks in the pulp for article formation may lead to desirable characteristics of the article to be formed, such as increased strength, for example.

[0012] Breaking down the fibres may be carried out via a chemical process. The chemical process may include a steam explosion or steam hydrolysis process. For the purposes of this specification, steam hydrolysis is to be understood as a thermalchemical pretreatment technique used to break down lignocellulosic materials into more accessible components and could be used as a pretreatment for enzymatic breakdown. Further, steam explosion is to be understood as a process which uses high-pressure, high-temperature steam to break down fibrous structure of plant materials. In the steam explosion process, when pressure is suddenly released, the rapid expansion of steam disrupts grain cell walls, exposing cellulose and hemicellulose which renders material more suitable for further processing.

[0013] The steam explosion process may include the following steps: loading BSG into a reactor chamber, injecting high-pressure steam into the chamber, and abruptly releasing pressure within the chamber, thereby causing steam trapped within fibres of the BSG to expand to break the fibres. The high-pressure steam may be high-pressure saturated steam. It is to be appreciated that saturated steam is to be understood as steam which is at saturation temperature, which means that the steam is in thermal equilibrium with water at the same pressure wherein any change of heat will result in a phase change. The high-pressure steam may raise the temperature (within the chamber) to a temperature in the range of 160°C to 260°C, which serves to loosen bonds in the grain lignocellulosic structure.

[0014] It is to be appreciated that after the steam explosion process, the material is collected with its lignocellulosic components more accessible for subsequent processes, such as, for example, enzymatic hydrolysis or incorporation into a new product, such as packaging material.

[0015] Advantages of using steam explosion for BSG:

[0016] • Breaking Down Lignin: The lignin in BSG forms a complex with cellulose and hemicellulose, making it hard to access. Steam explosion disrupts this barrier.

[0017] • Exposing Polysaccharides: This process increases the availability of cellulose and hemicellulose for chemical or enzymatic modification, which could enhance binding properties in pulp.

[0018] • Protein Liberation: BSG is protein-rich, and steam pretreatment can denature proteins, making them usable in bioplastics or other composites.

[0019] • Improving Pulping Efficiency: The treated BSG can integrate more easily with cardboard pulp, improving the bonding and strength of the final material.

[0020] • Creating Bioplastics: The liberated lignocellulosic fibres and proteins can be formulated into biodegradable materials like 6-pack rings or other bio-based packaging.

[0021] The chemical process may include cooking the grain in an alkaline solution, preferably including water, for a predetermined duration. The predetermined duration may be dependent on the quality of the BSG and / or on the chemicals in which the BSG is cooked. Cooking may be carried out under high pressure. It is to be appreciated that cooking the grain in an alkaline solution at high pressure may serve to reduce cooking time, reduce overall energy consumption, and improve penetration of chemicals into the grain which in turn may accelerate breaking down the fibres.

[0022] The chemical process may include a plurality of cooking processes, preferably to achieve a particular set of characteristics. The characteristics may include any one or more of the group including texture, thickness, and consistency. It is to be appreciated that the set of characteristics may be dependent on user requirements.

[0023] The plurality of cooking processes may include a first cooking process. In the first cooking process, the alkaline solution may have a relatively low pH level. In particular, the alkaline solution may have a pH level in the range of 8 and 9. The alkaline solution may include sodium carbonate or sodium bicarbonate. In the first cooking process, the grain and alkaline solution may be cooked at a temperature in the range of 75°C to 1 10°C, preferably being cooked at a temperature in the region of 100°C. A ratio of BSG to water to sodium bicarbonate may be in the ranges of 250ml to 1 000ml, to 0.5 litres to 2 litres, to 5g to 50g. Preferably, the ratio of BSG to water to sodium bicarbonate may be in the region of 500ml to 1 litre to 38g. A duration of the first cooking process may be in the range of 30 minutes to 90 minutes, preferably being in the region of 60 minutes. It is to be appreciated that the duration of the first cooking process may vary, and the process is typically complete once discoloration occurs.

[0024] After the first cooking process, the grain may be strained and washed to separate the grain from dissolved materials, chemicals and / or the alkaline solution. The grain may undergo any one or more of the group including cleaning, washing, rinsing, straining, and screening in order to remove undesired material. The undesired material may be in the form of any one or more of the group including non-fibrous material, impurities, and larger particles. It is to be appreciated that the undesired material may be used for other purposes so as to reduce production of waste, for example, the undesired material may be burnt in an energy generation process. In particular, the grain may be rinsed with water in order to remove the sodium carbonate or sodium bicarbonate therefrom. It is to be appreciated that this step is typically required to eliminate stickiness thereby making the grain easier to work with. Used water may be utilised as a substrate for the production of bioplastics, such as PHA (Polyhydroxyalkanoates) for example.

[0025] The plurality of cooking processes may include a second cooking process. In the second cooking process, the alkaline solution may have a higher pH level than the alkaline solution used in the first cooking process. In particular, the alkaline solution for the second cooking process may have a pH level in the range of 1 1 to 13. In particular, the alkaline solution in the second cooking process may include sodium hydroxide. In the second cooking process, the grain and alkaline solution may be cooked at a temperature in the range of 75°C and 1 15°C, preferably being cooked at a temperature in the region of 90°C. A duration of the second cooking process may be in the range of 30 minutes to 270 minutes, preferably being in the region of 150 minutes.

[0026] After the second cooking process, the grain may be strained and washed to separate the grain from dissolved materials and the alkaline solution. The grain may undergo any one or more of the group including cleaning, washing, rinsing, straining, and screening in order to remove undesired material. The undesired material may be in the form of any one or more of the group including non-fibrous material, impurities, and larger particles. It is to be appreciated that the undesired material may be used for other purposes so as to reduce production of waste, for example, the undesired material may be burnt in an energy generation process.

[0027] Breaking down the fibres may be carried out via a biological process. The biological process may include the use of enzymes. In particular, the biological process may include enzymatic hydrolysis. The enzymes may include any of the group including cellulases, hemicellulases, and lignin-degrading enzymes. The grain may undergo a pretreatment before enzymatic hydrolysis to increase efficacy thereof. The pretreatment may be in the form of any one or more of the group including a mechanical, chemical, and thermal pretreatment. It is to be appreciated that enzymebased methods are more environmentally friendly than chemical fibre breakdown.

[0028] Creating the pulp from the broken-down fibres may form part of a distinct step after breaking down the fibres. Alternatively, creating the pulp may form part of the fibre breakdown step. It is to be appreciated that the pulp is typically created during the fibre breakdown process, however, this pulp may require further processing or preparation in order to form an article with a set of characteristics required for use as packaging material.

[0029] Preparing the pulp may include adding water thereto, preferably in order to make final adjustments to the consistency of the pulp. It is to be appreciated that the consistency of the pulp influences the group of characteristics of the article including strength, durability, elasticity, flexibility, texture, porosity, weight, thickness, water or moisture resistance, and appearance. It is to be appreciated further that the ratio of pulp to water influences thickness of the article being formed therefrom. The amount of water added may be in the range of 1 .5 litres to 2.5 litres for every 500g of blended grain, preferably being in the amount of about 2 litres for every 500g of blended grain. It is to be appreciated that excess and / or used water may be re-used in various processes, including the production of bioplastics.

[0030] Preparing the pulp may include adding additives to the pulp, preferably to ensure that the article to be formed therefrom exhibits a set of characteristics which are particularly suited to the use and type of the article. The additives may be in the form of biodegradable additives. The biodegradable additives may include any one or more of the group including strength enhancers, hydrophobic agents, fillers, binding agents, antimicrobials, pigments, defoamers, wetting agents, flame retardants, plasticisers, and surface modifiers. The strength enhancers may include any one or more of the group including starch, cellulose, lignin, gelatine, and casein. The starch may include any one or more of the group including corn starch, potato starch, and wheat starch. The cellulose may be in the form of carboxymethyl cellulose. The hydrophobic agents may include any one or more of the group including okra, natural waxes, polylactic acid, chitosan, and cellulose derivatives. The cellulose derivatives may include hydroxypropyl cellulose. The fillers may include any one or more of the group including calcium carbonate, and clay. The binding agents may include any one or more of the group including okra, guar gum, xanthan gum, pectin, and alginates. The antimicrobials may include any one or more of the group including essential oils, chitosan, and plant-based extracts. The plant-based extracts may include tannins. The pigments may include any one or more of the group including plant-based dyes, and mineral-based pigments. The defoamers may include any one or more of the group including natural oils, and lecithin. The flame retardants may include any one or more of the group including phosphorous-based compounds, such as ammonium polyphosphate, and intumescent additives. The plasticisers may include any one or more of the group including okra, glycerol, sorbitol, and triacetin. The surface modifiers may include any one or more of the group including natural oils, waxes, and cellulose derivatives.

[0031] Preparing the pulp may include adding cardboard, preferably pulped recycled cardboard. It is to be appreciated that cardboard provides a cost-effective and abundant source of cellulose, which contributes to the binding of grain fibres during article formation.

[0032] The article to be formed may be in the form of any of the group including a sheet, panel, crate, and box.

[0033] The sheet may undergo any one or more of the group of operations including cutting, scoring, creasing, folding, stamping, embossing, gluing, laminating, coating, and perforating. The operations may be dependent on the type of packaging to be produced. For example, the sheet may undergo any one or more of the group including stamping, cutting, and folding to form ring-like retainers for holding and retaining a plurality of beverages together to facilitate transport and / or packing thereof.

[0034] In particular, to form the sheet, the pulp may be placed into a sheet forming mould. The sheet forming mould may include a mesh and a frame surrounding the mesh. The sheet forming mould may include a second frame, known as a deckle, which may be placed on top of the first frame once the pulp is received therein. Typically, the sheet forming mould may be lowered into a container containing the pulp with the deckle placed above the first frame so that the mesh is positioned therebetween. The mould may be moved in a scooping motion in order to allow the pulp to collect on top of the mesh. The mould may be raised out of the container, allowing water in the pulp to drip through the mesh to leave the fibrous material of the grain on top of the mesh. The mould may be placed on a surface and the fibrous material caught in the mesh may be allowed to dry so as to form the sheet. The surface may be porous and / or foraminous. A sponge may be used to facilitate the transfer and suck up additional water. Optionally, the sheet may be removed from the mould and pressed in order press out excess water and speed up the drying process. The sheet may be pressed using a 10 to 20 tonne or metric ton press.

[0035] Alternatively, the sheet may be formed using sheet forming machinery which receives the pulp and runs the pulp over a plurality of rollers which compresses, heats and dries the pulp to form a continuous sheet to be rolled around a spindle.

[0036] The sheet may be in the form any of the group including paper, craft paper, kraft paper, card, cardstock, board, card-board, and newsprint. It is to be appreciated that the above processes may be varied as necessary to form a sheet of the desired type. Preferably, the sheet may be in the form of kraft paper, card or carboard for allowing the sheet to be used as packaging material for consumables. The article may be formed using compression moulding. In particular, the article may be formed by being compressed and / or moulded into a desired shape. The compression moulding may include simultaneous heating and drying. Alternatively, drying may be carried out by placing the formed article into an oven or in sunlight. It is to be appreciated that compressed pulp should have a low moisture content as compression and heat will create steam and if the moisture content is too high the power of the steam can break open the compression machine, or the pulp will not dry sufficiently. Further, the spent grain can be placed into the mould and pressed and heated into the desired shape without first pulping the spent grain. The article formed by compression moulding may be a panel, crate, or box. The crate may be in the form of a bottle crate, such as a beer bottle crate.

[0037] Further alternatively, the article may be formed using injection moulding. The article formed by injection moulding may be in the form of a panel, crate, or box.

[0038] Treatments may be provided for enhancing the article’s properties according to the specific use thereof. Treatments may include any one or more of the group including sizing (for reducing ink spread and improving strength and water resistance), coating (for increased brightness, smoothness, and print quality), impregnating with chemicals (for attributes like fire resistance, insect repellence, or UV protection), dyeing (for colour and aesthetic purposes or categorization), antimicrobial treatment (for preventing microbial growth in medical or food packaging applications), acidneutralization (for making the paper acid-free and suitable for long-term archival use), and moisture-proofing (for creating water-resistant packaging materials). Treatments may be applied during any one or more of the group including moulding, after the sheet is folded into a particular packaging product, and after the sheet is moulded into a particular packaging product. For example, a packaging product to hold beverages or beers, may be dunked into a chitosan solution for improving biodegradability, biocompatibility, and / or antimicrobial properties. According to a second aspect of the invention, there is provided an article manufactured by the method as hereinbefore described for use as packaging material.

[0039] BRIEF DESCRIPTION OF THE DRAWINGS

[0040] A method for manufacturing packaging material in accordance with the invention will now be described by way of the following, non-limiting examples with reference to the accompanying drawings.

[0041] In the drawings: -

[0042] Figure 1 is a flow diagram showing the steps of the method of manufacturing packaging material in accordance with the present invention.

[0043] DETAILED DESCRIPTION OF THE INVENTION

[0044] Referring now to Figure 1 , reference numeral 10 refers generally to a method for manufacturing packaging material. The method for manufacturing packaging material 10 includes collecting residual grain, in the form of BSG (brewers spent grain) 12, from a beer brewing process 14, breaking down fibres 16 contained in the grain, creating a pulp 18 from the broken-down fibres, preparing the pulp 20 for article formation, including adding biodegradable additives to the pulp 22, and forming an article from the pulp 24 suitable for use as packaging.

[0045] It is to be appreciated that BSG is a byproduct of the beer brewing process, typically being formed after malted grains are mashed, wherein starches in the grain are broken down by enzymes, and a liquid known as wort is formed and removed.

[0046] The method includes drying the grain 26 after being collected. It is to be appreciated that BSG is a wet substance having a high moisture content, and drying is necessary to reduce the likelihood of spoiling during transportation and / or storage. The method includes grinding or milling the grain 28 to create a finer consistency before breaking down the fibres 16. It is to be appreciated that drying and / or milling the grain 28 before breaking down the fibres 16 or pulping may serve to improve even cooking or chemical treatment of the grain.

[0047] Although not shown in the figures, the method optionally includes a thermal treatment before breaking down the fibres 16.

[0048] Breaking down the fibres 16 contained in the grain is optionally carried out via a mechanical process 30. The mechanical process 30 includes any one or more of the group including refining, grinding, beating, stamping, pressing, flattening, rolling, and blending. During blending 32, a liquid in the form of water 34 is added to the grain for facilitating blending. The amount of water 34 added is dependent on the amount of grain to be blended. In particular, the amount of water 34 added is in the range of 200ml to 300ml of water for every 400g to 600g of grain. It is to be appreciated that the amount of water 34 to be added is dependent on the strength of the blender being used, typically adding more water to the grain for a weaker blender. It is to be appreciated further that it is desirable to add as little water as possible. It is to be appreciated yet even further that such processing is done to break down the grains sufficiently to ensure a finer grained article. In addition, such processing may improve bond quality between remaining fibres during article formation. The mechanical process 30 optionally includes flattening out with a weight, preferably using a mortar and pestle.

[0049] The mechanical process 30 is optionally carried out using a mill or a high-shear mixer (not shown). The mill (not shown) is in the form of a colloidal mill (not shown). The mill (not shown) is configured to break down the grain into a homogenous solution (not shown). The mill (not shown) is configured to break down the grain into small sizes in the range of 2 to 5 microns. It is to be appreciated that the benefit of breaking down the grains to such a size is that the surface area available for bonding is increased, which is in turn believed to increase the strength of a product to which the grain has been added.

[0050] It is to be appreciated that mechanical breakdown of the grain in the presence of fluid would create a pulp, however, this particular pulp may not have the required characteristics for certain articles to be formed.

[0051] Although not shown in the figure, the method optionally includes removing undesired material (not shown) from the grain after mechanical fibre breakdown. The undesired material (not shown) is utilised as a source of energy, typically by burning. Removal of undesired material (not shown) is carried out by sieving through a mesh (not shown) with mesh sizes smaller than the undesired material (not shown), or through a flotation process in which the undesired material (not shown) floats to a surface of a flotation medium (not shown). The undesired material (not shown) is in the form of husks (not shown) of the grain. It is to be appreciated that this step is optional and the inclusion of the husks in the pulp for article formation may lead to desirable characteristics of the article to be formed, such as increased strength, for example.

[0052] Breaking down the fibres 16 is optionally carried out via a chemical process 36. The chemical process 36 includes a steam explosion (not shown) or steam hydrolysis process (not shown). For the purposes of this specification, steam hydrolysis is to be understood as a thermal-chemical pretreatment technique used to break down lignocellulosic materials into more accessible components and could be used as a pretreatment for enzymatic breakdown. Further, steam explosion is to be understood as a process which uses high-pressure, high-temperature steam to break down fibrous structure of plant materials. In the steam explosion process, when pressure is suddenly released, the rapid expansion of steam disrupts grain cell walls, exposing cellulose and hemicellulose which renders material more suitable for further processing. Although not shown in the figure, the steam explosion process (not shown) includes the following steps: loading BSG into a reactor chamber, injecting high- pressure steam into the chamber, and abruptly releasing pressure within the chamber, thereby causing steam trapped within fibres of the BSG to expand to break the fibres. The high-pressure steam is high-pressure saturated steam. It is to be appreciated that saturated steam is to be understood as steam which is at saturation temperature, which means that the steam is in thermal equilibrium with water at the same pressure wherein any change of heat will result in a phase change. The high-pressure steam raises the temperature (within the chamber) to a temperature in the range of 160°C to 260°C, which serves to loosen bonds in the grain lignocellulosic structure.

[0053] It is to be appreciated that after the steam explosion process, the material is collected with its lignocellulosic components more accessible for subsequent processes, such as, for example, enzymatic hydrolysis or incorporation into a new product, such as packaging material.

[0054] Advantages of using steam explosion for BSG:

[0055] • Breaking Down Lignin: The lignin in BSG forms a complex with cellulose and hemicellulose, making it hard to access. Steam explosion disrupts this barrier.

[0056] • Exposing Polysaccharides: This process increases the availability of cellulose and hemicellulose for chemical or enzymatic modification, which could enhance binding properties in pulp.

[0057] • Protein Liberation: BSG is protein-rich, and steam pretreatment can denature proteins, making them usable in bioplastics or other composites.

[0058] • Improving Pulping Efficiency: The treated BSG can integrate more easily with cardboard pulp, improving the bonding and strength of the final material.

[0059] • Creating Bioplastics: The liberated lignocellulosic fibres and proteins can be formulated into biodegradable materials like 6-pack rings or other bio-based packaging. The chemical process 36 includes cooking the grain (not shown) in an alkaline solution, including water, for a predetermined duration. The predetermined duration is dependent on the quality of the BSG and on the chemicals in which the BSG is cooked.

[0060] Cooking (not shown) is carried out under high pressure. It is to be appreciated that cooking the grain in an alkaline solution at high pressure may serve to reduce cooking time, reduce overall energy consumption, and improve penetration of chemicals into the grain which in turn may accelerate breaking down the fibres.

[0061] Although not shown in the figure, the chemical process 36 includes a plurality of cooking processes to achieve a particular set of characteristics. The characteristics include any one or more of the group including texture, thickness, and consistency. It is to be appreciated that the set of characteristics is dependent on user requirements.

[0062] The plurality of cooking processes includes a first cooking process (not shown). In the first cooking process (not shown), the alkaline solution has a relatively low pH level. In particular, the alkaline solution has a pH level in the range of 8 and 9. The alkaline solution includes sodium carbonate or sodium bicarbonate. In the first cooking process, the grain and alkaline solution are cooked at a temperature in the region of 100°C. A ratio of BSG to water to sodium bicarbonate is in the ranges of 250ml to 1 000ml, to 0.5 litres to 2 litres, to 5g to 50g. More particularly, the ratio of BSG to water to sodium bicarbonate is in the region of 500ml to 1 litre to 38g. A duration of the first cooking process is in the region of 60 minutes. It is to be appreciated that the duration of the first cooking process may vary, and the process is typically complete once discoloration occurs.

[0063] After the first cooking process (not shown), the grain is strained and washed to separate the grain from dissolved materials, chemicals and the alkaline solution. The grain undergoes any one or more of the group including cleaning, washing, rinsing, straining, and screening in order to remove undesired material (not shown). The undesired material (not shown) is in the form of any one or more of the group including non-fibrous material, impurities, and larger particles. It is to be appreciated that the undesired material (not shown) can be used for other purposes so as to reduce production of waste, for example, the undesired material is burnt in an energy generation process. In particular, the grain is rinsed with water in order to remove the sodium carbonate or sodium bicarbonate therefrom. It is to be appreciated that this step is typically required to eliminate stickiness thereby making the grain easier to work with. Used water is utilised as a substrate for the production of bioplastics, such as PHA (Polyhydroxyalkanoates) for example.

[0064] The plurality of cooking processes includes a second cooking process (not shown). In the second cooking process (not shown), the alkaline solution has a higher pH level than the alkaline solution used in the first cooking process (not shown). In particular, the alkaline solution for the second cooking process (not shown) has a pH level in the range of 1 1 to 13. In particular, the alkaline solution in the second cooking process (not shown) includes sodium hydroxide. In the second cooking process, the grain and alkaline solution is cooked at a temperature in the region of 90°C. A duration of the second cooking process is in the region of 150 minutes.

[0065] After the second cooking process (not shown), the grain is strained and washed to separate the grain from dissolved materials and the alkaline solution. The grain undergoes any one or more of the group including cleaning, washing, rinsing, straining, and screening in order to remove undesired material (not shown). The undesired material (not shown) is in the form of any one or more of the group including non-fibrous material, impurities, and larger particles. It is to be appreciated that the undesired material (not shown) can be used for other purposes so as to reduce production of waste, for example, the undesired material (not shown) is burnt in an energy generation process.

[0066] Breaking down the fibres 16 is optionally carried out via a biological process 38. The biological process 38 includes the use of enzymes 40. In particular, the biological process 38 includes enzymatic hydrolysis (not shown). The enzymes 40 include any of the group including cellulases, hemicellulases, and lignin-degrading enzymes. Although not shown in the figure, the grain optionally undergoes a pretreatment (not shown) before enzymatic hydrolysis (not shown) to increase efficacy thereof. The pretreatment is in the form of any one or more of the group including a mechanical, chemical, and thermal pretreatment. It is to be appreciated that enzyme-based methods are more environmentally friendly than chemical fibre breakdown.

[0067] Creating the pulp 18 forms part of the fibre breakdown step 16. It is to be appreciated that the pulp is typically created during the fibre breakdown process 16, however, this pulp may require further processing or preparation in order to form an article with a set of characteristics required for use as packaging material.

[0068] Preparing the pulp 20 includes adding water thereto in order to make final adjustments to the consistency of the pulp. It is to be appreciated that the consistency of the pulp influences the group of characteristics of the article including strength, durability, elasticity, flexibility, texture, porosity, weight, thickness, water or moisture resistance, and appearance. It is to be appreciated further that the ratio of pulp to water influences thickness of the article being formed therefrom. The amount of water added is about 2 litres for every 500g of blended grain. It is to be appreciated that excess and / or used water can be re-used in various processes, including the production of bioplastics.

[0069] Preparing the pulp 20 includes adding biodegradable additives to the pulp 22 to ensure that the article to be formed therefrom exhibits a set of characteristics which are particularly suited to the use and type of the article. The biodegradable additives include any one or more of the group including strength enhancers, hydrophobic agents, fillers, binding agents, antimicrobials, pigments, defoamers, wetting agents, flame retardants, plasticisers, and surface modifiers. The strength enhancers include any one or more of the group including starch, cellulose, lignin, gelatine, and casein. The starch includes any one or more of the group including corn starch, potato starch, and wheat starch. The cellulose is in the form of carboxymethyl cellulose. The hydrophobic agents include any one or more of the group including okra, natural waxes, polylactic acid, chitosan, and cellulose derivatives. The cellulose derivatives include hydroxypropyl cellulose. The fillers include any one or more of the group including calcium carbonate, and clay. The binding agents includes any one or more of the group including okra, guar gum, xanthan gum, pectin, and alginates. The antimicrobials include any one or more of the group including essential oils, chitosan, and plant-based extracts. The plant-based extracts include tannins. The pigments include any one or more of the group including plant-based dyes, and mineral-based pigments. The defoamers includes any one or more of the group including natural oils, and lecithin. The flame retardants include any one or more of the group including phosphorous-based compounds, such as ammonium polyphosphate, and intumescent additives. The plasticisers include any one or more of the group including okra, glycerol, sorbitol, and triacetin. The surface modifiers include any one or more of the group including natural oils, waxes, and cellulose derivatives.

[0070] Although not shown in the figures, preparing the pulp optionally includes adding pulped recycled cardboard. It is to be appreciated that cardboard provides a cost- effective and abundant source of cellulose, which contributes to the binding of grain fibres during article formation.

[0071] Although not shown in the figures, the article to be formed is in the form of any of the group including a sheet, panel, crate, and box.

[0072] The sheet (not shown) undergoes any one or more of the group of operations including cutting, scoring, creasing, folding, stamping, embossing, gluing, laminating, coating, and perforating. The operations are dependent on the type of packaging to be produced. For example, the sheet may undergo any one or more of the group including stamping, cutting, and folding to form ring-like retainers for holding and retaining a plurality of beverages together to facilitate transport and / or packing thereof. In particular, to form the sheet (not shown), the pulp is placed into a sheet forming mould (not shown). The sheet forming mould (not shown) includes a mesh and a frame surrounding the mesh. The sheet forming mould includes (not shown) a second frame, known as a deckle, which is placed on top of the first frame once the pulp is received therein. Typically, the sheet forming mould (not shown) is lowered into a container containing the pulp with the deckle placed above the first frame so that the mesh is positioned therebetween. The mould (not shown) is moved in a scooping motion in order to allow the pulp to collect on top of the mesh. The mould (not shown) is raised out of the container, allowing water in the pulp to drip through the mesh to leave the fibrous material of the grain on top of the mesh. The mould (not shown) is placed on a surface and the fibrous material caught in the mesh is allowed to dry so as to form the sheet. The surface is porous and / or foraminous. A sponge is used to facilitate the transfer and suck up additional water. Optionally, the sheet is removed from the mould and pressed in order press out excess water and speed up the drying process. The sheet is pressed using a 10 to 20 tonne or metric ton press.

[0073] Alternatively, the sheet (not shown) is formed using sheet forming machinery which receives the pulp and runs the pulp over a plurality of rollers which compresses, heats and dries the pulp to form a continuous sheet to be rolled around a spindle.

[0074] The sheet (not shown) is in the form any of the group including paper, craft paper, kraft paper, card, cardstock, board, card-board, and newsprint. It is to be appreciated that the above processes are varied as necessary to form a sheet of the desired type. Preferably, the sheet (not shown) is in the form of kraft paper, card or carboard for allowing the sheet to be used as packaging material for consumables.

[0075] Alternatively, and although not shown in the figure, the article is optionally formed using compression moulding. In particular, the article is formed by being compressed and moulded into a desired shape. The compression moulding includes simultaneous heating and drying. Alternatively, drying is carried out by placing the desired shape into an oven or in sunlight. It is to be appreciated that compressed pulp should have a low moisture content as compression and heat will create steam and if the moisture content is too high the power of the steam can break open the compression machine, or the pulp will not dry sufficiently. Further, the spent grain can be placed into the mould and pressed and heated into the desired shape without first pulping the spent grain. The article formed by compression moulding is a panel, crate, or box. The crate is in the form of a bottle crate, such as a beer bottle crate.

[0076] Further alternatively, the article is optionally formed using injection moulding. The article formed by injection moulding is in the form of a panel, crate, or box.

[0077] Treatments are provided for enhancing the article’s properties according to the specific use thereof. T reatments includes any one or more of the group including sizing (for reducing ink spread and improving strength and water resistance), coating (for increased brightness, smoothness, and print quality), impregnating with chemicals (for attributes like fire resistance, insect repellence, or UV protection), dyeing (for colour and aesthetic purposes or categorization), antimicrobial treatment (for preventing microbial growth in medical or food packaging applications), acid-neutralization (for making the paper acid-free and suitable for long-term archival use), and moistureproofing (for creating water-resistant packaging materials). Treatments are applied during any one or more of the group including moulding, after the sheet is folded into a particular packaging product, and after the sheet is moulded into a particular packaging product. For example, a packaging product to hold beverages or beers, is dunked into a chitosan solution for improving biodegradability, biocompatibility, and / or antimicrobial properties.

[0078] It is, of course, to be appreciated that the method for manufacturing packaging material in accordance with the invention is not limited to the precise constructional and functional details as hereinbefore described with reference to the accompanying drawings and which may be varied as desired. Although only certain embodiments of the invention have been described herein, it will be understood by any person skilled in the art that other modifications, variations, and possibilities of the invention are possible. Such modifications, variations and possibilities are therefore to be considered as falling within the spirit and scope of the invention and hence form part of the invention as herein described and / or exemplified. It is further to be understood that the examples are provided for illustrating the invention further and to assist a person skilled in the art with understanding the invention and is not meant to be construed as unduly limiting the reasonable scope of the invention.

[0079] The inventor believes that packaging material in the form of Brewer's Spent Grain (BSG) is advantageous in that its high fibre content contributes to structural strength and durability, its organic and biodegradable nature aligns with sustainable and eco-friendly practices, the abundant supply from the brewing industry ensures steady availability, its application in packaging reflects circular economy principles by reusing waste products, and its lower environmental footprint compared to single-use plastics, along with its status as a renewable resource, presents significant opportunities for innovative and sustainable developments in packaging technologies. The inventor believes that the method according to the invention is advantageous in its simplicity and ease of integration with existing infrastructure relating to manufacturing of fibrous packaging.

Claims

CLAIMS1. A method for manufacturing packaging material including: - collecting residual grain from a brewing process; breaking down fibres contained in the grain; creating a pulp from the broken-down fibres; preparing the pulp for article formation, including adding biodegradable additives to the pulp; and forming an article from the pulp suitable for use as packaging.

2. A method as claimed in claim 1 wherein the residual grain is collected from a beer brewing process.

3. A method as claimed in claim 2 wherein the residual grain is in the form of BSG (brewers spent grain).

4. A method as claimed in any one or more of the preceding claims which includes drying the grain after being collected.

5. A method as claimed in any one or more of the preceding claims which includes grinding or milling the grain to create a finer consistency before breaking down the fibres.

6. A method as claimed in any one or more of the preceding claims which includes a thermal treatment before breaking down the fibres.

7. A method as claimed in any one or more of the preceding claims wherein breaking down the fibres contained in the grain is carried out via a mechanical process.

8. A method as claimed in claim 7 wherein the mechanical process includes any one or more of the group including refining, grinding, beating, stamping, pressing, flattening, rolling, and blending.

9. A method as claimed in claim 8 wherein, during blending, a liquid is added to the grain for facilitating blending, the liquid being in the form of water.

10. A method as claimed in claim 9 wherein the amount of water added is dependent on the amount of grain to be blended,1 1. A method as claimed in claim 9 or 10 wherein the amount of water added is in the range of 200ml to 300ml of water for every 400g to 600g of grain.

12. A method as claimed in claim 7 wherein the mechanical process is carried out using a mill or a high-shear mixer.

13. A method as claimed in any one or more of the claims 7 to 12 which includes removing undesired material from the grain after mechanical fibre breakdown.

14. A method as claimed in any one or more of the preceding claims wherein breaking down the fibres is carried out via a chemical process.

15. A method as claimed in claim 14 wherein the chemical process includes a steam explosion or steam hydrolysis process.

16. A method as claimed in claim 15 wherein the steam explosion process includes the following steps: loading BSG into a reactor chamber, injecting high-pressure steaminto the chamber, and abruptly releasing pressure within the chamber, thereby causing steam trapped within fibres of the BSG to expand to break the fibres.

17. A method as claimed in claim 16 wherein the high-pressure steam is high- pressure saturated steam.

18. A method as claimed in claim 14 wherein the chemical process includes cooking the grain in an alkaline solution for a predetermined duration.

19. A method as claimed in claim 18 wherein cooking is carried out under high pressure.

20. A method as claimed in any one or more of the claims 14 to 19 wherein the chemical process includes a plurality of cooking processes.

21. A method as claimed in claim 20 wherein the plurality of cooking processes includes a first cooking process.

22. A method as claimed in claim 21 wherein, in the first cooking process, the alkaline solution has a relatively low pH level.

23. A method as claimed in claim 22 wherein the alkaline solution has a pH level in the range of 8 and 9.

24. A method as claimed in claim 22 or 23 wherein the alkaline solution includes sodium carbonate or sodium bicarbonate.

25. A method as claimed in any one or more of the claims 21 to 24 wherein, in the first cooking process, the grain and alkaline solution is cooked at a temperature in the range of 75°C to 110°C.

26. A method as claimed in any one or more of the claims 21 to 25 wherein a ratio of BSG to water to sodium bicarbonate is in the ranges of 250ml to 1 000ml, to 0.5 litres to 2 litres, to 5g to 50g.

27. A method as claimed in any one or more of the claims 21 to 26 wherein, after the first cooking process, the grain is strained and washed to separate the grain from dissolved materials, chemicals and the alkaline solution.

28. A method as claimed in any one or more of the claims 20 to 27 wherein the plurality of cooking processes includes a second cooking process.

29. A method as claimed in claim 28 wherein, in the second cooking process, the alkaline solution has a higher pH level than the alkaline solution used in the first cooking process.

30. A method as claimed in claim 29 wherein the alkaline solution for the second cooking process has a pH level in the range of 11 to 13.

31. A method as claimed in claim 29 or 30 wherein the alkaline solution in the second cooking process includes sodium hydroxide.

32. A method as claimed in any one or more of the claims 28 to 31 wherein, in the second cooking process, the grain and alkaline solution is cooked at a temperature in the range of 75°C and 115°C.

33. A method as claimed in any one or more of the claims 28 to 32 wherein, after the second cooking process, the grain is strained and washed to separate the grain from dissolved materials and the alkaline solution.

34. A method as claimed in any one or more of the preceding claims wherein breaking down the fibres is carried out via a biological process.

35. A method as claimed in claim 34 wherein the biological process includes the use of enzymes.

36. A method as claimed in claim 35 wherein the biological process includes enzymatic hydrolysis.

37. A method as claimed in claim 35 or 36 wherein the enzymes include any of the group including cellulases, hemicellulases, and lignin-degrading enzymes.

38. A method as claimed in any one or more of the claims 35 to 37 wherein the grain undergoes a pretreatment before enzymatic hydrolysis to increase efficacy thereof.

39. A method as claimed in claim 38 wherein the pretreatment is in the form of any one or more of the group including a mechanical, chemical, and thermal pretreatment.

40. A method as claimed in any one or more of the preceding claims wherein preparing the pulp includes adding water thereto.41 . A method as claimed in claim 40 wherein the amount of water added is in the range of 1 .5 litres to 2.5 litres for every 500g of blended grain.

42. A method as claimed in any one or more of the preceding claims wherein preparing the pulp includes adding additives to the pulp.

43. A method as claimed in claim 42 wherein the additives are in the form of biodegradable additives.

44. A method as claimed in claim 43 wherein the biodegradable additives include any one or more of the group including strength enhancers, hydrophobic agents, fillers, binding agents, antimicrobials, pigments, defoamers, wetting agents, flame retardants, plasticisers, and surface modifiers.

45. A method as claimed in any one or more of the preceding claims wherein preparing the pulp includes adding pulped recycled cardboard.

46. A method as claimed in any one or more of the preceding claims wherein the article to be formed is in the form of any of the group including a sheet, panel, crate, and box.

47. A method as claimed in claim 46 wherein the sheet is in the form any of the group including paper, craft paper, kraft paper, card, cardstock, board, card-board, and newsprint.

48. A method as claimed in any one or more of the preceding claims wherein the article is formed using compression moulding.

49. A method as claimed in claim 48 wherein the article formed by compression moulding is a panel, crate or box.T150. A method as claimed in any one or more of the preceding claims wherein treatments are provided for enhancing the article’s properties according to the specific use thereof.

51. A method as claimed in claim 50 wherein the treatments include any one or more of the group including sizing (for reducing ink spread and improving strength and water resistance), coating (for increased brightness, smoothness, and print quality), impregnating with chemicals (for attributes like fire resistance, insect repellence, or UV protection), dyeing (for colour and aesthetic purposes or categorization), antimicrobial treatment (for preventing microbial growth in medical or food packaging applications), acid-neutralization (for making the paper acid-free and suitable for long-term archival use), and moisture-proofing (for creating water-resistant packaging materials).

52. A method as claimed in claim 50 or 51 wherein the treatments are applied during any one or more of the group including moulding, after the sheet is folded into a particular packaging product, and after the sheet is moulded into a particular packaging product.

53. An article manufactured by the method as claimed in any one or more of the preceding claims for use as packaging material.