Description:DESCRIPTION:
Field of the invention:
[0001] The present disclosure generally relates to the technical field of an eco-friendly biodegradable crockery manufacturing process, and in specific, relates to a method for preparing eco-friendly disposable crockery by utilizing an agricultural stubble as the primary raw material, thereby providing an alternative to plastic-based disposable utensils while addressing environmental concerns associated with stubble burning.
Background of the invention:
[0002] Plastic pollution has emerged as one of the most pressing environmental challenges of our time. The widespread use of plastic-based utilities, including disposable plates, cups, and cutlery, has significantly contributed to global waste accumulation. Due to their non-biodegradable nature, plastic products persist in landfills and oceans for hundreds of years, leading to severe ecological consequences. Marine life is particularly affected, as animals mistakenly consume microplastics, disrupting ecosystems. Furthermore, plastic waste releases harmful toxins into the soil and groundwater, posing health risks to humans and animals. Governments and organizations worldwide are implementing regulations and promoting sustainable alternatives to mitigate the environmental damage caused by plastic-based utilities.

[0003] Globally, agricultural activities generate an enormous amount of crop residue, including stalks, husks, and stems. According to studies, over 5 billion metric tons of crop residue are produced annually, with major contributions from countries like India, China, the United States, and Brazil. While some of this biomass is repurposed for animal feed and organic composting, a significant portion is burned as waste, leading to hazardous air pollution and severe health issues. Crop residue burning, especially in high-yield agricultural regions, contributes to increased carbon emissions and deteriorating air quality. Thus, repurposing agricultural waste, particularly stalks and husks, into biodegradable products presents an innovative solution that addresses both pollution control and sustainable development.

[0004] Traditional methods of producing biodegradable utility items have been practiced in various cultures for centuries. In many tropical regions, palm and coconut leaves have been used to create disposable plates and bowls, which decompose naturally without harming the environment. Similarly, straws made from bamboo and wheat stalks were common before the advent of synthetic materials. However, despite their sustainability, these traditional products are often limited by production scalability and durability. Coconut leaf plates, for example, require manual processing and are not as widely available as mass-produced plastic alternatives. Likewise, natural straws, though eco-friendly, face challenges related to durability and liquid absorption. These limitations have prevented traditional biodegradable utilities from becoming a viable large-scale replacement for plastic-based products.

[0005] Existing biodegradable crockery technologies have made significant progress in the real-world market. Companies are now utilizing bagasse (sugarcane pulp), cornstarch, and biodegradable plastics (PLA, PHA) to manufacture disposable tableware. These materials offer better sustainability than conventional plastics, yet they still pose challenges such as high production costs, dependence on industrial composting facilities, and variations in biodegradation rates. Some biodegradable plastics, for instance, require specific conditions to break down efficiently, making them less practical for widespread use. Moreover, the energy-intensive production of certain eco-friendly materials reduces their overall sustainability benefits. As the demand for sustainable crockery grows, it is imperative to develop solutions that overcome these challenges while maintaining affordability and accessibility.

[0006] Therefore, there is a need for a method that cost-effective, scalable, and environmentally sustainable alternative to plastic-based utilities while simultaneously addressing the issue of crop residue waste. There is also a need for a method that reduces plastic pollution but also supports farmers by offering an economic incentive for agricultural waste utilization. There is also a need for a method that produces biodegradable structures and decompose naturally within months, eliminating the need for specialized composting facilities Furthermore, there is also a need for a method that utilizes natural processing techniques, avoiding harmful synthetic chemicals or coatings.
Objectives of the invention:
[0007] The primary objective of the present invention is to provide a method for preparing eco-friendly disposable crockery by utilizing an agricultural stubble as the primary raw material, thereby providing an alternative to plastic-based disposable utensils while addressing environmental concerns associated with stubble burning.

[0008] Another objective of the present invention is to provide a method that utilizes agricultural stubble, which is often burned as waste, thereby addressing air pollution and reducing carbon emissions.

[0009] Another objective of the present invention is to provide a method that effectively repurposes agricultural waste, thereby minimizing its environmental footprint and providing an innovative use for crop residues.

[0010] Another objective of the present invention is to provide a method that offers economic incentives to farmers by purchasing stubble, providing them with an additional source of income.

[0011] Another objective of the present invention is to provide a method that encourages sustainable farming practices and strengthens the rural economy.

[0012] Another objective of the present invention is to provide a method that requires minimal chemical additives, reducing production costs compared to biodegradable plastics.

[0013] Another objective of the present invention is to provide a method that is adapted to produce a variety of crockery items, such as plates, spoons, cups, and cartons, catering to different market needs.

[0014] Another objective of the present invention is to provide a method that utilizes natural processing techniques, avoiding harmful synthetic chemicals or coatings.

[0015] Yet another objective of the present invention is to provide a method that supports government initiatives promoting sustainable and eco-friendly products.

[0016] Further objective of the present invention is to provide a method that aligns with global bans on single-use plastics, making it suitable for internation markets.
Summary of the invention:
[0017] The present disclosure proposes biodegradable modular structures and crockery items and method of preparing the same. The following presents a simplified summary in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview. It is not intended to identify key/critical elements or to delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

[0018] In order to overcome the above deficiencies of the prior art, the present disclosure is to solve the technical problem to provide a method for preparing eco-friendly disposable crockery by utilizing an agricultural stubble as the primary raw material, thereby providing an alternative to plastic-based disposable utensils while addressing environmental concerns associated with stubble burning.

[0019] According to one aspect, the invention provides a method for preparing biodegradable modular structures and crockery items. At one step, agricultural stubbles are collected and harvested from fields growing crops such as wheat, rice, and maize, which serves as a primary raw material. At another step, the collected stubbles are washed through industrial-grade washers, bleached with a natural bleaching agent, and transferred into an autoclave reactor for sterilization. In one embodiment, the washing process incorporates a plant-based antimicrobial solution to ensure food-grade safety and enhance biodegradability. In one embodiment, the autoclave reactor applies controlled heat and pressure to eliminate impurities, strengthening and increasing the durability of the final product.

[0020] At another step, the sterilized stubbles are processed into a refined taste using a beater machine to achieve a uniform consistency suitable for forming crockery and modular structures. At another step, the refined paste is passed through specialized rollers to form smooth and uniform biodegradable sheets with controlled thickness.

[0021] At another step, the employ precision molding and shaping machines to shape the biodegradable sheets into various crockery items, including plates, spoons, cup plates, and cartons. In one embodiment, the shaping process utilizes customizable molding dies to manufacture crockery items and modular structures of varying sizes and designs, catering to different applications and consumer preferences. Further, at another step, the various crockery items are subjected to controlled drying, trimming, and surface treatment to enhance durability, structural integrity, and moisture resistance.

[0022] In one embodiment, the various crockery items are configured for quality-checking, eco-friendly packaging, and preparing for commercial distribution to ensure compliance with food safety and environmental regulations. In one embodiment, the formed crockery items and modular structures are undergoing an eco-friendly surface coating derived from natural sources to improve water and oil resistance.

[0023] In one embodiment, the biodegradable crockery and modular structures decompose naturally within a predetermined period, eliminating the need for industrial composting facilities. In one embodiment, the manufacturing process is energy-efficient and waste-free, ensuring minimal environmental impact and promoting sustainable production.

[0024] Further, objects and advantages of the present invention will be apparent from a study of the following portion of the specification, the claims, and the attached drawings.
Detailed description of drawings:
[0025] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention, and, together with the description, explain the principles of the invention.

[0026] FIG. 1 illustrates a flowchart of a method for preparing biodegradable modular structures and crockery items, in accordance to an exemplary embodiment of the invention.
Detailed invention disclosure:
[0027] Various embodiments of the present invention will be described in reference to the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps.

[0028] The present disclosure has been made with a view towards solving the problem with the prior art described above, and it is an object of the present invention to provide a method for preparing eco-friendly disposable crockery by utilizing an agricultural stubble as the primary raw material, thereby providing an alternative to plastic-based disposable utensils while addressing environmental concerns associated with stubble burning.

[0029] According to one exemplary embodiment of the invention, FIG. 1 refers to a flowchart 100 of a method for preparing biodegradable modular structures and crockery items. The method utilizes agricultural stubble, which is often burned as waste, thereby addressing air pollution and reducing carbon emissions. The method effectively repurposes agricultural waste, thereby minimizing its environmental footprint and providing an innovative use for crop residues. The method offers economic incentives to farmers by purchasing stubble, providing them with an additional source of income. The method requires minimal chemical additives, reducing production costs compared to biodegradable plastics.

[0030] At step 102, the method begins with the collection and harvesting of agricultural stubble from fields where crops such as wheat, rice, and maize are cultivated. These stubbles, which are often discarded as agricultural waste or burned, are repurposed to serve as the fundamental raw material for biodegradable product manufacturing. The stubble is gathered, sorted, and transported to processing units, ensuring that only suitable fiber-rich material is selected for further treatment.

[0031] At step 104, the collected agricultural stubble undergoes thorough washing process using industrial-grade washers to eliminate dirt, dust, and unwanted residues. This step ensures that the raw material is free from contaminants that could affect the quality of the final product. The washed stubble is then subjected to bleaching using a natural bleaching agent, which enhances its visual and structural properties without introducing harmful chemicals. The cleaned and bleached stubble is transferred into an autoclave reactor, where it undergoes sterilization under controlled heat and pressure conditions. The sterilization process is critical as it ensures the elimination of microbial contaminants, enhances the mechanical strength of fibers, and prepares the material for further refining.

[0032] At step 106, the sterilized stubbles are processed into a refined paste using a beater machine, which effectively breaks down the fibers while ensuring uniform consistency and homogeneity. This step is essential for achieving a smooth, workable pulp that might be molded into crockery and modular structures without the need for excessive chemical additives. The beater machine refines the material to a precise fiber texture, ensuring that the final product has optimal thickness, strength, and flexibility. This step replaces traditional polymer blending and chemical processing, making the method highly sustainable and energy-efficient.

[0033] At step 108, the refined paste is passed through specialized rollers adapted to create smooth and uniform biodegradable sheets with controlled thickness. These rollers apply consistent pressure and shaping control, ensuring that the sheets have minimal defects and optimal mechanical properties for further processing. The rolling stage eliminates the need for synthetic binders by leveraging natural fiber bonding properties, which enhances the structural integrity and durability of the final product. By carefully controlling sheet thickness, the process enables the production of lightweight yet sturdy biodegradable items suitable for diverse applications.

[0034] At step 110, the prepared biodegradable sheets are then shaped into various crockery items and modular structures using precision molding and shaping machines. These machines employ customizable dies and pressure molding techniques to form products such as plates, spoons, cup plates, and cartons with high precision and efficiency. The shaping process is designed to accommodate various sizes, thicknesses, and structural requirements, making it possible to create a versatile range of products suitable for both domestic and commercial use.

[0035] At step 112, the biodegradable crockery items are subjected to a controlled drying process, which ensures that excess moisture is removed without compromising structural integrity. This step is crucial in preventing warping, cracking, or microbial growth in the final product. The drying process is conducted under regulated temperature and humidity conditions, ensuring a consistent finish across all items. Additionally, the products undergo trimming, where excess edges or irregularities are removed to achieve a polished, aesthetically pleasing appearance.

[0036] In another embodiment herein, the method is configured to enhance durability, water resistance, and usability, the crockery items are treated with an eco-friendly surface coating derived from natural sources such as plant-based waxes, starch derivatives, and biodegradable polymers. This surface treatment ensures that the products might withstand moisture and oils without degrading prematurely, thereby increasing their functional lifespan. Unlike plastic-coated disposable crockery, which generates microplastic waste, this treatment remains 100% biodegradable and compostable, aligning with environmental sustainability goals.

[0037] The biodegradable crockery items and modular structures are undergoing quality checks, packaging, and distribution using eco-friendly materials to maintain the sustainability of the process. This comprehensive method provides a scalable and commercially viable solution for producing biodegradable crockery and modular structures while ensuring zero waste, low energy consumption, and minimal environmental impact. The invention serves as a sustainable alternative to plastic disposables, directly addressing issues related to plastic pollution, stubble burning, and excessive agricultural waste.

[0038] In one embodiment herein, the primary raw material is used as the agricultural stubble, which includes wheat, rice, and maize stalks that remain after crop harvesting. Traditionally, this stubble is either burned, contributing to severe air pollution and greenhouse gas emissions, or left unused, creating agricultural waste management issues. By utilizing this abundant and renewable biomass, the invention not only prevents environmental degradation but also supports local farmers by creating an economic incentive for collecting stubble instead of burning it. The collected stubble undergoes a preliminary cutting process, where it is broken down into manageable pieces before being transported to the processing facility. This step ensures that the stubble is in a form that can be easily cleaned and processed in subsequent stages, making it suitable for commercial-scale manufacturing.

[0039] In another embodiment herein, the biodegradable crockery items, including plates, spoons, cups, small plates, and cartons, which are manufactured using agricultural stubble as the primary raw material. The biodegradable crockery and modular structures embody a sustainable and eco-friendly alternative to conventional plastic-based disposable utensils, effectively addressing the environmental concerns of plastic pollution and agricultural waste management. The visible texture and composition of the items indicate that they are derived from natural plant fibers, providing a sturdy yet compostable solution for daily use in food packaging and service industries. The use of biodegradable materials ensures that these products decompose naturally within a short duration, thereby eliminating long-term environmental hazards posed by plastic waste.

[0040] Among the biodegradable cups, priced at Rs 0.75 per piece, are a significant highlight. These cups are designed to replace plastic and Styrofoam cups, which are known for their detrimental environmental impact due to their non-biodegradable nature. The biodegradable cups in the image appear to have a rigid and durable structure, making them suitable for serving both hot and cold beverages without the risk of leakage or deformation. Unlike plastic cups, which contribute to microplastic pollution and landfill overflow, these biodegradable cups naturally break down into organic matter, reducing waste accumulation and promoting a circular economy in sustainable packaging.

[0041] Among the biodegradable plates priced at Rs 2 per piece, the biodegradable plates are priced at Rs 0.5 per piece, the biodegradable small plates are priced at Rs 1 per piece, and the biodegradable cartons are priced at Rs 150 per piece, which are significant highlights compared to plastic materials. The biodegradable products are recycled and provide better profit margins than cardboard cartons.

[0042] Numerous advantages of the present disclosure may be apparent from the discussion above. In accordance with the present disclosure, the method is disclosed. The proposed method utilizes agricultural stubble, which is often burned as waste, thereby addressing air pollution and reducing carbon emissions. The proposed method effectively repurposes agricultural waste, thereby minimizing its environmental footprint and providing an innovative use for crop residues. The proposed method offers economic incentives to farmers by purchasing stubble, providing them with an additional source of income.

[0043] The proposed method encourages sustainable farming practices and strengthens the rural economy. The proposed method requires minimal chemical additives, reducing production costs compared to biodegradable plastics. The proposed method is adapted to produce a variety of crockery items, such as plates, spoons, cups, and cartons, catering to different market needs. The proposed method utilizes natural processing techniques, avoiding harmful synthetic chemicals or coatings. The proposed method supports government initiatives promoting sustainable and eco-friendly products. The proposed method aligns with global bans on single-use plastics, making it suitable for internation markets.

[0044] It will readily be apparent that numerous modifications and alterations can be made to the processes described in the foregoing examples without departing from the principles underlying the invention, and all such modifications and alterations are intended to be embraced by this application.
, Claims:CLAIMS:
I/We Claim:
1. A method for preparing biodegradable modular structures and crockery items, comprising:
collecting and harvesting agricultural stubble from fields growing crops such as wheat, rice, and maize, which serves as a primary raw material;
washing the collecting stubbles through industrial-grade washers, bleaching it with a natural bleaching agent, and transferring cleaned stubbles into an autoclave reactor for sterilization;
processing the sterilized stubbles into a refined taste using a beater machine achieve a uniform consistency suitable for forming crockery and modular structures;
passing the refined paste through specialized rollers to form smooth and uniform biodegradable sheets with controlled thickness;
employing precision molding and shaping machines to shape the biodegradable sheets into various crockery items, including plates, spoons, cup plates, and cartons; and
subjecting the various crockery items to controlled drying, trimming, and surface treatment to enhance durability, structural integrity, and moisture resistance.
2. The method as claimed in claim 1, wherein the various crockery items are configured for quality-checking, eco-friendly packaging, and preparing for commercial distribution to ensure compliance with food safety and environmental regulations.
3. The method as claimed in claim 1, wherein the washing process incorporates a plant-based antimicrobial solution to ensure food-grade safety and enhance biodegradability.
4. The method as claimed in claim 1, wherein the autoclave reactor applies controlled heat and pressure to eliminate impurities, strengthening and increasing the durability of the final product.
5. The method as claimed in claim 1, wherein the formed crockery items and modular structures are undergoing an eco-friendly surface coating derived from natural sources to improve water and oil resistance.
6. The method as claimed in claim 1, wherein the biodegradable crockery and modular structures decompose naturally within a predetermined period, eliminating the need for industrial composting facilities.
7. The method as claimed in claim 1, wherein the shaping process utilizes customizable molding dies to manufacture crockery items and modular structures of varying sizes and designs, catering to different applications and consumer preferences.
8. The method as claimed in claim 1, wherein the manufacturing process is energy-efficient and waste-free, ensuring minimal environmental impact and promoting sustainable production.