DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION: A MOLDED FIBER PRODUCT PRODUCTION PROCESS AND SYSTEM MADE FOR SAID PROCESS THEREOF.
2. Applicants Detail:
Applicant
Sr. No. Name Nationality Address
1 PRATISHTHAN INDUSTRIES PRIVATE
LIMITED INDIA GOLDEN DREAMS, E-27, 4TH FLOOR CHIKALTHANA, MIDC, AURANGABAD, MAHARASHTRA 431006 INDIA
Inventor
Sr. No. Name Nationality Address
1. SHEKHAR CHAMPALAL DESARDA INDIA GOLDEN DREAMS, E-27, 4TH FLOOR CHIKALTHANA, MIDC, AURANGABAD, MAHARASHTRA 431006 INDIA
2. MADHURE CHANDRASHEKHAR DESARDA INDIA GOLDEN DREAMS, E-27, 4TH FLOOR CHIKALTHANA, MIDC, AURANGABAD, MAHARASHTRA 431006 INDIA
3. SAMEER SHANTILAL DHADIWAL INDIA GOLDEN DREAMS, E-27, 4TH FLOOR CHIKALTHANA, MIDC, AURANGABAD, MAHARASHTRA 431006 INDIA

3. Preamble to the description: The following specification particularly describes the invention and the manner in which it is to be performed.
FIELD
The present disclosure relates to the field of molded fiber and more particularly, the present invention relates to the molded fiber products production process and system made of said molded fiber product production process.
BACKGROUND
In existing molded fiber production process includes either one forming press and one hot press occupied with manual transfer of mold from the forming press to the hot press, or in the case of inline production type molded fiber production systems, wherein a single forming press configured with two hot presses on both sides of said forming press in the inline series manner. Further, in order to commence with said molded fiber production in said in-line series production system, a mold with the replica of the design along with the size and shape of a molded fiber product required to manufacture from said inline molded fiber production system configure with said forming module. Wherein the formation of a partially formed molded fiber product takes place in said forming press configured at a central part of said inline production system. Further said partially formed product required to be transferred to said hot press for further solidification and soaking manually followed by the trimming and another operation processed manually to form a complete finished product. In said inline production system said mold with said molded fiber product transfer processed manually from said forming press to said hot press and completely depends on the manual capacity of human being or operator as well as consumes more time for transfer of said mold from said forming press to said hot press to increase cycle time and production cost for said molded fiber production process.
However, in said conventional molded fiber production system said slurry required to form said molded fiber product fed directly to said forming press instead of any pre-processing that not only restricts a recycled material to use as an input for said molded fiber production system leads to increase in the raw material cost, but also increases the possibility of impurity and contamination in said slurry fed to said forming press to produce the defective product with a possible impurity which includes but not limits to said solid part or products, iron parts or products, pins and paper clips, plastic parts or particles, soil, etc. from said recycle material or mixed with said raw material while processing or transportation that can be dangerous if mixed the harmful ingredients or chemicals with said slurry in order to articulate said solution not fit for handling food grade material or food. Further, in case of said recycled raw material used or fed to forming press then there are the more possibility exists that said recycled material comprises the iron or solid particles to produce said molded fiber product from said iron or solid particles mixed in a slurry, wherein said iron or solid particle can also be blend in slurry and forms the defective molded fiber product having void or pores of said iron or solid particle of the type which include but not limits to surface defect, through hole, said solid or iron particle immersed within said molded fiber wall, etc. that can from the various flaws which include but not limits to form the leakage from said molded fiber product, produces product hazardous to human health and not suitable to handle food grade products, increases the amount of defective product to rework, can damage the component of said molded fiber production line and said mold die, and can lead into sever maintenance requirements to increase maintenance and product cost and forms very high possibilities of a catastrophic failure of not only said molded fiber production equipment’s but also the complete production line of said molded fiber products.
Hence, there is a technical gap that exists and needs to be alleviated by means of an effective, and efficient molded fiber product production process and system made of said molded fiber production process.
SUMMARY
The present invention envisages a molded fiber product production process and system made for said process thereof; wherein a molded fiber product production process comprising, a preparation of raw slurry configured with said molded fiber product production process and an addition of ingredients configured with said preparation of raw slurry. Further, at least three filtrations of said slurry can be performed prior to input for a forming module configured with a hot press. Wherein said molded fiber product production process commences with an input to forming from said forming module to produce an output from forming to supply an input to the first hot press. Next, an input to the forming can be provided to said forming module in order to form an output from the forming to provide the next input to the second hot press configured with said output from the forming. Whereas an input to forming is configured with said forming module and said input to the second hot press and output from forming to an input to the first hot press. Meanwhile, an output from the first hot press produced, and furthermore input to forming is supplied to produce the next output from forming to provide an input to the second hot press, and an output from the second hot press is produced to complete the cycle of forming and hot pressing. However, a trimming module configured with said output from the first hot press and said output from the first hot press and a stamping and a barcode configuration and holography configured with said trimming module to perform the product identification process. Moreover, a lamination process configured with said stamping and barcode configuration and holography and a stacking module configured with said lamination and/or said trimming module to finalize said molded fiber product for packaging and dispatch.
In another embodiment a molded fiber products production system comprising; a L-shaped layout or a U-shaped layout configured with a forming module. Further, a pair of the hot presses configured in said L-shaped layout or said U-shaped layout, and said forming module. However, a servo-controlled robotic arm configured with said pair of press and said forming module to transfer a molded fiber product smoothly from said forming module to said pair of press, a trimming station, and a stacking station.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
1. An object of the present disclosure is to input the slurry filtered for a plurality of filtration checks,
2. In another object of the present disclosure is to process the plurality of slurry types with enhanced pre-processing,
3. Another object of the present disclosure is to facilitate a compact production process for
said molded fiber products,
4. Yet another object of the present disclosure is to provide a more uniform production process.
5. Still another object of the present disclosure is to reduce cycle time with respect to the output
of said molded fiber products.
6. Still another object of the present disclosure is to better forming and soaking of molded fiber
products to induce strength and leakproof features.
7. The further object of the present disclosure is to enhance the overall quality of molded fiber products.
8. Furthermore object of the present disclosure is to the configuration of magnetic filtration for the removal of iron parts in order to make said molded fiber product compatible with said food-grade products,
9. Another object of the present invention is to increase efficiency by means of the implication of the robotic arm.
10. Yet another object of the present invention is the reduce the energy consumption and cost of said production process of said molded fiber product.
11. Moreover, the object of the present invention is to enhance safety and facilitate said molded fiber compatibility as a shelf product.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A molded fiber products production process and system made for said molded fiber products production thereof of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a molded fiber products production process;
Figure 2 illustrates a forming module;
Figure 2 illustrates a forming mold;
Figure 2 illustrates a partially formed molded fiber product;
Figure 3 illustrates a heating machine;
Figure 3a illustrates a completely formed molded fiber product;
Figure 3b illustrates a finaled molded fiber product;
Figure 4 illustrates an L shape Layout;
Figure 5 illustrates a U shape Layout;
Figure 6 illustrates a L shape centralized controlled layout;
Figure 7 illustrates a U shape centralized controlled layout;
Figure 8 illustrates a stacking of said molded fiber product;
Figure 9 illustrates a product identification means for said molded fiber product;
Figure 10 illustrates a bar code as said product identification means;
Figure 11 illustrates a holographic configuration as said product identification means.
LIST OF REFERENCE NUMERALS:
Numeral Reference
100 Molded fiber product production process
101 Preparation of raw slurry
102 Addition of ingredients
103 First filtration
104 Second filtration
105 Third filtration
106 Input to forming
107 Output from forming
108 Input to first hot press
109 Input to forming
110 Output from forming
111 Input to second hot press
112 Input to forming
113 Output from forming
114 Input to first hot press
115 Output from the first hot press
116 Input to forming
117 Output from forming
118 Input to second hot press
119 Output from the second hot press
120 Trimming module
121 Stamping and barcode configuration
122 Configuration of holography
123 Lamination
124 Stacking module
125 Packaging and barcode configuration
126 Dispatch
127 Forming Module
127a Mold
127b Slurry sink
127c Mold activation system
128 Hot press
129 Hot press
200 Molded fiber product production system
201 L-shaped layout
202 Forming module
203 Hot press
204 Hot press
205 Robotic arm
300 Molded fiber product production system
301 U-shaped layout
302 Forming module
303 Hot press
304 Hot press
305 Robotic arm
400 Molded fiber product production system
401 U-shaped layout
402 Forming module
403 Hot press
404 Hot press
405 Robotic arm
406 Central server
500 Molded fiber product production system
501 L-shaped layout
502 Forming module
503 Hot press
504 Hot press
505 Robotic arm
506 Central server
600 Molded fiber product production system
601 Molded fiber product
601a First partially formed product
601a’ First completely formed product
601aa Final molded fiber product
601b Second partially formed molded fiber product
601b’ Second completely formed product
601ba Final molded fiber product
601c Third partially formed molded fiber product
601c’ Third completely formed product
601ca Final molded fiber product
602 Trimming station
603 Stacking station
604 Spiral product stacking means
605 Vertical rib
606 Horizontal rib
607 Counter
608 Accept chute
609 Stand
610 Base
611 Disc
612 Surface
613 One sided bar code
614 Two-sided bar code
615 Holography
616 Master product

DETAILED DESCRIPTION
The present invention illustrates a molded fiber product production process (100) as shown in Figure No. 01 to 03; wherein said molded fiber product production process (100) commences functioning by means of a raw material (101) preparation by means of a plurality of material forms which include but not limited to existing pulp sheet, wood, recycled waste of paper and pulp, rejects from plant, etc. that can be further process for the articulation of semi-liquid type of solution or slurry by adding the water in accordance with the application requirement and considering said molded fiber process and product capabilities. In one of the preferred embodiments said consistency required to be maintained during the formulation of said slurry can be maintained in the range of 0.25 to 0.35% by weight of solution. Wherein said semi-liquid type of slurry further can be processed for the addition of ingredient (102) required in accordance with the application of a molded fiber product batch (610) or based on raw material (101) exists and/or by considering any other specific or implied conditions, which includes but not limits to the binder, deinking means, detoxifier, etc. Next to the compilation of all said ingredients (102) and water said semisolid liquid can be processed with a first filtration means (103) which can be performed for cleaning said semi-solid solution for removing the solid parts which include but not limits to the soil, small stone, or other particles etc., After said first filtration means (103), a second filtration means (104) commence with the action by means of cleaning of said semi-solid solution for removing the magnetic impurity which include but not limits to the iron parts which include but not limits to pins, paper clips, nails, etc., iron particles or residue, other magnetic parts or particles, etc. and in the final stage of said filtration called as a third filtration (105) remaining all types of the impurity that exists or predicted to exist in said semi-solid slurry which include but not limits to the plastic parts which include but not limits to pins, paper clips, other impurities which include but not limits to carry bag, pouches, other stationary items, etc. removed after completion of said at least three filtration cycle (103, 104, 105) and said slurry (101) can be consider as an intended epitome input for a forming of said molded fiber parts and can be supplied as an input to said forming module (127) for further processing.
Further, said input forming module (127) comprising a slurry sink (127b) configured with said forming module (127) in order to receive and store said third filtered slurry (105) as an input, a mold (127a) removably configured with a mold activation system (127c) in order to form a molded fiber product (601) as a replica of said mold (127a). Wherein as said slurry sink (127b) receives said filtered slurry, said mold activation system (127c) lowers said mold (127a) into said slurry sink (127b) and forms said molded fiber product (601) as a replica of said configured mold (127a). In one of the preferred embodiments said slurry can be maintained in the range of consistency 0.25 to 0.35% by weight of solution in order to produce the product with thickness in the range of 0.5mm to 0.7mm. Furthermore, said robotic arm (205, 305, 405, 505) configured with said molded fiber production system (200, 300, 400, 500) as a central communicating means comprising at least two adapting jaws (205a, 205b, 305a, 305b, 405a, 405b 505a, 505b) articulated in the manner that said robotic arm (205, 305, 405, 505) is capable of receiving input from said forming module (127) and/or pair of a hot press module (128, 129) and can perform up-down motion or flip the side of said jaws (205a, 205b, 305a, 305b, 405a, 405b 505a, 505b) in order to extract output from said forming module (127) and provide input to said pair of said hot press (128, 129) and/ or extract output from said pair of said hot press (128, 129) in accordance with servo powered controlling means. In one of the embodiments said servo powerd controlling means can be servo motor capable to rotate in both direction. In one of the preferred embodiments said servo powered controlling means can be servo operated or controlled bi-directional motor. Wherein said robotic arm (205, 305, 405, 505) can be further configured with said forming module (127) and at least the pair of said hot press (128, 129) in order to forward the processed mold as output from said forming module (127) and/or said molded fiber product (601) from one station which include but not limits to said forming module (127) or said hot press (128, 129) to the next satiation which include but not limits to said forming module (127) or said hot press (128, 129) in accordance with said molded fiber product production process (100). Further, said forming module (127) commences to process said input to forming (106) by means of said slurry in order to produce a partially formed product called as a first partially product (601a) articulated in accordance with said configured mold (127a). Wherein as said forming module (127) completes forming of said first partially formed product (601a) as said output from forming module (107), said robotic arm (205, 305, 405, 505) automatically activates and transfers said first partially formed product (601a) as an input to a first hot press (108) in order to process said first partially formed product (601a) to a first completely formed product (601a’) by means of a process which include but not limits to a soaking, heating, dewatering, etc. Whereas as said first hot press (128) process said first partially formed product (601a) by means of soaking, dewatering or removing moisture content from said first partially formed product (601a) by means of heating configuration configured with said hot press (128, 129) meanwhile said mold activation system (127c) activates and lowers said mold (127a) into said slurry sink (127b) in order to commence the functioning as an input to forming (109) in order to form another partially formed product as an output from forming module (110) in the form of a second partially formed molded fiber product (601b) from said forming module (110) and said robotic arm (205, 305, 405, 505) can operate in a manner to transfer said second partially formed product (601b) from said forming module (127) as an input to second hot press (129) in said stage of input to second hot press (111) to process said second partially formed product (601b) to a second completely formed product (601b’). As said robotic arm (205, 305, 405, 505) removes said second partially formed product (601b’) from said forming module (127), said forming module (127) immediately activates said mold activation system (127c) in order to lower said mold (127a) into said slurry sink (127b) and provides an input to said forming (112) forms a third partially formed product (601c) as an output from forming (113) that can be forwarded as the next input for to said first hot press (128) in said stage of input to first hot press (114) and extract completely process output from the first hot press (115) in the form of a first completely processed molded fiber product (601a’) in order to complete the first cycle for said molded fiber product production process (100). In case of the next or second cycle and/or continuing to said first cycle said mold actuation system (127c) performs lowering of said mold (127a) in order to supply an input to forming (116) wherein said robotic arm (205, 305, 405, 505) automatically turns to said forming module (127) to remove said fourth partially formed product (601d) from said mold (127a) configured as an output from forming module (117) in one of the side of said jaws (205a, 205b, 305a, 305b, 405a, 405b 505a, 505b) of said robotic arm (205, 305, 405, 505) and starts to travel towards said second hot press (129) in order to provide said fourth partially formed product (601d) an input to said second hot press (129) in said stage of input to said second hot press (118) and remove said second partially formed product (601b’) as an output from said second hot press (129) inputted as said first input that processed by said second hot press (129) into said stage of output from said second hot press (119). Whereas said robotic arm (205, 305, 405, 505) can continue to proceed further to place said completely formed products which include but not limited to said first completely formed product (601a’), said second completely formed product (601b’), etc. to a trimming module and/or ideal station (120) in order to commence with another applicable, intended, implied and/ or relevant process. In one of the embodiments said molded fiber product production process (100) can produce at least three number of said partially formed molded fiber products (601a, 601b, 601c) and at least two number of said completely formed molded fiber products (601a’, 601b’) in a single run of cycle.
In one of the preferred embodiments, it’s apparent to a person skilled in the art that the number of said partially formed molded fiber products (601a, 601b) and/or said completely formed molded fiber product (601a’, 601b’) can be produced at the single instance can varies in accordance with the number of impressions articulate on said mold (127a) or capacity of said forming module (127) to accommodate the impression or number of said mold (127a) at a single stage. In one of the preferred embodiments the number of said partially formed molded fiber products (601a, 601b) and/or said completely formed molded fiber product (601a’, 601b’) can be at least two in number.
In another preferred embodiment said cycle time for processing different actions can be in accordance with the below table:
Process
Time
Consistency
(in % by weight of solution) Forming Module (127)
(Processing time in seconds) First Hot Press Module (128)
(Processing time in seconds) Second Hot Press Module (129)
(Processing time in seconds) Thickness
(in mm)
Cycle 1 0.25 30 50 -- 0.5
Cycle 2 0.25 30 -- 50 0.5
Cycle 1 0.3 30 60 -- 0.6
Cycle 2 0.3 30 -- 60 0.6
Cycle 1 0.35 30 70 -- 0.7
Cycle 2 0.35 30 -- 70 0.7
Cycle 1 0.3 45 90 -- 1
Cycle 2 0.3 45 -- 90 1
Cycle 1 0.3 60 120 -- 1.2
Cycle 2 0.3 60 -- 120 1.2
In further preferred embodiment said robotic arm (205, 305, 405, 505) can follow the sequential steps to execute instructions imparted in order to perform the intended operation during said molded fiber product production process (100), whereas said forming module (127), said first hot press (128) and said second hot press module (129) functions simultaneously in accordance with said robotic arm (205, 305, 405, 505) configure in order to transport said partially or completely processed product (601a’, 601b’, 601c’, 601d’). Wherein after said complete processing of said product (601a’, 601b’, 601c’, 601d’) from said any of hot press (128, 129), said completely processed product (601a’, 601b’, 601c’, 601d’) can be further transferred to said trimming module (120) in order to perform the trimming operation by means of operation which include but not limits to a manual or an automatic and/or semi-automatic trimming module as required in order to achieve the intended size and shape for a final molded fiber product (601aa, 601ba, 601ca, 601da).
Furthermore, in order to enhance the security and safety level for said final molded fiber product (601aa, 601ba, 601ca, 601da), wherein said molded fiber product (601aa, 601ba, 601ca, 601da) can be further processed to configure a product identification process which includes but not limits to a stamping, embossing, bar code configuration, etc. in order to a stamp or emboss relevant information (121) on said final molded fiber product (601aa, 601ba, 601ca, 601da) and/or said bar code can be configured in order to track or locate said final molded fiber product (601aa, 601ba, 601ca, 601da) digitally and upgrade the authenticity for said final molded fiber product (601aa, 601ba, 601ca, 601da) and make said final molded fiber product (601aa, 601ba, 601ca, 601da) tamper-proof and protected from theft. In another embodiment in order to furthermore enhance the security level and in order to protect said final molded fiber product (601aa, 601ba, 601ca, 601da) and content stored in said final molded fiber product (601aa, 601ba, 601ca, 601da) from alteration or dilution more specifically in case of sectors which include but not limits to said pharma industry packaging, food product packaging, dairy product packaging or packaging of shelf product wherein the uniqueness and originality of said molded fiber product or identification of product for intended manufacturer highly demanded then said final molded fiber product (601aa, 601ba, 601ca, 601da) can be configured with a holography process (122) comprising original identification mark. Whereas after said product identification process said final molded fiber product (601aa, 601ba, 601ca, 601da) can be processed with a lamination (123) in order to facilitate a plethora, of features which include but not limited to enhancing resistant properties for said final molded fiber product (601aa, 601ba, 601ca, 601da), increasing capability handling a plurality of items for said final molded fiber product (601aa, 601ba, 601ca, 601da), formulating the barrier for food contact with said final molded fiber product (601aa, 601ba, 601ca, 601da), protect said stamped and/or embossed and/or bar code (121) and/or said holography (122) from scratching or tampering, provide the pleasant aesthetic to said final molded fiber product (601aa, 601ba, 601ca, 601da), etc. Moreover, said laminated product can be staked in a staking module (124) in order to determine the intended dimensions and/or features for said laminated molded fiber product (601ab), if the required dimension and/or features exist in said laminated molded fiber product (601ab)then said laminated molded fiber product (601ab) can be categorized as accepted or else can be removed as a reject quantity. Whereas said accepted laminated molded fiber product (601ac) can be shifted to a packaging unit (125) for further packing as intended for final dispatch (126). In still another embodiment if said accepted product doesn’t process with a product identification process which include but not limits to said stamping or bar code configuration (121) and said configuration of holography (122) previous to said lamination process (123) and after said lamination (123) of said product said product identification process (121, 122) required to perform, the said product identification process (121, 122) can be done by means of configuration of said product identification means (121, 122) manually by means of any of suitable sticking means and further protection layer can be applied for scratch proof property. In yet another embodiment said packing or final packaging and /or shipment can be configured with a bar code configuration (125) for enhanced security by means of elevated owner identification, tracking, locating and theft proofing, etc. of said molded fiber product (601ac) and make a dispatch or delivery of said molded fiber product (601ac) more swiftly without any hazard or theft with a completely original product delivery guarantee.
In another embodiment, as shown in Figure No. 04 and 05 a molded fiber products production system (200, 300) comprising a L shaped layout (201) and a U shaped layout (301) wherein a forming machine (202, 302) and a pair of hot press (203, 204, 303, 304) can be configured in ‘L’ or ‘U’ shape of said layout (201, 301) in order to produce said molded fiber product efficiently with utmost quality. Further, in the case of said ‘L’ shape layout (201) said pair of said hot press (203, 204) can be configured with only one side of said forming module and a robotic arm (205) can move in an angle of range from 0° to 90° on either side of said forming module (202). Furthermore, said L shape of the layout (201) can be implied in the case of the conditions which include but not limits to less horizontal/lateral space available, in case of only one-sided motion of said robotic arm allowed, slurry with high consistency, slurry with less soaking time, less travel time intended or less cycle time required for said molded fiber product production process, etc. Whereas in the case of said U-shaped layout (301) at least one of said hot presses (303, 304) can be configured on other sides of said forming module (302) in a manner a robotic arm (305) can move in 90° on both sides of said forming module (301), in a manner that said robotic arm (305) starts from said first hot press (303) with a pause at said forming module (302) and finally stop at said second hot press (304) total angle of movement can be up to 180° in symmetrically up to 90° on both sides of said forming module (302) or said robotic arm (305) location. However, said U shape of the layout (301) can be implied in the case of the conditions which include but not limits to less vertical/linear space available, in case of both-sided motion of said robotic arm allowed, slurry with low consistency, slurry with more soaking time requirement, more travel time intended or more cycle time required for said molded fiber product production process (100). Wherein in one of the embodiments said L-shaped layout (201) can be more efficient as compared to said U-shaped layout (301), whereas said U-shaped layout (301) can have more efficacy as compared to said L-shaped layout (201).
Moreover, as shown in figure no. 06 and 07 a molded fiber products production system (400, 500) comprising a L shaped layout (401) and a U shaped layout (501), wherein a forming module (402, 502) as well as the pair of a hot presses (403, 404, 503, 504) can be configured in a L shaped layout (401) or a U-shaped layout (501) can be controlled and operated in accordance with a centralized operating means (406, 506) which include but not limits to a centralized server control, programming / re-programing means, data storage and data processing means, production planning and control compatibility module, system diagnosis and rebooting module, data display means, input communication mean etc. articulated in manner to provide the instruction to said molded fiber product production system (400, 500) articulated in order to operate in a user-specific manner and can control parameter or process in accordance with the instructions which include but not limits to the confirming a robotic arm (405, 505) working in range and angle, deciding cycle time and time for each of said forming module (402, 502), said hot press (403, 404, 503, 504) soaking, and approach time for said robotic arm (405, 505), the direction of processing and cycle commencement, etc. Wherein in one of the embodiments said molded fiber product production system (400, 500) can be controlled remotely by means of remote control in order to avert emergency accident condition or faulty production conditions more specifically in case of the operator not present near to said molded fiber production system (400, 500) and if any malfunctioning occurred or accident commenced or commence to occur said operator can control or off operation of said molded fiber production system (400, 500) remotely from another location and can save the catastrophic failure or accident to safeguard financial and/or human loss. Moreover, said L shaped (401) and U-shaped (501) molded fiber production layout facilitates the plethora of advancements which include but not limits to a more compact and efficient process layout, provides adequate forming, provides adequate soaking and trimming time for said molded fiber product processing, sufficient forming time to formulates said partially formed product with higher strength, lesser rejection rate, said adequate soaking time in said hot presses allows said molded fiber to dried completely and offers the more strength, higher weight carrying capacity, better leakproof property and more sustainable to plurality of service condition, less rejection or production of damage of products, reduces the ideal time for said robotic arm (405, 505) with less travel distance and time, increases the yield and life of said robotic arm (405, 505) due to less distance and angle of rotation, increases the high quality production percentage to enhance the efficiency and efficacy of said molded fiber product production system (400, 50), reduces the cost for bigger production facility and high end machines in order to reduce the investment and operating cost along with the energy consumption, more versatile system that can facilitates plurality of slurry difference in accordance with the consistency and manufacture plurality of intricate shapes at ease, separate forming and hot press module provides flexibility for maintenance and operation if any of error occurred in any of module will not impact the production of other modules, centralized and easy programing module provides facility to modify feuded program in accordance with the cycle time and execute the any already saved program, requires less overall cost infrastructure requirement, and investment to assist in installation of new facility with low budget and facility requirement, etc.
In furthermore embodiment as shown in figure no. 08 a Molded fiber product production system (600) comprising a trimming station (602) configured with a spiral stacking station (603), wherein said trimmed molded fiber product (601) which include but not limits to all of said final molded fiber product (601aa, 601ba, 601ca, 601da) produced by said molded fiber production process (100), said molded fiber product production system (200, 300, 400, 500) can be staked in said spiral stacking station (603). Further said spiral stacking station (603) can be comprising a disc (611) configured with a spiral product qualification means (604) that can be articulated in accordance with an external dimension of said molded fiber product (601) and configure in accordance with said batch size (610) of said molded fiber products (601) in order to assist in quality control and exact batch (610) stacking. Said stacking station (603) operates in a manner said molded fiber product (601) can qualify for external dimensions by the internal dimension of said spiral product configuration means (604) and internal dimensions by means of a master product (616) which can be the first product per batch (610) calibrated in accordance with the features, size, shape and other geometrical and dimensional aspect intended to replicate in the final molded fiber product (601). In one of the embodiments, at least one of said molded fiber products (601) can be manually verified by means of said master product (616) in order to ensure the preciseness of said molded fiber product (601) before said stacking station (603) placement, whereas in another embodiment at least one batch (610) of said molded fiber product (601) manufactured precisely in accordance with said size, shape, features, dimensional and geometrical aspect and duly verified can be used as said master product (616) per batch (610) of said stacking process required to perform in said stacking station (604). Furthermore, after at least one of said molded fiber products (601) can be duly verified by means of said master product (616) said stacking process can be commenced in said stacking station (604), wherein said external dimension can be automatically verified by means of said spiral product configuration means (604) and the internal dimension can be verified during said stacking process by means of stacking of said other molded fiber product (601) over said verified fist molded fiber product (601) by means of the said master product (616) and/or stacking of other molded fiber product (601) directly over said master product (616) in order to verify the internal and/or below features, shapes, sizes, dimensions and other geometrical features accurately and assist in the product of same and/or similar type of said molded fiber products (601). The number and/or weight of said molded fiber product (601) during and/or after said stacking process in said stacking station (603) in said spiral product configuration means (604) can be verified by means of plurality of sensors and counters which include but not limits to the counter, weight sensor, density sensor etc. and after completion of the batch (610) of said molded fiber product (601) in accordance with said spiral product configuration means (604) a lowering means (607) can be activated in order to perform the lowering of the batch (610) of said molded fiber product (601) in an accept chute (608) in order to perform the packing of said batch (610). In another embodiment said stacking process can be performed completely mechanically without configuration of said counter and/or said sensors by means of designing the height of said spiral product configuration means (604) in accordance with the number of said molded fiber products (601) required to be stacked in said batch (610) at said stacking station (603) in order to perform the counting of the number of said molded fiber products (601) required to be stacked in said batch (610) of said molded fiber product (616) automatically and the complete batch (610) can be lowered by means of application of small push force from top of said batch (610) of said molded fiber product (616) in order to lower said accepted batch (610) into said accept chute (608) for packing of said molded fiber product (616). Whereas in case any of said molded fiber products (601) abrupt in features, shape, size, dimensions, geometrical, or any other parameters can be identified and isolated easily during verification and/or stacking by means of validation with said master product (616) and/or stacking of said molded fiber product (601) in gauged height of said spiral product configuration means (604) to measure the number and thickness of said molded fiber products (601). However, said spiral product configuration means (604) can be configure with plurality of vertical ribs (605) can be configured with said disc (611) in accordance with the external shape, size, features, dimensional parameter, geometrical parameters, etc. in order to articulate the internal shape of said spiral product configuration means (604) in accordance with the external shape of said molded fiber product (601). Wherein said plurality of vertical ribs (605) can be configured with a plurality of horizonal ribs (606) in order to support said vertical ribs (605) to configure with each other firmly in order to articulate said spiral product configuration means (604). In one of the embodiment a tips (605a) of said vertical ribs (605) can be inclined in a manner to allow smooth stacking of said molded fiber product (601). In another embodiment said stacking means (603) can be cage type configured in accordance with type which include but not limits to circular, rectangular, square, hexagonal, elliptical, spherical, octagonal, spheroidal, etc. constructed in accordance with said molded fiber product (601). In one of the preferred embodiment said spiral product configuration means (604) can circular, hexagonal, spherical, ellipsoidal in shape in case of said molded fiber product (601) can be of type which include but not limits to coffee cup lid, circular containers, bottles, circular bowls, circular plates, circular dishes, etc. all types of circular molded fiber products (601), whereas said spiral product configuration means (604) can be square or rectangular in shape in case of said molded fiber product (601) can be shape which included but not limits to triangular, square or rectangular boxes, square or rectangular plates or dishes, square or rectangular lunch box or meal tray, square or rectangular bowl or cup or containers, etc. Moreover, said disc (611) can be configure with plurality of said spiral product configuration means (604) configured equidistantly along said disc (611) in accordance with the number of batch (610) of said molded fiber product (601) required to produce over a single disc (611). In one of the embodiments at least four number of said spiral product configuration means (604) can be configured with said disc (611) equally at 90° apart in order to perform said stacking of said molded fiber product (601) effectively. In one of the embodiments said disc (611) can be of shape which include but not limits to circular, spherical, octagonal, hexagonal, square, rectangular, etc. In of the preferred embodiment said disc (611) can be circular, spherical, square shaped. Wherein said disc (611) can be rotatable configure with said stand (608) and said stand (608) can be fixedly configure with a base (609) in order to facilitate the firm and rigid configuration of said disc (611) with said stand (610) and said stacking station (603) and rotated said disc (611) in any direction in order to configure any of the available and vacant spiral product configuration means (604) with said trimming station (602). In one of the embodiments said stacking means (603) can be rotated manually by means of configuring rotatable configuration of said disc (611) and said stand (609) by means of manual rotating means which include but not limits to bearing, manual gearing etc. or automatically or semi-automatically by means of rotatable configuration of said disc (611) and said stand (609) by means of rotating means which include but not limits to servo motor, gear box, remote operated rotating means etc. In one of the preferred embodiments pluralities of said trimming station (602) can be configured with said spiral stacking station (603) and perform said stacking more efficiently and effectively. In one of the preferred embodiments said stacking station (602) can be compatible to facilitate stacking of molded fiber product (601) which includes at least coffee cup leads, containers, bowls, plates, meal box, dishes for food and/or nonfood grade applications.
In yet another embodiment as shown in Figure No. 09 to 11, said molded fiber product (601) can be configure with a bar code (613, 614) and/or a holography (615) configured on a surface (612) of said molded fiber product (601) in a manner said bar code (613, 614) can comprise the information which includes but not limits to a manufacturer’s information, manufacturing instruction and details, service information, delivery location, etc., as intended for identification and safe delivery of said molded fiber product (601). Wherein said bar code (613, 614) can be a one-sided bar code (613) or a two-sided bar code (614) that can be configured prior to lamination and/or after lamination on said surface (612) of said molded fiber products (601). In case of said one-sided bar code (613) the only one side comprises the intended information whereas other side of said one sided bar code (613) can be blank or include the fixing means which include but not limits to said glue or sticking agent, adhesives, etc. Said one-sided bar code (613) can be more suitable in case of configuration prior to said lamination and can have an over-coating of said lamination material in order to achieve enhanced tamper-proof and theft-proof properties. Whereas in the case of said two-sided bar code (614), both sides of said bar code (614) comprises said intended information and said bar code possess the property to leave an exact impression as articulated on the surface after removal of said two sided bar code (614). Said two-sided bar code (614) can be configured on said surface (612) or said final batch (610) of packing in order to locate or fix any tampering or theft action by means of leaving of exact impression on said surface (612) of said molded fiber product (601) or packaging. However, said holography (615) can also be configure with said molded fiber product (601) more preferably prior to said lamination or after lamination with over-coating or gluing means to facilitate tamper-proof property and ensure originality or circulation of delivery of intended product up to the consumer and avert any piracy in the supply chain in order to safeguard the manufacturers or packer’s interest.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to, said molded fiber products production process and system made for said molded fiber products production thereof of that:
• Articulate the molded fiber product from the pre-processed and filter slurry input after a plurality of filtration checks,
• Comprises a capability to process the plurality of slurry types with enhanced pre-processing,
• Facilitate a compact production process for said molded fiber products,
• More uniform production process without or minimal human intervention,
• Reduce cycle time with respect to the output of said molded fiber products.
• Better forming and soaking of molded fiber products to induce strength and leakproof features.
• Enhance the overall quality of molded fiber products and increase efficiency by means of the use of the robotic arm.
• Reduce the energy consumption and cost of said production of molded fiber product,
• Tamperproof product compatible with shelf and food-grade items,
• Less investment and space required to set up,
• More safe and secure functioning with less reluctance to failure.
The embodiment herein and the various features and advantages details thereof are explained with reference to the non-limiting embodiment in the following descriptions. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiment herein, the examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiment herein. Accordingly, the examples should not be constructed as limiting the scope of the embodiment herein. The foregoing description of the scientific embodiment will so fully revel the general nature of the embodiment herein that others can, by applying current knowledge, readily modify and / or adapt for various application such as specific embodiments without departing from the generic concept, and, therefore, such adaptions and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.
It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiment those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of embodiment as described herein.
Throughout this specification the word “comprises”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of the any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggested the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or result.
Any discussion of documents, acts, materials, devices, products, or the like that has been included in this specifications is solely for the purpose of providing a context for the disclosure, it is not to be taken as an admission that any or all of these matters from a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiment, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the forgoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as an limitation.
Dated this 17th day of April 2023
Shailendra Khojare,
IN/PA-4041
Applicants Patent Agent

,CLAIMS:

CLAIMS
We claim;
1. A molded fiber product production process (100) comprising;
a preparation of raw slurry (101) configured with said molded fiber product production process (100);
an addition of ingredients (102) configured with said preparation of raw slurry (101);
a first filtration (103) configures with said addition of ingredients (102);
a second filtration (104) configures with said first filtration (103);
a third filtration (105) configure with said second filtration (104);
a forming module (127) configured with said third filtration (105);
a hot press (128, 129) configured with said forming module (127);
an input to forming (106) configured with said forming module (127);
an output from forming (107) configured with said input to forming (106);
an input to the first hot press (108) configured with said hot press (128, 129) and said output from forming (107);
an input to the forming (109) configured with said forming module (127);
an output from the forming (110) configured with said input to the forming (109);
an input to the second hot press (111) configured with said output from the forming (110);
an input to forming (112) configured with said forming module (127) and said input to the second hot press (111);
an output from forming (113) configured with said input to forming (112);
an input to the first hot press (114) configured with said output from forming (113);
an output from the first hot press (115) configured with said input to the first hot press (114);
an input to forming (116) configured with said forming module (127);
an output from forming (117) configured with said input to forming (116) and said input to forming (116);
an input to the second hot press (118) configured with said output from forming (117);
an output from the second hot press (119) configured with said input to the second hot press (118);
a trimming module (120) configured with said output from the first hot press (115) and said output from the first hot press (119);
a stamping and a barcode configuration (121) and holography (122) configured with said trimming module (120);
a lamination (123) configured with said stamping and barcode configuration (121) and holography (122);
a stacking module (124) configured with said lamination (123) and/or said trimming module (120);
a packaging (125) configured with said stacking module (124).
2. The molded fiber product production process (100) as claimed in claim 1; wherein said slurry during said can be maintained in the range of 0.25 to 0.35% by weight of solution during said molded fiber product production process (100).
3. The molded fiber product production process (100) as claimed in claim 1; wherein said molded fiber product production process (100) commence after said first filtration means (103), a second filtration means (104) and said third filtration (105).
4. The molded fiber product production process (100) as claimed in claim 1; wherein said molded fiber product production process (100) configure with said first filtration means (103), a second filtration means (104) and said third filtration (105)can perform at least cleaning of said semi-solid solution for removing the magnetic impurity.
5. The molded fiber product production process (100) as claimed in claim 1; wherein, said input forming module (127) comprising a slurry sink (127b) configured with said forming module (127) in order to receive and store said third filtered slurry (105) as an input, a mold (127a) removably configured with a mold activation system (127c).
6. The molded fiber product production process (100) as claimed in claim 1; wherein as said slurry sink (127b) receives said filtered slurry, said mold activation system (127c) lowers said mold (127a) into said slurry sink (127b) and forms a molded fiber product (601) as a replica of said configured mold (127a).
7. The molded fiber product production process (100) as claimed in claim 1; wherein said molded fiber product (601) can include the thickness in the range of 0.5mm to 1.2mm.
8. The molded fiber product production process (100) as claimed in claim 1; wherein a robotic arm (205, 305, 405, 505) configure with said forming module (127) and pair of said hot press modules (128, 129).
9. The molded fiber product production process (100) as claimed in claim 1; wherein said robotic arm (205, 305, 405, 505) can perform up-down motion or flip the side of said jaws (205a, 205b, 305a, 305b, 405a, 405b 505a, 505b) in order to extract output from said forming module (127) and provide input to said pair of said hot press (128, 129) and/ or extract output from said pair of said hot press (128, 129) in accordance with servo powered controlling means.
10. The molded fiber product production process (100) as claimed in claim 1; wherein said servo powered controlling means can be a servo operated bi-directional motor.
11. The molded fiber product production process (100) as claimed in claim 1; wherein the number of partially formed molded fiber products (601a, 601b) and/or a completely formed molded fiber product (601a’, 601b’) produced at a single instance can be at least two in number.
12. The molded fiber product production process (100) as claimed in claim 1; wherein after said complete processing of said product (601a’, 601b’, 601c’, 601d’) from said any of hot press (128, 129), said completely processed product (601a’, 601b’, 601c’, 601d’) can be further transferred to said trimming module (120).
13. The molded fiber product production process (100) as claimed in claim 1; wherein said molded fiber product (601aa, 601ba, 601ca, 601da) can be, the further process to configure a product identification process (121) which includes but not limits to a stamping, embossing, bar code configuration.
14. The molded fiber product production process (100) as claimed in claim 1; wherein said laminated product can be staked in a staking module (124) in order to determine the intended dimensions and/or features for said laminated molded fiber product (601ab).
15. A molded fiber products production system (200, 300, 400, 500, 600) comprising;
a L-shaped layout (201, 401) or a U-shaped layout (301, 501);
a forming module (202, 302, 402, 502) configured with said L-shaped layout (201, 401) or said U-shaped layout (301, 501);
a pair of the hot press (203, 204, 303, 304, 403, 404, 503, 504) configured in said L-shaped layout (201, 401); or said U-shaped layout (301, 501), and said forming module (202, 302, 402, 502);
a servo-controlled robotic arm (205, 305, 405, 505) configured with said pair of hot press (203, 204, 303, 304, 403, 404, 503, 504) and said forming module (202, 302, 402, 502) in order to transfer a molded fiber product (601) smoothly from said forming module (202, 302, 402, 502) to said pair of hot press (203, 204, 303, 304, 403, 404, 503, 504).
16. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein in said ‘L’ shape layout (201, 401) said pair of said hot press (203, 204, 403, 404) can be configured with only one side of said forming module (202, 402).
17. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said robotic arm (205, 405) can move in an angle of range from 0° to 90° on either side of said forming module (202, 402).
18. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said U-shaped layout (301, 501) configured with at least one of said hot presses (303, 304, 503, 504) configured on other sides of said forming module (302) in a manner said robotic arm (305, 505) can move in 90° on both sides of said forming module (301, 501).
19. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein in the case of said U-shaped layout (301, 501) said robotic arm (305, 505) starts from said first hot press (303, 503) with a pause at said forming module (302, 502) and finally stop at said second hot press (304, 504).
20. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein in the case of said U-shaped layout (301, 501) said robotic arm (305, 505) moves up to 180° and symmetrically up to 90° on both sides of said forming module (302, 502).
21. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said molded fiber products production system (400, 500) can be controlled and operated in accordance with a centralized operating means (406, 506).
22. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said centralized operating means (406, 506) include a centralized server control, programming / re-programing means, data storage, and data processing means, production planning and control compatibility module, system diagnosis, and rebooting module, data display means, input communication means.
23. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said molded fiber product production system (400, 500) can be controlled remotely.
24. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said molded fiber product production system (600) comprising a trimming station (602) configured with a spiral stacking station (603), said trimmed molded fiber product (601) including all of said final molded fiber product (601aa, 601ba, 601ca, 601da) can be staked in said spiral stacking station (603).
25. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said spiral stacking station (603) configured with a disc (611) configured with a spiral product qualification means (604) articulated in accordance with an external dimension of said molded fiber product (601) and configure in accordance with said batch size (610) of said molded fiber products (601).
26. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said stacking station (603) operates in a manner said molded fiber product (601) can qualify for external dimensions by the internal dimension of said spiral product configuration means (604) and internal dimensions by means of a master product (616).
27. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein the number and/or weight of said molded fiber product (601) during and/or after said stacking process in said stacking station (603) in said spiral product configuration means (604) can be verified by means of plurality of sensors and counters.
28. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said spiral product configuration means (604) a lowering means (607) can be activated in order to perform the lowering of the batch (610) of said molded fiber product (601) in an accept chute (608).
29. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said stacking process can be performed completely mechanically without configuration of said counter and/or said sensors by means of designing the height of said spiral product configuration means (604) in accordance with the number of said molded fiber products (601) required to be stacked in said batch (610) at said stacking station (603) in order to perform the counting of the number of said molded fiber products (601) required to be stacked in said batch (610) of said molded fiber product (616) automatically and the complete batch (610) can be lowered by means of application of small push force from the top of said batch (610).
30. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said molded fiber products (601) abrupt in features, shape, size, dimensions, geometrical, or any other parameters can be identified and isolated during verification and/or stacking by means of validation with said master product (616) and/or stacking of said molded fiber product (601) in gauged height of said spiral product configuration means (604).
31. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said spiral product configuration means (604) can be configure with plurality of vertical ribs (605) can be configured with said disc (611) in accordance with the external shape, size, features, dimensional parameter, geometrical parameters.
32. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said plurality of vertical ribs (605) can be configured with a plurality of horizontal ribs (606).
33. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein a tip (605a) of said vertical ribs (605) can be inclined in a manner to allow smooth stacking of said molded fiber product (601).
34. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein at least four number of said spiral product configuration means (604) can be configured with said disc (611) equally at 90° apart.
35. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said disc (611) can be rotatable configured with said stand (608) and said stand (608) can be fixedly configured with a base (609).
36. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said stacking station (602) can be compatible to facilitate stacking of molded fiber product (601) which includes at least coffee cup leads, containers, bowls, plates, meal box, dishes for food and/or nonfood grade applications.
37. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said molded fiber product (601) can be configure with a bar code (613, 614) and/or a holography (615) configured on a surface (612) of said molded fiber product (601).
38. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said bar code (613, 614) can comprise the information which includes but not limits to a manufacturer’s information, manufacturing instruction and details, service information, delivery location, etc., as intended for identification and safe delivery of said molded fiber product (601).
39. The molded fiber products production system (200, 300, 400, 500, 600) as claimed in claim 15; wherein said bar code (613, 614) can be a one-sided bar code (613) or a two-sided bar code (614) that can be configured prior to lamination and/or after lamination on said surface (612) of said molded fiber products (601).
Dated this 17th day of April 2023

Shailendra Khojare,
IN/PA-4041
Applicants Patent Agent