Process for making repulpable corrugated box

Abstract

A repulpable moisture resistant poultry box having a composite structure with a fluted medium, a top backing board secured to one side of the fluted medium and a bottom backing board secured to the other side of the fluted medium. The backing boards and the fluted medium are impregnated with a hydrogenated triglyceride. The backing boards each have an outer surface coated with an emulsion of hydrogenated triglyceride and styrene acrylic to provide moisture resistance repulpable and recyclable box.

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         13 . A process for making a repulpable and recyclable poultry box comprising the steps of:
 a). impregnating a corrugated paper medium with hydrogenated triglyceride;   b). impregnating a first paper liner board with hydrogenated triglyceride;   c). impregnating a second paper liner board with hydrogenated triglyceride;   d). coating said impregnated first paper liner board with a coating of emulsified styrene acrylic co-polymer and hydrogenated triglyceride on one side;   e). coating said impregnated second paper liner board with a coating of emulsified styrene acrylic co-polymer and hydrogenated triglyceride on one side;   f). securing said first impregnated and coated liner board, said impregnated corrugated medium and said second impregnated and coated liner board together with the corrugated medium in the middle with an adhesive to form a composite sheet; and   g). curing said composite sheet with heat to cure said adhesive.   
     
     
         14 . A process as claimed in  claim 13  wherein said hydrogenated triglyceride ranges from about 5% to about 25% by weight of the coating. 
     
     
         15 . A process as claimed in  claim 13  wherein said coating of emulsified styrene acrylic co-polymer and hydrogenated triglyceride is in a water solution and said styrene acrylic co-polymer ranges from about 50% to about 55% by weight of the solution. 
     
     
         16 . A process as claimed in  claim 13  wherein said hydrogenated triglyceride is tallow, said tallow comprising about 20% by weight of the coating. 
     
     
         17 . A process as claimed in  claim 13  wherein the hydrogenated triglyceride is an animal fat selected from one or more of a group consisting of beef tallow, pork lard, poultry grease, and fish oils. 
     
     
         18 . A process as claimed in  claim 13  wherein the hydrogenated triglyceride is a hydrogenated vegetable oil selected from one or more of a group consisting of soybean oil, peanut oil, olive oil, palm oil, coconut oil and cottonseed oil. 
     
     
         19 . A process for making a repulpable and recyclable poultry box as claimed in  claim 13  including the additional step of:
 h). cooling the composite sheet causing a temperature drop of said composite sheet to at least 70° F. 
 
     
     
         20 . A process for making a repulpable and recyclable poultry box as claimed in  claim 19  including an additional step after step h) of:
 i). cutting the composite sheet into box blanks. 
 
     
     
         21 . A process for making a repulpable and recyclable poultry box in an inline corrugating machine comprising the steps of:
 a). impregnating a corrugated paper medium with hydrogenated triglyceride;   b). impregnating a first paper liner board with hydrogenated triglyceride;   c). impregnating a second paper liner board with hydrogenated triglyceride;   d). coating said impregnated first paper liner board with a coating of emulsified styrene acrylic co-polymer and hydrogenated triglyceride in a water solution on one side;   e). coating said impregnated second paper liner board with a coating of emulsified styrene acrylic co-polymer and hydrogenated triglyceride in a water solution on one side;   f). securing said first impregnated and coated liner board, said impregnated corrugated medium and said second impregnated and coated liner board together with said impregnated corrugated medium in the middle with an adhesive to form a composite sheet;   g). curing said composite sheet with heat to cure said adhesive; and   h). cooling said composite sheet to a suitable temperature to allow cutting and stacking.   
     
     
         22 . A process as claimed in  claim 21  wherein the hydrogenated triglyceride is an animal fat selected from one or more of a group consisting of beef tallow, pork lard, poultry grease, and fish oils. 
     
     
         23 . A process as claimed in  claim 21  wherein the hydrogenated triglyceride is a hydrogenated vegetable oil selected from one or more of a group consisting of soybean oil, peanut oil, olive oil, palm oil, coconut oil and cottonseed oil. 
     
     
         24 . A process for making a repulpable and recyclable poultry box as claimed in  claim 21  wherein said cooling step:
 includes cooling the composite sheet until it reaches a temperature of about 70° F. 
 
     
     
         25 . A process for making a repulpable and recyclable poultry box as claimed in  claim 21  including an additional step i) of:
 i). cutting the cooled composite sheet into blanks. 
 
     
     
         26 . A process as claimed in  claim 21  wherein said hydrogenated triglyceride is tallow ranging from about 5% to about 25% by weight of the coating. 
     
     
         27 . A process as claimed in  claim 21  wherein said styrene acrylic co-polymer ranges from about 50% to about 55% by weight of the solution. 
     
     
         28 . A process as claimed in  claim 21  wherein said hydrogenated triglyceride is tallow and is about 20% by weight of the coating. 
     
     
         29 . A process for making a repulpable and recyclable poultry box in an inline corrugating machine comprising the steps of:
 a). impregnating a corrugated paper medium with tallow;   b). impregnating a first paper liner board with tallow;   c). impregnating a second paper liner board with tallow;   d). coating said impregnated first paper liner board with a coating of emulsified styrene acrylic co-polymer and tallow in a water solution on one side;   e). coating said impregnated second paper liner board with a coating of emulsified styrene acrylic co-polymer and tallow in a water solution on one side;   f). securing said first impregnated and coated liner board, said corrugated medium and said second impregnated and coated liner board together with glue with the corrugated medium positioned between said first and second impregnated and coated liner board to form a composite sheet;   g). curing said composite sheet with heat to cure said glue;   h). cooling said composite sheet until it reaches about ambient temperature; and   i). cutting said dried composite sheet into blanks and stacking said blanks.   
     
     
         30 . A process as claimed in  claim 29  wherein said tallow ranges from 5% to about 25% by weight of the coating and said styrene acrylic co-polymer ranges from about 75% to about 95% by weight of the coating. 
     
     
         31 . A process as claimed in  claim 29  wherein said corrugated paper medium ranges from about 30 pounds to about 40 pounds per 1000 sq. ft. (MSF). 
     
     
         32 . A process as claimed in  claim 29  wherein said first and second liner board is impregnated with tallow at about 2.5 lbs./MSF.