In-line paperboard moisturizing

Abstract

An in-line paperboard moisturizing and pressware forming system broadly comprising a paperboard moisturizing system and a pressware forming system in-line with the paperboard moisturizing system. The paperboard moisturizing system broadly comprises a supply roll carrier, a payout roller, a water spreader, and a control system. The supply roll carrier dispenses paperboard material. The payout roller meters the paperboard material from the supply roll carrier. The water spreader evenly moisturizes the paperboard material. The control system controls a feed rate and moisture level so that the paperboard material has a desired moisture content as the paperboard moisturizing system delivers the moisturized paperboard material to the pressware forming system.

1 . An in-line paperboard moisturizing and pressware forming system comprising:
 a paperboard moisturizing system comprising:
 a supply roll carrier configured to dispense paperboard material; 
 a water spreader configured to deliver water evenly to the paperboard material to moisturize the paperboard material; 
 a water supply configured to meter the water to the water spreader; and 
 a control system comprising a controller configured to instruct the supply roll carrier to advance the paperboard material according to a feed rate; and 
   a pressware forming system configured to directly receive the moisturized paperboard material, the control system being further configured to instruct the water supply to meter water to the paperboard material via the water spreader according to a desired moisture level so that the paperboard material has a desired moisture content as the paperboard moisturizing system delivers the moisturized paperboard material to the pressware forming system.   
     
     
         2 . The in-line paperboard moisturizing and pressware forming system of  claim 1 , the control system further comprising:
 a moisture reader communicatively connected to the controller, the moisture reader being configured to detect a moisture content of the paperboard material after the paperboard material has been moisturized via the water spreader.   
     
     
         3 . The in-line paperboard moisturizing and pressware forming system of  claim 2 , the control system being further configured to adjust at least one of the feed rate and a flow rate of the water supply based on the moisture content as detected by the moisture reader. 
     
     
         4 . The in-line paperboard moisturizing and pressware forming system of  claim 1 , the control system further comprising a human machine interface (HMI) configured to receive user commands including the desired moisture level and the feed rate. 
     
     
         5 . The in-line paperboard moisturizing and pressware forming system of  claim 1 , the water supply comprising:
 a valve fluidly connected to a water source;   a tank fluidly connected to the valve; and   a pump fluidly connected to the tank.   
     
     
         6 . The in-line paperboard moisturizing and pressware forming system of  claim 5 , the control system further comprising:
 a tank switch configured to activate the valve according to an amount of water in the tank.   
     
     
         7 . The in-line paperboard moisturizing and pressware forming system of  claim 5 , the control system further comprising:
 a moisture reader communicatively connected to the controller, the moisture reader being configured to detect a moisture content of the paperboard material after the paperboard material has been moisturized via the water spreader, the controller being further configured to modulate the pump according to the moisture content as detected by the moisture reader.   
     
     
         8 . The in-line paperboard moisturizing and pressware forming system of  claim 1 , wherein the controller is further configured to implement closed loop automatic moisture control. 
     
     
         9 . The in-line paperboard moisturizing and pressware forming system of  claim 1 , wherein the controller is further configured to automatically set the feed rate according to user inputs of paperboard material thickness, paperboard material width, and a desired moisture level, and forming quality of previously formed products. 
     
     
         10 . The in-line paperboard moisturizing and pressware forming system of  claim 1 , wherein the controller is further configured to synchronize an unwinding speed of the supply roll carrier and a feed rate of the paperboard forming machine. 
     
     
         11 . An in-line paperboard moisturizing and pressware forming system comprising:
 a paperboard moisturizing system comprising:
 a supply roll carrier configured to dispense paperboard material; 
 a water spreader configured to deliver water evenly to the paperboard material to moisturize the paperboard material; 
 a water supply configured to meter the water to the water spreader; and 
 a first control system comprising a controller configured to:
 instruct the supply roll carrier to advance the paperboard material according to a first feed rate; and 
 instruct the water supply to meter water to the paperboard material via the water spreader according to a desired moisture level so that the paperboard material has a desired moisture content; and 
 
   a pressware forming system in-line with the paperboard moisturizing system, the pressware forming system comprising:
 a scoring station configured to receive the paperboard material from the paperboard moisturizing system, the scoring station including a scoring tool configured to be pressed against the paperboard material thereby scoring the paperboard material; and 
 a forming station configured to receive the scored paperboard material from the scoring station, the forming station comprising a forming tool including a mold configured to shape the paperboard material. 
   
     
     
         12 . The in-line paperboard moisturizing and pressware forming system of  claim 11 , wherein the first control system is further configured to instruct the scoring station and the forming station to advance the paperboard material according to the feed rate. 
     
     
         13 . The in-line paperboard moisturizing and pressware forming system of  claim 11 , wherein the pressware forming system further comprises a second control system configured to instruct the scoring station and the forming station to advance the paperboard material according to a second feed rate based on the first feed rate. 
     
     
         14 . The in-line paperboard moisturizing and pressware forming system of  claim 11 , wherein the pressware forming system further comprises a second control system configured to determine a forming quality of the forming station, the first control system being configured to change the first feed rate based on the forming quality determination. 
     
     
         15 . The in-line paperboard moisturizing and pressware forming system of  claim 14 , wherein the first control system is further configured to change a water flow rate of the water supply based on the forming quality determination. 
     
     
         16 . The in-line paperboard moisturizing and pressware forming system of  claim 11 , the pressware forming system further comprising a picking station downstream of the forming station and configured to pick shaped products from the forming tool. 
     
     
         17 . The in-line paperboard moisturizing and pressware forming system of  claim 16 , the pressware forming system further comprising a stacking station downstream of the picking station and configured to receive rows of the shaped products from the picking station. 
     
     
         18 . The in-line paperboard moisturizing and pressware forming system of  claim 16 , the pressware forming system further comprising a chopping station downstream of the picking station and configured to cut waste paperboard material for recycling or disposal. 
     
     
         19 . A method of moisturizing paperboard material, the method comprising steps of:
 dispensing paperboard material from a supply roll carrier;   metering water to a water spreader via a pump of a water supply;   delivering the water from the water spreader evenly to the paperboard material so the paperboard material is evenly moisturized;   advancing the moisturized paperboard material to a pressware forming system;   instructing, via a controller, a motor of the supply roll carrier to advance the paperboard material according to a feed rate; and   instructing, via the controller, the pump to meter the water according to a desired moisture level so that the paperboard material has a desired moisture content as the paperboard material advances to the pressware forming system.   
     
     
         20 . The method of  claim 19 , further comprising steps of:
 detecting, via a moisture reader, a moisture level of the paperboard material after the paperboard material has been moisturized via the water spreader;   detecting, via a roll diameter reader, an amount of paperboard material remaining on the supply roll carrier;   effecting the feed speed and a moisture level of the paperboard material according to user commands received via a human machine interface;   pressing a scoring tool of a scoring station of the pressware forming system against the moisturized paperboard material thereby scoring the paperboard material; and   shaping the moisturized paperboard material via a mold of a forming tool of a forming station of the pressware forming system thereby forming a product.