Issues (1) Product Overview Paper fiber molded tableware is a disposable catering container made from food packaging paper or pulp as a main raw material and subjected to stamping or molding. Compared with polystyrene (EPS) foam plastic tableware, which is still dominant in the market today, it has no toxic side effects on the human body during production and use, and can be naturally degraded after being discarded. This type of tableware is therefore in the 20th century. After the 80's came out, it immediately swept the world, and some developed countries' products have entered the fourth generation. China's research and development of paper fiber cutlery began in the early 1990s, and its promotion prospects have been promising.
(2) Development status As the manufacturing cost of paper fiber molded tableware itself remains high, the product quality is not stable enough, the production scale is small and scattered, and the related external regulations and regulations are lagging behind, lack of supporting funds and the immature consumer market. Therefore, this cross-century green product has so far failed to effectively occupy the domestic market and has assumed the historic mission of eradicating the "white pollution" that has long been high in society, and even shakes people's confidence in their development. Looking at the above-mentioned constraints, the most fundamental issue is still its own problem. The fatal one is that its production scale and batch size do not go up. This has caused the cost and price to fail to come. No matter whether it is quantity or price, it cannot be compared with traditional foaming. Tableware competition. At present, the research and development of paper fiber molded tableware technology and equipment in the country are relatively decentralized and independent. In particular, most of the product manufacturing units are small in scale, and the production volume is not large, the varieties are monotonous, and some are still in the stage of trial production. Meet the growing demand of the market.
To sum up, whether the domestic production and total volume of paper fiber cutlery can be increased to above the economic volume, the formation of economies of scale, the survival of this product, but also related to the sustainable development of the tableware industry. The only correct way to solve this problem is to study large-scale production technologies and develop new products in the system.
Research contents and main ideas (1) Large-scale production technology—In the manufacturing process, the wet method is formed into a dry method, that is, paper pulp molding is changed to paper powder molding. Although this improvement has the same economic effect as the previous process, the pulping process will be pulverized and the subsequent processes will greatly reduce the energy consumption and time for semi-finished product drying.
——Change the single vertical reciprocating molding equipment to the assembly line plane rotary wheel molding equipment on the manufacturing equipment. Although this improvement has increased the absolute cost of equipment investment at one time, it has also doubled the production capacity of the equipment. Its input-output cost, ie relative cost, is much lower than that of stand-alone equipment. The one-off molding quantity and speed of the equipment has always been the "knock neck" process that restricts its production capacity.
——The single-piece mold is changed to a combined mold on the forming mold, that is, a plurality of units can be arranged on a single mold, that is, the consumption of the unit mold is saved, and the number of one-time molding is increased.
- Drying on drying tunnel drying equipment. Drying in single machine production is often heated by a mold. Drying takes a long time and the batch size is small when the Dacheng (whole) type is used. Drying and drying in a tunnel kiln can increase the drying batch size and speed.
- In the sterilization process, the heat sterilization is changed to ultraviolet tunnel sterilization. This device can be installed after the drying process and before the packaging process.
——In the operation, manual and semi-automatic are changed into full-automatic electromechanical integration and computer control is introduced. From the materials to the ingredients, molding, finishing, drying, sterilization, packaging and transfer of all processes between the use of automated assembly line equipment, which can reduce the number of operators, improve the manufacturing speed.
The current key or relative difficulty of this technology is 3 points.
1 First of all, it is still an additive problem, because in addition to the waterproof, oil-repellent, ink-resistant, and non-toxic functions of the wet process additives, the dry process additives should be particularly emphasized that they should have solidification capabilities. Otherwise, how to form a scattered sand.
2 The second is the material transfer technology. It is necessary to ensure that the paper powder particles are distributed evenly between the mold gaps. This is not a problem for the fluid-like pulp in the wet method, but it is just for the paper powder that is solid. Problem. How to solve, the initial idea is to pre-mix the additives and paper powder into a paste.
3 Finally, there is also a mold problem, because the assembly mold manufacturing, installation requirements are much higher than the stand-alone single-piece mold.
(2) Series Product Development - Develop new varieties and specifications. Existing box-shaped, bowl-shaped cutlery can be made in the shape and specifications of some variants, such as covered, no cover, large, medium and small capacity. In addition, dishes, dishes, cups, pots, bowls, and other utensils can also be developed, and different specifications can be added. In addition to white, color can be considered or painted to meet people’s consumption habits. Consumer psychology and consumer demand. It can be imagined that on the table in the near future, disposable "full-paper" paper cutlery including a paper table, a paper napkin, chopsticks, and a paper spoon can be included.
—— Formulate standards for serial products, formulate technical standards in accordance with product varieties and specifications, and make them serialized and standardized. Can first engage in corporate standards, and then engage in industry standards, national standards, or the use of international standards and advanced foreign standards.
- The key to this technology is the development of new product molds. Because, for each product of a different variety and different specifications, a new set of molds needs to be developed, and it is almost impossible to implement universal universal molds.
Prediction of project results (1) Social effects If the project is successfully developed and timely promoted, white pollution caused by domestic foam plastic tableware can be eradicated in 3 to 5 years, and the sustainable development of the Chinese tableware industry can be promoted, and the production process of foam plastic products can be reduced. The destruction of the atmospheric ozone layer in the Freon area fulfills China’s obligations as a party to the Montreal International Convention to improve the people’s lives and living environment and improve people’s dietary hygiene and health.
(2) Economic effects China has a population of 1.3 billion people. Currently, the domestic consumer demand for all kinds of paper tableware is about 10 billion pieces/year, and it is predicted that it can be turned 1 to 2 times in 5 years, reaching 200 to 40 billion pieces/year. The average per capita is only 150 to 300 pieces per year, and less than 1 per day. If we consider the increase in the number of inbound tourism and the export to neighboring countries in South Asia and Southeast Asia, the potential of the consumer market is huge, which is the highest in the world. According to the above estimation alone, if large-scale production technology is used, and a series of new product developments are carried out, each integrated cost reduction will be 0.1 yuan or more, and the country will be able to increase direct profits by 2-4 billion yuan each year. (Author: Nantong Rugao Plastic Machinery Plant weeks climax)
(2) Development status As the manufacturing cost of paper fiber molded tableware itself remains high, the product quality is not stable enough, the production scale is small and scattered, and the related external regulations and regulations are lagging behind, lack of supporting funds and the immature consumer market. Therefore, this cross-century green product has so far failed to effectively occupy the domestic market and has assumed the historic mission of eradicating the "white pollution" that has long been high in society, and even shakes people's confidence in their development. Looking at the above-mentioned constraints, the most fundamental issue is still its own problem. The fatal one is that its production scale and batch size do not go up. This has caused the cost and price to fail to come. No matter whether it is quantity or price, it cannot be compared with traditional foaming. Tableware competition. At present, the research and development of paper fiber molded tableware technology and equipment in the country are relatively decentralized and independent. In particular, most of the product manufacturing units are small in scale, and the production volume is not large, the varieties are monotonous, and some are still in the stage of trial production. Meet the growing demand of the market.
To sum up, whether the domestic production and total volume of paper fiber cutlery can be increased to above the economic volume, the formation of economies of scale, the survival of this product, but also related to the sustainable development of the tableware industry. The only correct way to solve this problem is to study large-scale production technologies and develop new products in the system.
Research contents and main ideas (1) Large-scale production technology—In the manufacturing process, the wet method is formed into a dry method, that is, paper pulp molding is changed to paper powder molding. Although this improvement has the same economic effect as the previous process, the pulping process will be pulverized and the subsequent processes will greatly reduce the energy consumption and time for semi-finished product drying.
——Change the single vertical reciprocating molding equipment to the assembly line plane rotary wheel molding equipment on the manufacturing equipment. Although this improvement has increased the absolute cost of equipment investment at one time, it has also doubled the production capacity of the equipment. Its input-output cost, ie relative cost, is much lower than that of stand-alone equipment. The one-off molding quantity and speed of the equipment has always been the "knock neck" process that restricts its production capacity.
——The single-piece mold is changed to a combined mold on the forming mold, that is, a plurality of units can be arranged on a single mold, that is, the consumption of the unit mold is saved, and the number of one-time molding is increased.
- Drying on drying tunnel drying equipment. Drying in single machine production is often heated by a mold. Drying takes a long time and the batch size is small when the Dacheng (whole) type is used. Drying and drying in a tunnel kiln can increase the drying batch size and speed.
- In the sterilization process, the heat sterilization is changed to ultraviolet tunnel sterilization. This device can be installed after the drying process and before the packaging process.
——In the operation, manual and semi-automatic are changed into full-automatic electromechanical integration and computer control is introduced. From the materials to the ingredients, molding, finishing, drying, sterilization, packaging and transfer of all processes between the use of automated assembly line equipment, which can reduce the number of operators, improve the manufacturing speed.
The current key or relative difficulty of this technology is 3 points.
1 First of all, it is still an additive problem, because in addition to the waterproof, oil-repellent, ink-resistant, and non-toxic functions of the wet process additives, the dry process additives should be particularly emphasized that they should have solidification capabilities. Otherwise, how to form a scattered sand.
2 The second is the material transfer technology. It is necessary to ensure that the paper powder particles are distributed evenly between the mold gaps. This is not a problem for the fluid-like pulp in the wet method, but it is just for the paper powder that is solid. Problem. How to solve, the initial idea is to pre-mix the additives and paper powder into a paste.
3 Finally, there is also a mold problem, because the assembly mold manufacturing, installation requirements are much higher than the stand-alone single-piece mold.
(2) Series Product Development - Develop new varieties and specifications. Existing box-shaped, bowl-shaped cutlery can be made in the shape and specifications of some variants, such as covered, no cover, large, medium and small capacity. In addition, dishes, dishes, cups, pots, bowls, and other utensils can also be developed, and different specifications can be added. In addition to white, color can be considered or painted to meet people’s consumption habits. Consumer psychology and consumer demand. It can be imagined that on the table in the near future, disposable "full-paper" paper cutlery including a paper table, a paper napkin, chopsticks, and a paper spoon can be included.
—— Formulate standards for serial products, formulate technical standards in accordance with product varieties and specifications, and make them serialized and standardized. Can first engage in corporate standards, and then engage in industry standards, national standards, or the use of international standards and advanced foreign standards.
- The key to this technology is the development of new product molds. Because, for each product of a different variety and different specifications, a new set of molds needs to be developed, and it is almost impossible to implement universal universal molds.
Prediction of project results (1) Social effects If the project is successfully developed and timely promoted, white pollution caused by domestic foam plastic tableware can be eradicated in 3 to 5 years, and the sustainable development of the Chinese tableware industry can be promoted, and the production process of foam plastic products can be reduced. The destruction of the atmospheric ozone layer in the Freon area fulfills China’s obligations as a party to the Montreal International Convention to improve the people’s lives and living environment and improve people’s dietary hygiene and health.
(2) Economic effects China has a population of 1.3 billion people. Currently, the domestic consumer demand for all kinds of paper tableware is about 10 billion pieces/year, and it is predicted that it can be turned 1 to 2 times in 5 years, reaching 200 to 40 billion pieces/year. The average per capita is only 150 to 300 pieces per year, and less than 1 per day. If we consider the increase in the number of inbound tourism and the export to neighboring countries in South Asia and Southeast Asia, the potential of the consumer market is huge, which is the highest in the world. According to the above estimation alone, if large-scale production technology is used, and a series of new product developments are carried out, each integrated cost reduction will be 0.1 yuan or more, and the country will be able to increase direct profits by 2-4 billion yuan each year. (Author: Nantong Rugao Plastic Machinery Plant weeks climax)
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