Pulp Storage Containers
Disadvantages of Plastic Containers
In 2015 many products are packaged and stored using various forms of plastic. The production of plastic is heavily dependent on unsustainable use of fossil fuels, this means in the future plastic will become more costly to manufacture.
I realise this is a huge issue for 2070 and my solutions are based around the requirement in 2070 for a sustainable, low-cost and easy to manufacture replacement to traditional plastic storage container. Paper and cardboard is highly recyclable, many paper plants in NZ produce only recycled pulp, breaking down used paper with water and chemicals. This recycled pulp is then reused. Most traditional plastic ends up in a land fill, and could be replaced with sustainable, recyclable paper packaging.
Plastic Storage containers are used everywhere from holding food and ingredients air-tight in the kitchen, to organising and cataloguing parts and products in warehouses. These sorts of containers are usually made from polycarbonate, low density polyethylene or other similar polymer plastics.
Several studies have shown that cheaply made or incorrectly synthesised plastic containers can leech the hardener Bisphenol A (BPA) into our foods. BPA copies the effects of oestrogens and interferes with the hormone levels and cell signalling system in the body. Exposure to these types of chemicals can promote cancer growth, diabetes, infertility, heart disease and is harmful to children’s development.
Introducing the Moulded Pulp Storage Container
A formed pulp storage container does not contain harmful chemicals, is renewable, biodegradable and recyclable. It is therefore feasible that plastic storage containers could be futureproofed for 2070 by making them out of pulp.
Producing Storage containers out of pulp will fill a gap in the market in 2070. With petroleum running out therefore meaning plastic will become prohibitively expensive to produce, a way to store items is needed. One example of a use for this type of container is in the food industry, dry foods will need to be stored in airtight containers in order to prevent them from going off.
This CAD animation shows how the moulds work to form the pulp base of the container
The file must load before it plays smoothly
How the Pulp is Formed
An egg carton style transfer moulded pulp container will not be able to produce pulp at the thickness required and therefore the strength required to hold heavy items. A process is called “Thermoformed Fibre” moulded pulp is being developed, a pulp sheet at the correct thickness is pressed into a heated core and cavity mould. See the mould in action in the .gif above (it does load, be patient!) The pulp cures under high heat and high pressure, creating a smooth product that has the appearance and strength of a plastic material.
It produces a much higher quality, more accurate, better defined and denser product than a traditional pulp transfer mould. A pulp container created using this method will replace plastic containers in the future. Some plastic containers employ a rubber seal to ensure the product is air tight. This will still be possible with a thermoformed paper containers as the rigidity is similar to plastic, this should allow a tight seal for preserving foods.
Timeline
