Raw Material Preparation for Packaging

Automated packaging material processing station for filling containers with paper cushions. The station has a paper cushioning device with a dispensing and cutting feature. A robot discharges the cushions from the device. Needle grippers on the robot strip off the cushions. Multiple independent cushion supply lines coordinate production. Robots store cushions in trays. The station can have a housing, conveyor, alignment, and material supply. A controller links the devices.

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Form-fill-seal packaging machine that allows using a common film for different products without needing separate pre-printed films. The machine prints product information on both sides of the film before forming bags. This eliminates the need for different films with pre-printed labels for each product. The printing is synchronized with film transport and can be done with a single printer head. The printed areas are adjacent or integrated to avoid needing separate printer heads for each side. The printer contacts the heated areas for thermal printing.

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Device for producing custom slit sheet packing material on demand for shipping applications. The device allows companies to make their own slit sheet packing material tailored to specific packaging requirements instead of relying on pre-slit rolls. It has a movable carriage with rotary blades inside a chamber. The carriage can move back and forth to cut patterns into the packing material as it advances through the device. A controller moves the carriage in response to user input. This allows creating custom slit patterns on the packing material to optimize fill, cushioning, and protection for different sized packages.

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Packaging material manufacturing machine that pulls material from the inside of a roll to make products like cushioning packaging. The machine has a feed mechanism with a deflection roller to introduce the material from the roll interior. This reduces the risk of web breaks compared to feeding from the outside. The feed mechanism has a guide wall that funnels the material towards the deflection roller. The guide wall covers a section of the rollers and protrudes over them. This helps deflect the material into the rollers. The feed mechanism also has a shorter guide path compared to the roller length. The shorter path reduces the material's travel distance. The machine further includes a forming device downstream to shape the material into the final product.

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A biodegradable packaging material made from chicken feathers and a biodegradable polymer called polybutylene adipate terephthalate (PBAT). The process involves extracting keratin from chicken feathers and combining it with PBAT to create a biodegradable composite film for packaging applications. The goal is to replace conventional plastics with a sustainable and compostable alternative that reduces waste and environmental impact.

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Method for manufacturing a rigid, eco-friendly paper string for packaging that can replace plastic straps. The paper string is made by applying an adhesive to a paper base, joining two side bands, folding the paper multiple times, coating it, and winding it. This provides a paper string that is stronger, doesn't break easily, and can be reused or recycled after packaging. The coated paper string is wound around a roller to increase rigidity. It is a sustainable alternative to plastic straps as it can be reused, recycled, and composted after use.

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An automated rice straw packaging machine that cuts rice straw into smaller pieces for easier packaging and compacting. The machine has a sliding blade to chop straw, telescopic rods to move straw, a conveyor to transport straw, motorized rollers to compress straw, a weight sensor to detect full rings, a robotic gripper to tie straw bundles, a motorized spool to wrap and unwrap adhesive sheets around straw, and a circular slider to pack straw. The machine can automatically pack rice straw into compact rings with tied bundles and adhesive sheets.

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A process for making biodegradable packaging materials from waste jute bags that has enhanced mechanical strength, water absorption, flame and heat resistance, low thermal conductivity, and high reflectance. The process involves delignifying the waste jute, phosphorylating it, washing, drying, and further treatments like homogenization, sonication, freezing, and lyophilization to modify the jute fiber properties. This results in biodegradable packaging materials with improved functionalities like water absorption, flame retardancy, and low thermal conductivity compared to unmodified jute bags.

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Folding device for forming gussets in packaging films before sealing to prevent excess film on the sides. The folding device has multiple coupling mechanisms with crank and swing elements. The folding fingers engage the film from the sides and inwardly fold it. The crank elements rotate at different phases to coordinate sequential finger engagement. A drive device controls the crank rotations. This allows simultaneous finger movement without collisions. It folds the film before sealing to eliminate excess on the sides.

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Eco-friendly packaging composition made from fried food waste, biomass, and a solvent. The composition can be molded into 3D structures and used as a sustainable packaging alternative. The fried food waste provides a binding agent, the biomass adds strength, and the solvent helps mix it all together. The composition is derived from fried food scraps, like oil-rich crumbs, and uses biodegradable materials to reduce environmental impact compared to traditional petroleum-based plastics.

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Manufacturing method for high-speed, cost-effective production of barrier-coated paper or cellulose-based substrates with improved gas barrier properties for use in packaging materials like cartons. The method involves coating a web of selected cellulose substrate at high speed using aqueous solutions of gas barrier polymers like PVOH/EVOH. The coated substrate is then dried while maintaining surface temps 60-95°C. Repeating the coating-drying steps once or more. This provides thin, adherent barrier coatings on the cellulose substrate without defects. The resulting barrier-coated cellulose substrate can be further coated with nanometer thin vapor deposited metal/oxide layers. The coated substrate can then be laminated into packaging materials with outer layers for protection and sealing.

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Laminate with high oxygen and water vapor barrier properties that can be applied to substrates using a simplified manufacturing process compared to depositing thin films. The laminate has a barrier layer made from a composition containing a water-soluble polymer, an inorganic layered compound, and optionally metal alkoxides or hydrolyzed metal alkoxides. The ratio of water-soluble polymer to inorganic layered compound in the barrier composition is 0.3 to 3.0. This balanced composition provides good barrier properties without requiring additional thin film deposition steps. The laminate can be used in packaging bags to reduce oxygen and water vapor transfer to packaged goods.

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Modular apparatus and method for manufacturing cushioned packaging receptacles like mailers using paper instead of plastic. The apparatus allows switching between paper-paper and polymer-polymer materials. It has specific modules for embossing, coating, sealing, folding, compressing, and cutting paper layers to make cushioned receptacles. This enables making reusable mailers with paper cushioning instead of plastic. It also allows making receptacles with polymer cushioning and polymer outer layers for compatibility with existing equipment.

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A process for manufacturing biodegradable and compostable packaging material from flower waste. The process involves extracting cellulosic substance from dried flower waste using sodium hydroxide, then combining it with a water-soluble polymer, adhesive, epoxy resin, and hardening agent to form a viscous solution. The solution is stirred, pressed, and cured to create the biodegradable packaging material. The flower waste-based packaging is compostable and degrades easily when buried.

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Cellulose-based wrapping paper with transparent areas that can be easily manufactured without the need for plastic windows. The paper has cellulose layers with paraffin coating on one side that crystallizes into a transparent zone. The paraffin coating is applied to one side of the cellulose paper and allowed to crystallize, creating the transparent zone. This is done during the paper manufacturing process. The paraffin coating forms a crystalline structure that allows light transmission through the paper. The transparent zones can serve as windows in packaging materials. The paper can be made without separate plastic window materials, reducing cost and complexity.

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Eco-friendly and biodegradable system for packing vials in a way that reduces waste, improves packing efficiency, and protects vials during transport. The system uses flat cardboard unformed vial holders that are transformed into 3D formed holders using a picking and folding unit. Vials are then placed into the formed holders using a matrix unit. This eliminates the need for separate vial holders and allows forming the holders on-demand. A camera-based rejection unit checks for defects. The formed vial assemblies are loaded into cartons using a conveyor system. The cardboard holders are biodegradable and eliminates the need for plastic holders.

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A solventless two-component adhesive for packaging materials that provides excellent adhesion to metal foils and metal deposition layers. The adhesive contains a polyisocyanate composition with a specific polyisocyanate compound and a polyol composition containing a polyol and a compound like dimethylolpropionic acid or dimethylolbutanoic acid. The adhesive can be used to laminate base materials without volatile organic solvents, reducing environmental impact and improving worker safety compared to traditional solvent-based adhesives. The adhesive cures when the two components are mixed and applied to the base materials before bonding.

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Preparing a grass-derived multifunctional nanomaterial film for food packaging that enhances mechanical properties, water resistance, UV protection, oxygen scavenging, and antimicrobial properties. The film is made by incorporating nanomaterials extracted from dried darbha grass, like carbon dots, cellulose nanofibers, and silver nanoparticles, into PVA films. The grass nanomaterials improve the film's performance compared to standard PVA films.

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Barrier-coated cellulose-based substrate for oxygen-sensitive packaging applications. The substrate has a thin cellulose base with a gas barrier coating. But the key is a ductile pre-coating applied before the gas barrier. This allows thinner, more cost-effective gas barrier layers. The ductile pre-coating provides a smooth foundation for the gas barrier and helps prevent pinholes. The pre-coating is made by dispersion coating onto the cellulose base, then drying and calendering.

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Method for producing biodegradable and compostable containers and packaging using agricultural and food waste as starting material. The method involves mixing the waste with a plasticizer, hydrothermal treatment to modify the components, and thermoforming to shape the material into containers. The resulting containers have high biodegradability and compostability due to using waste with specific fiber, lipid, protein, and carbohydrate content ranges. The method enables sustainable production of biodegradable packaging without additional waste or emissions.

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A packaging machine, heating device, and method to improve packaging quality by preventing material damage and maintaining appearance. The machine has an upstream heating section with rollers that bend the packaging material to raise its temperature. This heated material is then fed into the bag maker where it bonds better due to the raised temperature. The heating section prevents floating and damage issues by softening the material before sealing.

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Producing paper packaging material with reduced energy consumption compared to conventional corrugated cardboard. The method involves forming a wave structure directly in the paper without using heat or steam. It involves deforming a paper base material between corrugating rollers to create a structural layer with parallel waves. This eliminates the need for energy-intensive corrugating processes. The paper used has specific properties like elongation of at least 5% in the machine direction. The resulting packaging material has comparable properties like strength and tear resistance compared to corrugated cardboard.

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A method to produce paper-based packaging material with reduced energy consumption compared to conventional corrugated cardboard. The method involves forming the packaging material by plastic deformation of a base paper using corrugating rollers without steam or heat. The resulting structural layer has a wave structure similar to corrugated cardboard but without the energy-intensive corrugating process. The base paper is kraft paper with high elongation to allow plastic deformation.

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Producing a printable, multi-layer liner web for packaging with improved print quality and sustainability. The method involves making a printable packaging liner with a white, printable top layer by combining bleached and unbleached pulps. The process is: 1) Make a bleached pulp for the top layer. 2) Make an unbleached pulp for the bottom layer. 3) Form the top layer from the bleached pulp. 4) Form the bottom layer from the unbleached pulp. 5) Assemble the layers into the final liner web. The unbleached bottom layer prevents contaminants from transferring to the top layer, maintaining white print quality.

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Device for reliably separating and supplying a single Tyvek sheet from a stack of sheets stored in a container for sealing packaging containers. The device has a storage unit with guide bars and a separation section. The separation section has air injection holes to initially separate the top sheet from the stack. The top sheet is then supported at both ends by jaws and curved upward. This deformation separates the top sheet from the rest of the stack.

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A method and device for producing fiber-based packaging with deeper cavities for blister packaging applications. The method involves forming cavities in a fiber-based packaging material, then joining a second packaging element to create the final blister pack with deeper cavities. The forming step shapes the fiber-based element with a first opening cross section, and the joining step joins it to a second element to change the opening cross section and create deeper cavities. The joining also allows steeper cavity flanks compared to forming alone. This enables deeper fiber-based cavities for blister packaging compared to just forming the cavities in fiber-based material.

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Automated manufacturing process for producing packaging buffer paper that can be used for delivery packaging as well as various cushioning applications. The process involves laminating bubble wrap onto a base paper, heating and shaping the laminated paper before cutting it to size. This allows mass production of thin, paper-based cushioning material that can be easily disposed of after use. The automated process involves transferring the bubble wrap onto the base paper, firing the laminated paper to fix the shape, vertically and horizontally transporting it, then cutting it to size.

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A method for manufacturing laminated packaging material webs for liquid food containers using inkjet printing and infrared drying without reducing paperboard moisture levels. The method involves inkjet printing color pigments and solvent onto the paperboard, then drying using infrared radiation applied to the printed side. An absorption surface on the other side absorbs transmitted IR to prevent paperboard moisture loss. This allows full ink drying without dehydrating the paperboard.

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Automated system for making padded mailers or pouch packages with cushioning. The system has two key components: a machine that converts sheet material into a strip of expanded dunnage, and a machine that assembles the pouch package from the expanded strip. The first machine applies adhesive to one sheet, layers it with an expanded slit sheet, and bonds them together to create the expanded strip. The second machine creases the strip, applies adhesive to the ends, and folds the strip into a pouch shape.

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Method for manufacturing eco-friendly packaging material using mushroom mycelium that is biodegradable and compostable. The method involves culturing mushroom mycelium on a medium made of sawdust and rice bran, then removing the culture vessel to allow secondary growth. This results in a mycelium composite material that can be dried to create an alternative to Styrofoam packaging. The composite material is made using a sawdust:rice bran ratio of 80:20 for optimal mycelium growth.

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Method to manufacture gas barrier laminates for packaging that provides good appearance and barrier performance. The method involves forming a metal oxide layer on a base layer using vacuum deposition, then applying a gas barrier coating composition, preheating with IR rays, and curing at 50-120°C. This allows uniform curing of the barrier layer without excessive heat on the laminate, preventing wrinkles and hard spots. The coating composition contains silanes, siloxanes, and water-soluble polymers. The method also allows an anchor coat layer between base and metal oxide for better metal adhesion.

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Robotic system for automated unfolding, forming and gluing of cardboard boxes to improve efficiency and speed in packaging applications. The system uses a robot and automated grippers to unfold and form blank cardboard sheets into boxes, a sliding table for gluing, and folding guides. This allows fully automated cardboard box production without manual intervention for unfolding and forming.

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Packaging system and feeding method for a deep-drawing packaging machine that eliminates the need for pre-formed cardboard trays and allows on-demand tray formation. The feeding system uses a transport belt to move cardboard blanks into a transfer area inside the packaging machine. Lifting devices collect blanks from the belt one by one, fold them into tray shapes, and move them into positions for the gripper to pick up. This intermittent lifting and advancing forms the trays in-place without requiring pre-formed blanks.

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Making biodegradable plastic films from food waste and food byproducts using a simple extraction and blending process. The method involves treating starchy foods like bananas, potatoes, or grains with an acid to extract the starch. The starch precipitates are separated, dried, and mixed with water to form a slurry. This slurry can be cast into films along with other biopolymers like chitosan. The films have properties like strength, elongation, and water resistance suitable for packaging applications. The blended films can be biodegradable in water, soil, or compost.

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An immersion treatment apparatus for packaging material like sheets used in container production that reduces defects. The apparatus has a tank filled with sterilizing liquid and a pump to quickly fill the tank. A roller inside the tank rotates and draws the sheet into the liquid. This immersion treatment can sterilize and clean the sheet. The quick filling pressure can damage the sheet, but lower pressures would extend fill time. The roller and sheet contact prevent damage. The tank bottom has a screen to prevent debris from entering the roller. This reduces container defects caused by sheet issues generated during sterilization due to high filling pressures.

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Process to make biodegradable bottles using natural materials like areca leaf and cellulose bio-polymer. The process involves cleaning and soaking the areca leaf sheath, drying it, compressing it with cellulose film to form a biodegradable material, thermoforming into bottle shape, and trimming. The resulting biodegradable bottle reduces plastic waste and promotes environmental sustainability compared to conventional plastic bottles.

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Automated system for loading packaging material rolls into packaging machines without the need for conveyors. An automated guided vehicle (AGV) with a roll holder moves rolls to a parking station near the packaging machine. The roll is then transferred to the paper tube shaft using a guide. A support member lifts the roll's end and attaches it to the machine's end holder. The AGV moves the roll between the parking station and machine using air-driven movers. The support member keeps the roll's end straight and prevents bending during transport. It also prevents roll ends from getting misaligned during loading.

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A method for creating cardboard blank for packaging items using a laser scoring machine that allows customization of blank size without expensive tool changes. The method involves laser scoring and cutting a cardboard sheet to create the blank shape for packing items. The laser allows dynamic adjustment of scoring lines based on the item dimensions. This eliminates the need for swapping expensive mechanical scoring tools for each item size. The laser scores the sheet without needing to demount and reposition tools. It enables on-the-fly blank customization for different item sizes using the same laser setup.

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Packaging machine for forming sterile packets of pourable food products from a web of packaging material. The machine has a stamping apparatus to apply opening devices to the web before forming the packets. The stamping apparatus is located upstream of a sterilization device that uses electron beam irradiation to sterilize the web. By stamping the opening devices before sterilization, lower sterilization doses are needed compared to sterilizing the web with the devices already applied. This reduces the risk of degrading the opening devices during sterilization.

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Automatic packaging material roll supply device for a packaging machine that uses an automated guided vehicle (AGV) to move and transfer packaging rolls. The AGV has a roll holder to grip and transport rolls. It stops at a station near the machine, aligns the roll holder with the machine's roll feed, and transfers rolls between them. The AGV can also collect used rolls and core tubes from the machine. This allows automated, space-saving roll supply without needing dedicated conveyors.

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Composite paper for packaging applications made from cellulose fibers and mineral particles derived from purified phosphate mining waste. The paper aims to repurpose phosphate washing sludge as a sustainable alternative raw material in packaging. The sludge undergoes chemical treatment to remove toxic metals. The treated sludge particles are mixed with cellulose fibers to make composite paper. The composite paper has improved thermal and fire resistance compared to cellulose-only paper. It can be further coated with thermoplastic materials for enhanced water resistance.

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Automated wrapping paper cutting and separation device for packaging boxes that significantly improves productivity by allowing continuous box forming. It cuts paper, separates wrapping paper from waste, stores good wrapping paper separately, reads images to find defects, and discharges defective wrapping paper. This avoids manual separation, reduces damage, and allows continuous box forming after cutting.

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A method for manufacturing a packaging sheet with controllable internal structure. The method involves depositing a mixture of natural fiber (first fibers) and coated fiber (second fibers with a thermoplastic coating) onto a mesh belt. The deposited fiber web is heated to melt the coating on the second fibers. The web is then consolidated and cooled under pressure. This causes the coating to solidify and bind the second fibers together at contact points. The natural fiber retains its original shape and provides additional structure. The resulting packaging sheet has a controlled internal fiber arrangement with bound coated fiber regions and unbound natural fiber regions.

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Method for producing packaging elements from flat fiber materials like paper and cardboard with improved deep drawing capabilities. The method involves making cuts into the flat material and then forming it into 3D shapes. The cuts are placed adjacent to the formed areas to prevent tearing during deep drawing. The cuts allow controlled folding and wrinkling of the material during forming. This allows steeper flanks and more complex shapes compared to direct deep drawing of flat fiber materials.

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Recycling discarded laminated wallpaper into packaging cushioning material by grinding it into individual fibers and improving fiber retention during papermaking. The ground fibers are pulped in water to form a slurry. Retention agents like polymers and microparticles are added to enhance fiber binding during papermaking. This improves the amount of fiber that adheres to the mold and forms the final product. The resulting paper cushioning material can be used in food packaging applications.

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Biodegradable packing material made from plant fibers like corn husks that is environmentally friendly and can replace plastic foam filler. The packing material is manufactured by blending corn husks with water to form a paste, adding starch, carbonate material, and a mild acid, pouring into a mold, and heating. The acid-carbonate reaction generates gas that forms closed cellular structures for compressibility. The biodegradable packing material is made from renewable resources, unlike plastic foam fillers.

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A method for producing a packaging element from a flat fiber material like paper that involves partially moistening defined surface areas of the fiber material before forming the packaging element. The moistening is done using a porous moisture transfer medium like a sponge. This allows targeted introduction of moisture into specific areas without saturating the entire fiber material. This preconditioning improves forming processes like molding and joining by enabling better shaping and joining of moistened sections. The transfer medium can be compressed to actively suck in humidification medium or a negative pressure applied to the other side for active suction. The moisture transfer medium is controlled to release an equal amount for each moistened area.

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Active biodegradable plastic packaging film made from pear waste that has improved mechanical properties, UV barrier, oil barrier, and biodegradability compared to conventional plastics. The film is made by combining mashed pear peel and pulp extract, starch solution, and glycerol. The pear waste acts as a filler to enhance properties, starch as a crosslinking agent, and glycerol as a plasticizer. The film is cast and cured to create a biodegradable packaging material with functional properties like antioxidant activity and moisture control. The film can be used in food packaging, pharmaceuticals, and other applications requiring sustainable and active packaging solutions.

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Method of making biodegradable packaging material from rice straw waste using delignification and phosphorylation to create sustainable, biodegradable, and thermally stable packaging. The process involves delignifying rice straw to remove lignin, then phosphorylating it to improve properties like strength and water resistance. The phosphorylated rice straw is dispersed in water, sonicated, cast, and dried to make films, cups, aerogels, and drinking straws for food packaging. The biodegradable packaging replaces single-use plastics and reduces waste.

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Automated system to convert web-shaped starting material into packaging bags using a feeding device, forming device, and guide device. The system allows converting web materials like paper into bags without manual setup. The feeding device pulls the web. The guide device safely guides the leading edge from feed to forming. The forming device shapes the web into a pocket with a receiving cavity. The guide and forming devices have deflections to guide the web. The feeding device pushes the web. This allows automated, consistent, and fast conversion of web materials into bags.

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