Multi-tank Moulded Cellulose Pilot

Production of innovative 3D cellulose objects

Produce 3D moulded cellulose objects on a small scale
Test and select fibre raw materials and functional additives
Prototype new products (mould testing, etc.)
Research innovative manufacturing concepts

The little story of the pilot

Have you ever heard of moulded cellulose? Yes, of course, egg cartons... that’s no big deal ! In fact, it has much wider potential in the manufacture of : dishes, plates, containers, cans and even
and even bottles ! This attractive, light, rigid and 100% ecological (renewable, recyclable, biodegradable) material is a response to current environmental issues.
The CTP has therefore developed a pilot plant to produce thermoformed objects in moulded cellulose and has patented an innovative concept : multi-layer moulded cellulose, which provides new functionalities and opens up a whole new range of applications. This facility enables companies to test and prototype their ideas, optimise raw materials and additives and explore new properties.
This new pilot will welcome all your ideas... Contact us !

Link to the episode #PlusBelleLaFibre about the moulded cellulose pilot :
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Characteristics

Forming unit	Drying unit : hot press
Single tank	Pressure : 20 to 50 kN Temperature : up to 240°C Time : variable Suction during thermo pressing
Pulp volume : 20L, 100L, 250L Concentration : 3 to 15 g/l Formation time : modular (1-20 sec) Max vacuum level : 200 mbar absolute (-800 mbar)
Multi tank carousel	Available moulds
Pulp volume 4*40L Ability to produce 2D and 3D objects	2D: 17 x 27 cm plates for screening, optimisation and physical and barrier characterisation. Thickness can be adjusted to obtain variable densities between 0.2 and 1.1 3D: 190 x 140 x 45 mm trays for demonstration purposes Specific moulds to meet customer requirements.
Production output
From 20 to 60 objects per day depending on the complexity of the shape and the number of compositions to be tested.

Description of the equipment

The equipment comprises a wet forming unit with a diluted slurry tank and an arm supporting the vacuum filter mould. The arm dips into the slurry for a few seconds to deposit an initial mat of fibres on the surface of the mould
The multi-tank carousel enables several fibre layers to be added by repeating the process with several tanks of different suspensions.
The preformed single or multi-layer object is then conveyed to the heated press equipped with two male/female moulds. Connected to the vacuum drainage system, the heated press dries the preform at high temperature to produce objects with dense, smooth walls and precise contours. Alternatively, the object can be oven dried following formation, resulting in a rougher surface and lower density, adapted for cushioning applications.

Typical services

Evaluation of fibrous raw materials or functional additives: preparation of pulps, moulding tests in 2D and 3D to the desired characteristics (grammage, thickness, density, etc.) and characterization (physical, mechanical, barriers, etc.)
Assistance with the development of a specific mould. In this case, all the moulds will be adapted to our tools (dimensions, interfacing, etc.) before the moulding tests are carried out.
Development of new production concepts to give 3D objects specific properties: functional barrier, enhanced mechanical properties, special surface characteristics, etc.


Equipment acquired in the context of the MALICS platform with support from the Auvergne-Rhône-Alpes regional.

Also to be seen

Centre of Excellence

Biobased Materials DIVISION