Composite Containers For Bulk Solids, Related Systems And Methods

Abstract

A container for holding bulk solids, the container including a tubular body extending at least partially around an interior of the container to form a tubular body having a top end and a bottom end, at least one sealing member positioned in the interior of the container spaced away from each of the top end and the bottom end of the tubular body, the at least one sealing member sealably engaging at least a portion of the tubular body, a reclosable lid attached to the top end of the tubular body to form a closed top end of the container, the reclosable lid comprising pulp fibers, and a bottom plate attached to the bottom end of the tubular body to form a closed bottom end of the container, the bottom plate comprising pulp fibers.

1 . A container for holding bulk solids, the container comprising:
 a tubular body extending at least partially around an interior of the container to form a tubular body having a top end and a bottom end;   at least one sealing member positioned in the interior of the container spaced away from each of the top end and the bottom end of the tubular body, the at least one sealing member sealably engaging at least a portion of the tubular body;   a reclosable lid attached to the top end of the tubular body to form a closed top end of the container, the reclosable lid comprising molded pulp fibers; and   a bottom plate attached to the bottom end of the tubular body to form a closed bottom end of the container, the bottom plate comprising molded pulp fibers.   
     
     
         2 . The container of  claim 1 , wherein the bottom plate is free from plastic material. 
     
     
         3 . The container of  claim 2 , wherein the bottom plate defines an outward flange engaged with the bottom end of the tubular body. 
     
     
         4 . The container of  claim 2 , further comprising a rim attached to the top end of the tubular body above the sealing member such that the reclosable lid contacts the rim. 
     
     
         5 . The container of  claim 4 , wherein the rim comprises pulp fibers and is free from plastic material. 
     
     
         6 . The method container of  claim 4 , wherein the at least one sealing member is a top sealing member spaced away from each of the top end of the tubular body and the bottom end of the tubular body, and the container further comprises a bottom sealing member positioned in the container spaced away from each of the top end of the tubular body, the bottom end of the tubular body, and the first sealing member. 
     
     
         7 . A method of forming a container for holding bulk solids, the method comprising:
 obtaining a body blank;   positioning the body blank extending at least partially around an interior of the container to form a tubular body having a top end and a bottom end;   positioning at least one sealing member in the interior of the container spaced away from each of the top end and the bottom end of the tubular body, the at least one sealing member sealably engaging at least a portion of the tubular body;   attaching a reclosable lid to the top end of the tubular body to form a closed top end of the container, the reclosable lid comprising molded pulp fibers; and   attaching a bottom plate to the bottom end of the tubular body to form a closed bottom end of the container, the bottom plate comprising molded pulp fibers.   
     
     
         8 . The method of  claim 7 , wherein the bottom plate is free from plastic material. 
     
     
         9 . The method of  claim 8 , wherein the bottom plate defines an outward flange, and attaching the bottom plate comprises engaging the bottom end of the tubular body with the flange of the bottom plate. 
     
     
         10 . The method of  claim 8 , wherein attaching the reclosable lid to the top end of the tubular body comprises attaching a rim to the top end of the tubular body above the at least one sealing member such that the reclosable lid contacts the rim. 
     
     
         11 . The method of  claim 10 , wherein the rim comprises pulp fibers and is free from plastic material. 
     
     
         12 . The method of  claim 11 , wherein the at least one sealing member is a top sealing member spaced away from each of the top end of the tubular body and the bottom end of the tubular body, and the method further comprises positioning a bottom sealing member in the container spaced away from each of the top end of the tubular body, the bottom end of the tubular body, and the first sealing member, the bottom sealing member sealably engaging the tubular body. 
     
     
         13 . The method of  claim 7 , wherein positioning the body blank extending at least partially around the interior of the container comprises transferring the body blank to a body forming station, bending the body blank with the body forming station, and bringing two opposing edges of said body blank together in an end-to-end join with the body forming station to form an intermediate container, the at least one sealing member is a top sealing member, and positioning the top sealing member in the interior of the container comprises transferring the intermediate container to a top sealing station and attaching the top sealing member to the tubular body with the top sealing station. 
     
     
         14 . The method of  claim 13 , further comprising transferring the intermediate container to a filling station and filling the intermediate can with bulk solids through the bottom end of the tubular body with the filling station to form a filled intermediate container. 
     
     
         15 . The method of  claim 14 , further comprising transferring the filled intermediate container to a bottom sealing station and sealably attaching a bottom sealing member to the tubular body such that the bottom sealing member is spaced away from the top sealing member. 
     
     
         16 . The method of  claim 15 , further comprising positioning filled intermediate container on a conveyor and transferring the filled intermediate container to a lid attachment station, attaching the reclosable lid comprises attaching the reclosable lid to the top end of the tubular body with the lid attachment station. 
     
     
         17 . The method of  claim 16 , further comprising transferring the filled intermediate container to a top rim application station and attaching a rim to the top end of the tubular body above the sealing member with the top rim application station such that the reclosable lid is positioned contacting the rim. 
     
     
         18 . The method of  claim 17 , wherein filling the intermediate can with bulk solids comprises supplying a protective gas to the bulk solids. 
     
     
         19 . The method of  claim 18 , further comprising positioning a scoop between the top sealing member and the reclosable lid in the interior of the container. 
     
     
         20 . An assembly line for forming a container for holding bulk solids, the assembly line comprising:
 a supply of body blanks, sealing members, reclosable lids, and bottom plates, the bottom plates and the reclosable lids comprising molded pulp fibers;   a body forming station for bending a body blank from the supply of body blanks at least partially around an interior of the container;   a sealing station for attaching a sealing member from the supply of sealing members to the tubular body in the interior of the container;   a filling station for filing the interior of the container with bulk solids through a bottom end of the tubular body;   a bottom plate application station for attaching a bottom plate from the supply of bottom plates to the bottom end of the tubular body to form a closed bottom end of the container;   a lid attachment station for attaching a reclosable lid from the supply of reclosable lids to the top end of the tubular body to form a closed top end of the container; and   a body plate application station for attaching a bottom plate from the supply of bottom plates to the bottom end of the tubular body to form a closed bottom end of the container.   
     
     
         21 . The assembly line of  claim 20 , wherein the bottom plates of the supply of bottom plates are free from plastic material. 
     
     
         22 . The assembly line of  claim 21 , wherein the reclosable lids of the supply of reclosable lids comprises pulp fibers. 
     
     
         23 . The assembly line of  claim 20 , further comprising a supply of rims and a rim attachment station configured to apply a rim from the supply of rims to the top end of the tubular body. 
     
     
         24 . The assembly line of  claim 23 , wherein the rims of the supply of rims comprise pulp fibers and are free from plastic material. 
     
     
         25 . The assembly line of  claim 24 , wherein the sealing members are top sealing members, the sealing station is a top sealing station for attaching a top sealing member of the supply of top sealing members to the tubular body in the interior of the container, and the assembly line further comprises a supply of bottom sealing members and a bottom sealing station, the bottom sealing station configured to apply a bottom sealing member of the supply of bottom sealing members to the tubular body in the interior of the container spaced away from the top sealing member.