Biodegradable molded articles

A biodegradable molded article produced by molding under pressure a residue remaining after taking out essential portions of effective elements in foods, and/or in materials thereof, such as lees of Sake, squeezed and strained lees of fruits, etc. This enables the residues to be effectively re-utilized by producing therefrom molded articles which can be used in a variety of fields. As being biodegradable, the molded article also permits an easy disposal without creating an environmental problem.

The present invention relates to biodegradable molded articles obtained by 
effectively re-utilizing residues remaining after taking out essential 
portions of effective elements in foods, such as vegetables, fruits, 
grains, etc., and/or in materials of the above foods. 
BACKGROUND OF THE INVENTION 
Recently, a variety of beverages and processed foods are being produced 
from foods such as vegetables, fruits, grains, etc. However, the 
production of the above beverages and processed food results in a large 
amount of residues remaining after taking out essential portions of the 
effective elements. Normally, the residues are either disposed of as 
wastes or re-utilized as feed for animals. 
Conventionally, as to the materials for the containers, wrapping materials, 
etc., plastics such as foamed polystyrene are generally used. 
The amount of residues remaining after taking out essential portions of the 
effective element of a variety of foods shows a yearly increase. However, 
there is a limit in re-utilizing the residues as the feed for animals. 
Therefore, a method for effectively producing industrial products from the 
residues is desired. 
Furthermore, plastics such as foamed polystyrene used for the containers, 
wrapping materials, etc., have the following problems: the 
biodegradability thereof is extremely low; and a toxic gas may be 
generated during the process of incineration. Thus, the difficulties in 
the waste disposal (burying, incinerating, etc.,) of the plastics present 
serious social problems. 
SUMMARY OF THE INVENTION 
An object of the present invention is to provide biodegradable molded 
articles obtained by effectively re-utilizing residues remaining after 
taking out essential portions of effective elements from foods, such as 
vegetables, fruits, grains, etc., and/or from materials used in the above 
foods, the biodegradable molded articles enabling an easy waste disposal 
without creating environmental problems. 
In order to achieve the above object, biodegradable molded articles of the 
present invention are characterized in that they are obtained from 
residues remaining after taking out essential portions of effective 
elements from foods and/or from materials used in the foods by molding the 
residues under pressure. 
Conventionally, the residues were either disposed of as wastes or 
re-processed as feed for animals. In pursuit of the more effective 
re-utilization of the residues, the above arrangement of the present 
invention enables molded articles, which can be used in a variety of 
fields, to be obtained. Furthermore, because the molded articles are 
biodegradable, they are easily decomposed by microbes, bacteria, etc., in 
the soil. Thus, the biodegradable molded articles of the present invention 
permit an elimination of the problem existing in the waste disposal of the 
conventional containers made of plastics. 
In order to achieve the above object, another type of biodegradable molded 
articles of the present invention is characterized in that it is obtained 
by molding a mixture under pressure, the mixture being composed of 
residues, remaining after taking out essential portions of effective 
elements from foods and/or from materials used in the foods, and a binding 
agent. 
Besides the above effect of the biodegradable molded articles obtained by 
molding the residues under pressure, additional effects can be achieved 
for certain compositions of the materials by mixing with the binding 
agent. For example, biodegradable molded articles with improved working 
efficiencies in the producing processes, such as a process for pouring the 
materials into molds, and biodegradable molded articles with better 
moldability and homogeneous structure can be achieved. 
For a fuller understanding of the nature and advantages of the invention, 
reference should be made to the ensuing detailed description. 
DETAILED DESCRIPTION OF THE EMBODIMENTS 
As to residues remaining after taking out essential portions of effective 
elements from foods, and/or from materials used in the foods, for example, 
the following residues may be used. Here, it should be noted that the 
present invention is not limited to the following residues. 
(1) Squeezed and strained residues resulting from producing, or processing 
foods made of vegetables or fruits such as celery, carrot, tomato, citrus 
fruits (orange, lemon, grapefruit, etc.), apple, grape, berries, 
pineapple, sugar cane, sugar beet, etc. 
(2) Residues resulting from producing processed foods made from grains (for 
example, bean curd), or producing liquors (Sake, distilled spirits, beer, 
etc.) from grains. 
(3) Extractive residues of table luxuries (coffee, tea, ptisan, green tea, 
oolong tea, etc.), or extracted tea leaves. 
(4) Residues resulting from removing oil by squeezing, pressing, or 
extracting soybean, corn, rapeseed, sesame, etc. 
(5) Residues such as wheat bran, rice bran, rice hull, etc. resulted from 
refining grains, or residues such as gluten meal resulting from producing 
starch. 
(6) Residues such as crumbs of biscuit, cone cups, etc., resulting from 
producing confectioneries. 
(7) Mixtures of the above residues 
In addition, the above residues may be used after being processed for 
drying, grinding, etc., if necessary. 
In producing the molded articles, residues are placed in a desired shaped 
mold and then a pressure is applied. Here, the pressure may be set 
according to the strengths etc., of the molded articles required for the 
usages thereof, preferably in the range of 0.5 -500 kg/cm.sup.2. A press 
time is not specified, and a pressure may be applied either 
instantaneously, or for a predetermined time, preferably set in the range 
of 0.5 seconds-10 minutes, more preferably in the range of 5-300 seconds. 
Although a molding temperature is not specified, considering working 
efficiency, or moldability in producing the molded articles, it is 
preferably set in the range of 30.degree.-300.degree. C., more preferably 
in the range of 50.degree.-200.degree. C. 
In pursuit of obtaining improved strengths of the molded articles, the 
molded articles of the present invention may be produced by mixing 
auxiliary materials, such as powdered grains, cellulose, insoluble 
minerals, seasoning matters, salts, powdered bones, shells, or egg shells, 
etc., with the residues of the above foods or of materials used in the 
above foods. 
Suitable binding agents include, for example, water, plasticizers, 
emulsifying agents, fats and oils, saccharides, proteins, starches, 
thickening polysaccharides, and the mixtures of the above. 
For more concrete examples of the above binding agent, such plasticizers as 
glycerin, polyglycerin, ethylene glycol, or propylene glycol may be used. 
Suitable emulsifying agents include monoglycerides, derivatives of 
monoglyceride, sugar esters, propylene glycol esters, esters of fatty acid 
with polyglycerin, and esters of fatty acid with sorbitan, etc. 
Suitable fats and oils include, for example, plant or animal fats and oils, 
and hardened or mixed fats and oils. Suitable saccharides include, for 
example, monosaccharides such as glucose, fructose, disaccharides such as 
sucrose, maltose, lactose, etc., sugar alcohols such as sorbitol, 
maltitol, etc., oligosaccharides, thick malt syrups, dextrins, isomeric 
saccharides, and the mixtures of the above. 
Suitable proteins include plant or animal proteins such as soybean protein, 
egg white, corn protein, casein, milkserum protein, wheat protein, 
collagen, etc., and the mixtures of the above proteins. 
Suitable starches include those of corn, potato, tapioca, sweet potato, 
wheat, etc., .alpha.-starches or denatured starches of the above, and the 
mixtures of the above starches. 
Suitable thickening polysaccharides include xanthan gum, locust bean gum, 
guar gum, pectin, gellan gum, arabic gum tamarindus gum, carrageenan, 
karaya gum, tara gum, and the mixtures of the above. 
The molded articles of the present invention can be used as the containers 
for hamburger, hot dog, French fried potato, deep fried chicken, Takoyaki, 
sausage, rice cake, ice cream, Chinese noodle, Japanese noodle, 
vegetables, fruits, meats, fishes, dried foods, etc. Not only the 
containers for foods, the molded articles of the present invention can be 
used in a variety of fields, such as flowerpots, golf tees, wrapping 
materials, garbage boxes, chopsticks, folding fans, etc. 
The molded articles made of the above materials are biodegradable, and thus 
they are easily decomposed by microbes, bacteria, etc., in the soil. 
Additionally, although the period required for the decomposition differs 
depending on the materials used in the molded articles, it is generally in 
the range of substantially 2-4 weeks. 
After being used, the molded articles may be disposed of in the soil, and 
for certain materials of the molded articles, the used molded articles may 
be used as feed for animals. Moreover, when the molded articles are used 
as the containers for foods, by improving the flavors, appearances, etc., 
the molded articles may be arranged so as to be edible together with the 
foods. 
The following will discuss a method for producing a molded article step by 
step in accordance with the present invention.

EXAMPLE 1 
First, 100 parts by weight of residues of Sake was poured into a mold which 
had been heated to 150.degree. C., and molded under the pressure of 50 
kg/cm.sup.2 for 60 seconds. Thereafter, it is taken out from the mold, and 
then cooled off at room temperature, thereby obtaining a molded article 
(A). 
The obtained molded article (A) had a smooth surface and good flavor. 
This example proved that the residues of Sake, i.e., a by-product resulted 
from brewing Sake, could be effectively re-utilized by producing therefrom 
the molded article through the process of pressure molding. Because the 
molded article is biodegradable, it is easily decomposed by microbes, 
bacteria, etc., in the soil. This advantage can be realized, for example, 
when the molded articles are used for disposable tablewares. The 
conventional disposable tablewares were not easily decomposed, and thus 
they were not suitable for restaurants' use. As described, the molded 
article of the present embodiment permits an elimination of the disposal 
problem, and also saves time which would be taken up by dish washing. 
Additionally, the usage of the molded article of the present embodiment is 
not limited to the disposal tablewares. 
The molded article can be used in a wider field, as the desired strength, 
shape, etc., can be obtained by changing the molding conditions, such as a 
pressing condition, heating temperature, etc., or by selecting a suitable 
type of mold. 
EXAMPLE 2 
Squeezed and strained residues of orange, egg white (binding agent), and 
water (binding agent) were prepared in the proportion shown in Table 1. 
Then, the materials were mixed using a mixer for two minutes. 
TABLE 1 
______________________________________ 
Material Parts by Weight 
______________________________________ 
Squeezed and Strained Residues of Orange 
100 
Egg White 10 
Water Suitable Amount* 
______________________________________ 
*Water is preferably added so that the parts by weight thereof in the 
mixture is in the range of 5-50 weight %. 
A predetermined weight of the mixture was poured into a mold which had been 
heated to 150.degree. C., and molded under the pressure of 50 kg/cm.sup.2 
for 30 seconds. Then, the product was taken out from the mold, and then 
cooled off at room temperature, thereby obtaining a molded article (B). 
The obtained molded article (B) had a better moldability and homogeneous 
structure, and a smooth and glossy surface. 
This example proved that by mixing the squeezed and strained residues of 
orange with the egg white and water (binding agents), the molded article 
permitting an improved re-utilization can be obtained, which were 
conventionally either re-utilized as feed for animals or disposed as 
wastes. Furthermore, the addition of the egg white and water (binding 
agents) enables the working efficiency in the molding process to be 
improved, and also enables the molded article (B) to have an improved 
moldability and a homogeneous structure. Like the molded article (A) of 
example 1, the molded article (B) of this example can be used in a variety 
of fields. After being used, the molded article (B) may be re-utilized as 
feed for animals. Moreover, the molded article (B) enables an easy 
disposal by burying it into the soil, since the used molded article (B) 
can be easily decomposed by microbes, bacteria, etc. in the soil. 
EXAMPLE 3 
Residues of bean curd as a residue resulted from producing bean curd and 
glycerin (plasticizer) as a binding agent were prepared in the proportion 
shown in Table 2. Then, the materials were homogeneously mixed using a 
mixer. 
TABLE 2 
______________________________________ 
Material Parts by Weight 
______________________________________ 
Residues of Bean Curd 
100 
Glycerin 20 
______________________________________ 
A predetermined weight of the mixture was poured into a mold which had been 
heated to 150.degree. C., and molded under the pressure of 50 kg/cm.sup.2 
for 60 seconds. Thereafter, the product was taken out from the mold, and 
then cooled off at room temperature, thereby obtaining a molded article. 
The obtained molded article had a better moldability and homogeneous 
structure. 
EXAMPLE 4 
Residues of bean curd as a residue resulted from producing bean curd, 
glycerin (binding agent), and egg white (binding agent) were prepared in 
the proportion shown in Table 3, and homogeneously mixed using a mixer. 
TABLE 3 
______________________________________ 
Material Parts by Weight 
______________________________________ 
Residues of Bean Curd 
100 
Egg White 10 
Glycerin 20 
______________________________________ 
A predetermined weight of the mixture was poured into a mold which had been 
heated to 150.degree. C., and molded under the pressure of 50 kg/cm.sup.2 
for 60 seconds. Thereafter, the product was taken out from the mold, and 
then cooled off at room temperature, thereby obtaining a molded article. 
The obtained molded article had a better moldability and homogeneous 
structure. 
EXAMPLE 5 
Residues of Sake, glycerin (binding agent), and unrefined soybean oil 
(binding agent) were prepared in the proportion shown in Table 4, and 
homogeneously mixed using a mixer. 
TABLE 4 
______________________________________ 
Material Parts by Weight 
______________________________________ 
Residues of Sake 120 
Glycerin 10 
Unrefined Soybean Oil 
6 
______________________________________ 
A predetermined weight of the mixture was poured into a mold which had been 
heated to 130.degree. C., and molded under the pressure of 50 kg/cm.sup.2 
for 60 seconds. Thereafter, the product was taken out from the mold, and 
then cooled off at room temperature, thereby obtaining a molded article. 
The obtained molded article had a better moldability and homogeneous 
structure. 
EXAMPLE 6 
Squeezed and strained residues of orange, glycerin (binding agent), 
unrefined soybean oil (binding agent), starch (binding agent), and water 
(binding agent) were prepared in the proportion shown in Table 5, and 
homogeneously mixed using a mixer. 
TABLE 5 
______________________________________ 
Material Parts by Weight 
______________________________________ 
Squeezed and Strained Residues of Orange 
100 
Glycerin 20 
Unrefined Soybean Oil 2 
Starch 5 
Water 7 
______________________________________ 
A predetermined weight of the mixture was poured into a mold which had been 
heated to 150.degree. C., and molded under the pressure of 50 kg/cm.sup.2 
for 60 seconds. Thereafter, the product was taken out from the mold, and 
then cooled off at room temperature, thereby obtaining a molded article. 
The obtained molded article had a better moldability and homogeneous 
structure. 
EXAMPLE 7 
Squeezed and strained residues of orange, glycerin (binding agent), 
unrefined soybean oil (binding agent), starch (binding agent), and 
sorbitol (binding agent) were prepared in the proportion shown in Table 6, 
and homogeneously mixed using a mixer. 
TABLE 6 
______________________________________ 
Material Parts by Weight 
______________________________________ 
Squeezed and Strained Residues of Orange 
100 
Glycerin 20 
Unrefined Soybean Oil 3 
Starch 5 
Sorbitol 30 
______________________________________ 
A predetermined weight of the mixture was poured into a mold which had been 
heated to 150.degree. C., and molded under the pressure of 50 kg/cm.sup. 2 
for 60 seconds. Thereafter, the product was taken out from the mold, and 
then cooled off at room temperature, thereby obtaining a molded article. 
The obtained molded article had a better moldability and homogeneous 
structure. 
The invention being thus described, it will be obvious that the same may be 
varied in many ways. Such variations are not to be regarded as a departure 
from the spirit and scope of the invention, and all such modifications as 
would be obvious to one skilled in the art are intended to be included 
within the scope of the following claims.