Patent Publication Number: US-2018030659-A1

Title: Methods and Apparatus For Manufacturing Fiber-Based, Slidable Packaging Assemblies

Description:
TECHNICAL FIELD 
     The present invention relates, generally, to ecologically sustainable methods and apparatus for manufacturing containers and packaging materials and, more particularly, to the use of novel slurries for use in vacuum forming molded fiber products to replace plastics. 
     BACKGROUND 
     Pollution caused by single use plastic containers and packaging materials is epidemic, scarring the global landscape and threatening the health of ecosystems and the various life forms that inhabit them. Trash comes into contact with waterways and oceans in the form of bits of Styrofoam and expanded polystyrene (EPS) packaging, to-go containers, bottles, thin film bags and photo-degraded plastic pellets. 
     As this ocean trash accumulates it forms massive patches of highly concentrated plastic islands located at each of our oceans&#39; gyres. Sunlight and waves cause floating plastics to break into increasingly smaller particles, but they never completely disappear or biodegrade. A single plastic microbead can be one million times more toxic than the water around it. Plastic particles act as sponges for waterborne contaminants such as pesticides. Fish, turtles and even whales eat plastic objects, which can sicken or kill them. Smaller ocean animals ingest tiny plastic particles and pass them on to us when we eat seafood. 
     Sustainable solutions for reducing plastic pollution are gaining momentum. However, continuing adoption requires these solutions to not only be good for the environment, but also competitive with plastics from both a performance and a cost standpoint. The present invention involves replacing plastics with revolutionary technologies in molded fiber without compromising product performance, within a competitive cost structure. 
     By way of brief background, molded paper pulp (molded fiber) has been used since the 1930s to make containers, trays and other packages, but experienced a decline in the 1970s after the introduction of plastic foam packaging. Paper pulp can be produced from old newsprint, corrugated boxes and other plant fibers. Today, molded pulp packaging is widely used for electronics, household goods, automotive parts and medical products, and as an edge/corner protector or pallet tray for shipping electronic and other fragile components. Molds are made by machining a metal tool in the shape of a mirror image of the finished package. Holes are drilled through the tool and then a screen is attached to its surface. The vacuum is drawn through the holes while the screen prevents the pulp from clogging the holes. 
     The two most common types of molded pulp are classified as Type 1 and Type 2. Type 1 is commonly used for support packaging applications with 3/16 inch (4.7 mm) to ½ inch (12.7 mm) walls. Type 1 molded pulp manufacturing, also known as “dry” manufacturing, uses a fiber slurry made from ground newsprint, kraft paper or other fibers dissolved in water. A mold mounted on a platen is dipped or submerged in the slurry and a vacuum is applied to the generally convex backside. The vacuum pulls the slurry onto the mold to form the shape of the package. While still under the vacuum, the mold is removed from the slurry tank, allowing the water to drain from the pulp. Air is then blown through the tool to eject the molded fiber piece. The part is typically deposited on a conveyor that moves through a drying oven. 
     Type 2 molded pulp manufacturing, also known as “wet” manufacturing, is typically used for packaging electronic equipment, cellular phones and household items with containers that have 0.02 inch (0.5 mm) to 0.06 inch (1.5 mm) walls. Type 2 molded pulp uses the same material and follows the same basic process as Type 1 manufacturing up the point where the vacuum pulls the slurry onto the mold. After this step, a transfer mold mates with the fiber package on the side opposite of the original mold, moves the formed “wet part” to a hot press, and compresses and dries the fiber material to increase density and provide a smooth external surface finish. See, for example, http://www.stratasys.com/solutions/additive-manufacturing/tooling/molded-fiber; http://www.keiding.com/molded-fiber/manufacturing-process/; Grenidea Technologies PTE Ltd. European Patent Publication Number EP 1492926 B1 published Apr. 11, 2007 and entitled “Improved Molded Fiber Manufacturing”; and http://afpackaging.com/thermoformed-fiber-molded-pulp/. The entire contents of all of the foregoing are hereby incorporated by this reference. 
     Fiber-based packaging products are biodegradable, compostable and, unlike plastics, do not migrate into the ocean. However, presently known fiber technologies are not well suited for use with meat and poultry containers, prepared food, produce, microwavable food containers, and lids for beverage containers such as hot coffee. 
     Methods and apparatus are thus needed which overcome the limitations of the prior art. 
     Various features and characteristics will also become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background section. 
     BRIEF SUMMARY 
     Various embodiments of the present invention relate to methods, chemical formulae, and apparatus for manufacturing vacuum molded, fiber-based packaging and container products including, inter alia: i) meat, produce, horticulture, and utility containers embodying novel geometric features which promote structural rigidity; ii) meat, produce, horticulture containers having embedded and/or topical moisture/vapor barriers; iii) vacuum tooling modified to re-direct spray nozzles to increase the size of vent holes in produce and horticulture containers; iv) microwavable/oven-heated containers embodying embedded and/or topical moisture, oil, and/or vapor barriers, and/or retention aids to improve chemical bonding; v) meat containers embodying a moisture/vapor barrier which preserves structural rigidity over an extended shelf life; vi) lids for hot beverage containers embodying a moisture/vapor barrier; vii) vacuum tooling modified to include a piston for ejecting beverage lids having a negative draft from the mold; and viii) a packaging kit for shipping flat screen televisions and other electronics. 
     It should be noted that the various inventions described herein, while illustrated in the context of conventional slurry-based vacuum form processes, are not so limited. Those skilled in the art will appreciate that the inventions described herein may contemplate any fiber-based manufacturing modality, including 3D printing techniques. 
     Various other embodiments, aspects, and features are described in greater detail below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       Exemplary embodiments will hereinafter be described in conjunction with the appended drawing figures, wherein like numerals denote like elements, and: 
         FIG. 1  is a schematic block diagram of an exemplary vacuum forming process using a fiber-based slurry in accordance with various embodiments; 
         FIG. 2  is a schematic block diagram of an exemplary closed loop slurry system for controlling the chemical composition of the slurry in accordance with various embodiments; 
         FIG. 3  is a perspective view of an exemplary produce container depicting a rolled edge, overhanging skirt, and ribbed structural features for enhancing hoop strength in accordance with various embodiments; 
         FIG. 4  is an end view of the container shown in  FIG. 3  in accordance with various embodiments; 
         FIG. 5A  is a perspective view of an exemplary produce container including extended vent holes in accordance with various embodiments; 
         FIG. 5B  is an end view of the container shown in  FIG. 5A  in accordance with various embodiments; 
         FIGS. 6A-6C  are alternate embodiments of food containers illustrating various shelf and rib features in accordance with various embodiments; 
         FIG. 7  is a perspective view of an exemplary rinsing tool including spray nozzles configured to rinse pulp from vent hole inserts in accordance with various embodiments; 
         FIG. 8  is a close up view of the spray nozzles shown in  FIG. 7  in accordance with various embodiments; 
         FIG. 9  is a perspective view of the excess fiber targeted for removal by the spray nozzles shown in  FIGS. 7 and 8  in accordance with various embodiments; 
         FIG. 10  is a perspective view of an exemplary microwavable food container in accordance with various embodiments; 
         FIG. 11A  is a perspective view of an exemplary meat container in accordance with various embodiments; 
         FIG. 11B  is an end view of the microwavable food container shown in  FIG. 11A  in accordance with various embodiments; 
         FIG. 12  is an alternative embodiment of a shallow food tray illustrating a shelf having off-set ribs in accordance with various embodiments; 
         FIG. 13  is a perspective view of an exemplary lid for a liquid (e.g., soup or a beverage such as coffee or soda) container in accordance with various embodiments; 
         FIG. 14  is a top view of the lid shown in  FIG. 13  in accordance with various embodiments; 
         FIG. 15  is a side elevation view of the lid shown in  FIGS. 13 and 14  in accordance with various embodiments; 
         FIG. 16  is a perspective view of an exemplary mold for use in manufacturing the lid shown in  FIGS. 13-15  in accordance with various embodiments; 
         FIG. 17  is a side elevation view of the mold of  FIG. 16  shown in the retracted position in accordance with various embodiments; 
         FIG. 18  is a side elevation view of mold of  FIG. 17  shown in the extended position in accordance with various embodiments; 
         FIG. 19  is a perspective view of utility (non-food) container in accordance with various embodiments; 
         FIG. 20  is a perspective view of a shipping kit for flat screen televisions and other electronics and fragile components in accordance with various embodiments; 
         FIGS. 21-35  are schematic perspective views of a telescopic packaging assembly for shipping big screen televisions in accordance with various embodiments; and 
         FIGS. 36-52  depict an alternative “end cap” technique for packaging ODM boxes in accordance with various embodiments. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EXEMPLARY EMBODIMENTS 
     The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description. 
     Various embodiments of the present invention relate to fiber-based or pulp-base products for use both within and outside of the food and beverage industry. By way of non-limiting example, the present disclosure relates to particular chemical formulations of slurries adapted to address the unique challenges facing the food industry including oil barriers, moisture barriers, and water vapor barriers, and retention aids, the absence of which have heretofore prevented fiber-based products from displacing single use plastic containers and components in the food industry. The present disclosure further contemplates fiber-based containers having geometric and structural features for enhanced rigidity. Coupling these features with novel chemistries enables fiber-based products to replace their plastic counterparts in a wide variety of applications such as, for example: frozen, refrigerated, and non-refrigerated foods; medical, pharmaceutical, and biological applications; microwavable food containers; beverages; comestible and non-comestible liquids; substances which liberate water, oil, and/or water vapor during storage, shipment, and preparation (e.g., cooking); horticultural applications including consumable and landscaping/gardening plants, flowers, herbs, shrubs, and trees; chemical storage and dispensing apparatus (e.g., paint trays); produce (including human and animal foodstuffs such as fruits and vegetables); salads; prepared foods; packaging for meat, poultry, and fish; lids; cups; bottles; guides and separators for processing and displaying the foregoing; edge and corner pieces for packing, storing, and shipping electronics, mirrors, fine art, and other fragile components; buckets; tubes; industrial, automotive, marine, aerospace and military components such as gaskets, spacers, seals, cushions, and the like; and associated molds, wire mesh forms, recipes, processes, chemical formulae, tooling, slurry distribution, chemical monitoring, chemical infusion, and related systems, apparatus, methods, and techniques for manufacturing the foregoing components. 
     Referring now to  FIG. 1 , an exemplary vacuum forming system and process  100  using a fiber-based slurry includes a first stage  101  in which mold (not shown for clarity) in the form of a mirror image of the product to be manufactured is envelop in a thin wire mesh form  102  to match the contour of the mold. A supply  104  of a fiber-based slurry  104  is input at a pressure (P 1 )  106  (typically ambient pressure). By maintaining a lower pressure (P 2 )  108  inside the mold, the slurry is drawn through the mesh form, trapping fiber particles in the shape of the mold, while evacuating excess slurry  110  for recirculation back into the system. 
     With continued reference to  FIG. 1 , a second stage  103  involves accumulating a fiber layer  130  around the wire mesh in the shape of the mold. When the layer  130  reaches a desired thickness, the mold enters a third stage  105  for either wet or dry curing. In a wet curing process, the formed part is transferred to a heated hot press (not shown) and the layer  130  is compressed and dried to a desired thickness, thereby yielding a smooth external surface finish for the finished part. In a dry curing process, heated air is passed directly over the layer  130  to remove moisture therefrom, resulting in a more textured finish much like a conventional egg carton. 
     In accordance with various embodiments the vacuum mold process is operated as a closed loop system, in that the unused slurry is re-circulated back into the bath where the product is formed. As such, some of the chemical additives (discussed in more detail below) are absorbed into the individual fibers, and some of the additive remains in the water-based solution. During vacuum formation, only the fibers (which have absorbed some of the additives) are trapped into the form, while the remaining additives are re-circulated back in vacuum tank. Consequently, only the additives captured in the formed part must be replenished, as the remaining additives are re-circulated with the slurry in solution. As described below, the system maintains a steady state chemistry within the vacuum tank at predetermined volumetric ratios of the constituent components comprising the slurry. 
     Referring now to  FIG. 2 , is a closed loop slurry system  200  for controlling the chemical composition of the slurry. In the illustrated embodiment a tank  202  is filled with a fiber-based slurry  204  having a particular desired chemistry, whereupon a vacuum mold  206  is immersed into the slurry bath to form a molded part. After the molded part is formed to a desired thickness, the mold  206  is removed for subsequent processing  208  (e.g., forming, heating, drying, top coating, and the like). 
     In a typical wet press process, the Hot Press Temperature Range is around 150-250 degree C., with a Hot Press Pressure Range around 140-170 kg/cm 2 . The final product density should be around 0.5-1.5 g/cm 3 , and most likely around 0.9-1.1 g/cm 3 . Final product thickness is about 0.3-1.5 mm, and preferably about 0.5-0.8 mm. 
     With continued reference to  FIG. 2 , a fiber-based slurry comprising pulp and water is input into the tank  202  at a slurry input  210 . In various embodiments, a grinder may be used to grind the pulp fiber to create additional bonding sites. One or more additional components or chemical additives may be supplied at respective inputs  212 - 214 . The slurry may be re-circulated using a closed loop conduit  218 , adding additional pulp and/or water as needed. To maintain a steady state balance of the desired chemical additives, a sampling module  216  is configured to measure or otherwise monitor the constituent components of the slurry, and dynamically or periodically adjust the respective additive levels by controlling respective inputs  212 - 214 . Typically the slurry concentration is around 0.1-1%, most ideally around 0.3-0.4%. In one embodiment, the various chemical constituents are maintained at a predetermined desired percent by volume; alternatively, the chemistry may be maintained based on percent by weight or any other desired control modality. 
     The pulp fiber used in  202  can also be mechanically grinded to improve fiber-to-fiber bonding and improve bonding of chemicals to the fiber. In this way the slurry undergoes a refining process which changes the freeness, or drainage rate, of fiber materials. Refining physically modifies fibers to fibrillate and make them more flexible to achieve better bonding. Also, the refining process can increases tensile and burst strength of the final product. Freeness, in various embodiments, is related to the surface conditions and swelling of the fibers. Freeness (csf) is suitably within the range of 200-700, and preferably about 220-250 for many of the processes and products described herein. 
     The chemical formulae (sometimes referred to herein as “chemistries”) and product configurations for various fiber-based packages and containers, as well as their methods for manufacture, will now be described in conjunction with  FIGS. 3-19 . 
     Produce Containers 
       FIG. 3  is a perspective view of an exemplary produce container (e.g., mushroom till)  300  depicting a rolled edge  302 , overhanging skirt  304 , and various structural features including side ribs  306  and bottom ribs  308  for enhancing hoop strength. In this context, the term hoop strength refers to a measure of the applied lateral force along opposing vectors  310  versus the resulting deflection. Although the initial hoop strength of a container is primarily a function of geometry, hoop strength tends to degrade as the container absorbs moisture leached or otherwise liberated from its contents (e.g., mushrooms). The present inventor has determined that coupling various geometric features with slurry chemistries optimized for various applications can sustain hoop strength over extended shelf times. That is, by incorporating a moisture repellant barrier into the slurry (and/or applying a moisture repellant surface coating), the hoop strength may be maintained for a longer period of time even as the container contents bleed moisture. 
       FIG. 4  is an end view of a container  400  generally analogous to the container shown in  FIG. 3 , and illustrates a width dimension  402 , a height dimension  404 , and a skirt length  408  in the range of 0.1 to 5 millimeters, and preferably about 1.5 mm. In the illustrated embodiment, the skirt extends downwardly; alternatively, the skirt may extend at an oblique or obtuse angle relative to a vertical plane. Width and height dimensions  402 ,  404  may be any desired values, for example in the range of 20 to 400 mm, and preferably about 60 to 200 mm. 
     As briefly mentioned above, the various slurries used to vacuum mold containers according to the present invention comprises a fiber base mixture of pulp and water, with added chemical components to impart desired performance characteristics tuned to each particular product application. The base fiber may include any one or combination of at least the following materials: softwood (SW), bagasse, bamboo, old corrugated containers (OCC), and newsprint (NP). Alternatively, the base fiber may be selected in accordance with the following resources, the entire contents of which are hereby incorporated by this reference: “Lignocellulosic Fibers and Wood Handbook: Renewable Materials for Today&#39;s Environment,” edited by Mohamed Naceur Belgacem and Antonio Pizzi (Copyright 2016 by Scrivener Publishing, LLC) and available at https://books.google.com/books?id=jTL8CwAAQBAJ&amp;printsec=frontcover#v=onepage&amp;q&amp;f=false; “Efficient Use of Flourescent Whitening Agents and Shading Colorants in the Production of White Paper and Board” by Liisa Ohlsson and Robert Federe, Published Oct. 8, 2002 in the African Pulp and Paper Week and available at http://www.tappsa.co.za/archive/APPW2002/Title/Efficient use of fluorescent w/efficient use of fluorescent w/html; Cellulosic Pulps, Fibres and Materials: Cellucon &#39;98 Proceedings, edited by J F Kennedy, G O Phillips, P A Williams, copyright 200 by Woodhead Publishing Ltd. and available at https://books.google.com/books?id=xO2iAgAAQBAJ&amp;printsec=frontcover#v=onepage&amp;q&amp;f=false; and U.S. Pat. No. 5,169,497 A entitled “Application of Enzymes and Flocculants for Enhancing the Freeness of Paper Making Pulp” issued Dec. 8, 1992. 
     For vacuum molded produce containers manufactured using either a wet or dry press, a fiber base of OCC and NP may be used, where the OCC component is between 50%-100%, and preferably about 70% OCC and 30% NP, with an added moisture/water repellant in the range of 1%-10% by weight, and preferably about 1.5%-4%, and most preferably about 4%. In a preferred embodiment, the moisture/water barrier may comprise alkylketene dimer (AKD) (for example, AKD 80) and/or long chain diketenes, available from FOBCHEM at http://www.fobchem.com/html products/Alkyl-Ketene-Dimer%EF%BC%88AKD-WAX%EF%BC%89.html#.VozozykrKUk; and Yanzhou Tiancheng Chemical Co., Ltd. at http://www.yztianchengchem.com/en/index.php?m=content&amp;c=index&amp;a=show&amp;catid=38&amp;id=124&amp;gclid=CPbn65aUg80CFRCOaQodoJUGRg. 
     In order to yield specific colors for molded pulp products, cationic dye or fiber reactive dye may be added to the pulp. Fiber reactive dyes, such as Procion MX, bond with the fiber at a molecular level, becoming chemically part of the fabric. Also, adding salt, soda ash and/or increase pulp temperature will help the absorbed dye to be furtherly locked in the fabric to prevent color bleeding and enhance the color depth. 
     To enhance structural rigidity, a starch component may be added to the slurry, for example, liquid starches available commercially as Topcat® L98 cationic additive, Hercobond, and Topcat® L95 cationic additive (available from Penford Products Co. of Cedar Rapids, Iowa). Alternatively, the liquid starch can also be combined with low charge liquid cationic starches such as those available as Penbond® cationic additive and PAF 9137 BR cationic additive (also available from Penford Products Co., Cedar Rapids, Iowa). 
     For dry press processes, Topcat L95 may be added as a percent by weight in the range of 0.5%-10%, and preferably about 1%-7%, and particularly for products which need maintain strength in a high moisture environment most preferably about 6.5%; otherwise, most preferably about 1.5-2.0%. For wet press processes, dry strength additives such as Topcat L95 or Hercobond which are made from modified polyamines that form both hydrogen and ionic bonds with fibers and fines. Those additives may be added as a percent by weight in the range of 0.5%-10%, and preferably about 1%-6%, and most preferably about 3.5%. In addition, wet processes may benefit from the addition of wet strength additives, for example solutions formulated with polyamide-epichlorohydrin (PAE) resin such as Kymene 577 or similar component available from Ashland Specialty Chemical Products at http://www.ashland.com/products. In a preferred embodiment, Kymene 577 may be added in a percent by volume range of 0.5%-10%, and preferably about 1%-4%, and most preferably about 2%. Kymene 577 is of the class of polycationic materials containing an average of two or more amino and/or quaternary ammonium salt groups per molecule. Such amino groups tend to protonate in acidic solutions to produce cationic species. Other examples of polycationic materials include polymers derived from the modification with epichlorohydrin of amino containing polyamides such as those prepared from the condensation adipic acid and dimethylene triamine, available commercially as Hercosett 57 from Hercules and Catalyst 3774 from Ciba-Geigy. 
     In some packaging applications it is desired to allow air to flow through the container, for example, to facilitate ripening or avoid spoliation of the contents (e.g. tomatoes). However, conventional vacuum tooling typically rinses excess fiber from the mold using a downwardly directed water spry, thereby limiting the size of the resulting vent holes in the finished produce. The present inventor has determined that re-directing the spray facilitates greater fiber removal during the rinse cycle, producing a larger vent hole in the finished product for a given mold configuration. 
     More particularly,  FIG. 5A  is a perspective view of an exemplary produce container  500  including extended relief holes  502 .  FIG. 5B  is an end view of a container  504  illustrating extended vent holes  506 . In this context, the term “extended vent holes” refers to holes made using the modified tooling shown in  FIGS. 9-7 , discussed below. 
     Referring now to  FIGS. 6A-6C , various combinations of geometric features may be employed to enhance the structural rigidity/integrity of food containers. By way of non-limiting example, one or more horizontally extending shelfs  602 ,  604  may be disposed between an upper region and a lower region of a side wall. For side walls containing a single shelf, the shelf may be disposed in the range of 30%-50% of the wall height from the top of the tray, and preferably about 35%. The shelf may be created by indenting the side panel and/or varying the draft angle. For example, in the embodiment shown in  FIG. 6C , a lower region  606  exhibits a draft angle in the range of about 4-6° (and preferably about 5°), while an upper region  608  exhibits a draft angle in the range of about 6-8° (and preferably about 7°). 
     With continued reference to  FIGS. 6A-6C , various rib configurations  610  may be disposed along the bottom and up the side panels of food containers. Ribs may be configured to terminate at a shelf, above the shelf (e.g., in the upper region of a side wall, for example 25% of the distance down from the top edge), below the shelf (e.g., in the lower region of a side wall, for example 25% of the distance down from the shelf), or at the top edge of the side wall. As shown in  FIG. 6C , ribs  612  may extend from the bottom of the container upwardly and terminate at the shelf, whereupon subsequent ribs  614  may be off set from the ribs  612  and extend upwardly from the shelf. The ribs may terminate in a rounded, squared, or other desired geometrical shape or configuration. 
     Vent Hole Tooling 
       FIG. 7  is a directional water impingement cleaning system  700  including a plurality of re-directed spray nozzles  704  configured to rinse excess pulp from vent hole inserts  706 . More particularly, a mold (not shown) is covered by a wire mesh  708 , the mold including the inserts which correspond to vent holes in the finished product. A supply conduit  702  distributes rinse water to a manifold  711  which includes a plurality of spray nozzles, each configured to direct rinse water to remove excess fiber proximate the inserts. 
     With momentary reference to  FIG. 8 , a close up view  800  of a section of a manifold  811  depicts a spray nozzle  802  configured to direct rinse water proximate a corresponding insert  706 . In this way, a greater extent of the residual fibers surrounding the inserts is removed, resulting in extended vent holes in the finished produce vis-a-vis presently known systems which simply rinse the mold with water sprayed from above. Importantly, the extended vent holes may be realized without having to adjust the underlying mold or inserts. 
     As seen in  FIG. 9 , the excess fiber  900  targeted for removal by the improved spray nozzles of the present invention provides extended vent holes using existing molds and presently known inserts. 
     Microwavable Containers 
     Building on knowledge obtained from the development of the aforementioned produce containers, the present inventor has determined that molded fiber containers can be rendered suitable as single use food containers suitable for use in microwave, convection, and conventional ovens by optimizing the slurry chemistry. In particular, the slurry chemistry should advantageously accommodate one or more of the following three performance metrics: i) moisture barrier; ii) oil barrier; and iii) water vapor (condensation) barrier to avoid condensate due to placing the hot container on a surface having a lower temperature tan the container. In this context, the extent to which water vapor permeates the container is related to the porosity of the container, which the present invention seeks to reduce. That is, even if the container is effectively impermeable to oil and water, it may nonetheless compromise the user experience if water vapor permeates the container, particularly if the water vapor condenses on a cold surface, leaving behind a moisture ring. The present inventor has further determined that the condensate problem is uniquely pronounced in fiber-based applications because water vapor typically does not permeate a plastic barrier. 
     Accordingly, for microwavable containers the present invention contemplates a fiber or pulp-based slurry including a water barrier, oil barrier, and water vapor barrier, and an optional retention aid. In an embodiment, a fiber base of softwood (SW)/bagasse at a ratio in the range of about 10%-90%, and preferably about 7:3 may be used. As a moisture barrier, AKD may be used in the range of about 0.5%-10%, and preferably about 1.5%-4%, and most preferably about 3.5%. As an oil barrier, the grease and oil repellent additives are usually water based emulsions of fluorine containing compositions of fluorocarbon resin or other fluorine-containing polymers such as UNIDYNE TG 8111 or UNIDYNE TG-8731 available from Daikin or World of Chemicals at http://www.worldofchemicals.com/chemicals/chemical-properties/unidyne-tg-8111.html. The oil barrier component of the slurry (or topical coat) may comprise, as a percentage by weight, in the range of 0.5%-10%, and preferably about 1%-4%, and most preferably about 2.5%. As a retention aid, an organic compound such as Nalco 7527 available from the Nalco Company of Naperville, Ill. May be employed in the range of 0.1%-1% by volume, and preferably about 0.3%. Finally, to strengthen the finished product, a dry strength additive such as an inorganic salt (e.g., Hercobond 6950 available at http://solenis.com/en/industries/tissue-towel/innovations/hercobond-dry-strength-additives/; see also http://www.sfm.state.or.us/CR2K_SubDB/MSDS/HERCOBOND_6950.PDF) may be employed in the range of 0.5%-10% by weight, and preferably about 1.5%-5%, and most preferably about 4%. 
     Referring now to  FIG. 10 , an exemplary microwavable food container woo depicts two compartments; alternatively, the container may comprise any desired shape (e.g., a round bowl, elliptical, rectangular, or the like). As stated above, the various water, oil, and vapor barrier additives may be mixed into the slurry, applied topically as a spry on coating, or both. 
     Meat Containers 
     Presently known meat trays, such as those used for he display of poultry, beef, pork, and seafood in grocery stores, are typically made of plastic based materials such as polystyrene and Styrofoam, primarily because of their superior moisture barrier properties. The present inventor has determined that variations of the foregoing chemistries used for microwavable containers may be adapted for use in meat trays, particularly with respect to the moisture barrier (oil and porosity barriers are typically not as important in a meat tray as they are in a microwave container). 
     Accordingly, for meat containers the present invention contemplates a fiber or pulp-based slurry including a water barrier and an optional oil barrier. In an embodiment, a fiber base of softwood (SW)/bagasse and/or bamboo/bagasse at a ratio in the range of about 10%-90%, and preferably about 7:3 may be used. As a moisture/water barrier, AKD may be used in the range of about 0.5%-10%, and preferably about 1%-4%, and most preferably about 4%. As an oil barrier, a water based emulsion may be employed such as UNIDYNE TG 8111 or UNIDYNE TG-8731. The oil barrier component of the slurry (or topical coat) may comprise, as a percentage by weight, in the range of 0.5%-10%, and preferably about 1%-4%, and most preferably about 1.5%. Finally, to strengthen the finished product, a dry strength additive such as Hercobond 6950 may be employed in the range of 0.5%-10% by weight, and preferably about 1.5%-4%, and most preferably about 4%. 
     As discussed above in connection with the produce containers, the slurry chemistry may be combined with structural features to provide prolonged rigidity over time by preventing moisture/water from penetrating into the tray. 
       FIG. 11A  is a perspective view of an exemplary meat container  1100 , and  FIG. 11B  is an end view of the meat container shown in  FIG. 11A  including sidewall ribs  1102  and bottom ribs  1104 . 
       FIG. 12  is a perspective view of an exemplary shallow meat container  1200  including a rib  1202  extending along the bottom and upwardly along the side wall, terminating at a shelf  1204 . A second rib  1206 , offset from the first rib  1202 , extends upwardly from the shelf. 
     Beverage Lids 
     Although fiber and pulp based paper cups are widely known, the beverage industry still needs a sustainable fiber-based lid solution. A significant impediment to the widespread adoption of fiber-based lids surrounds the ability to incorporate a zero or negative draft into the lid, in a manner which allows it to be conveniently removed from the mold. In addition, the fiber-based chemistry must be adapted to provide an adequate moisture/water barrier so that the rigidity of the lid is not compromised in the presence of liquid. The methods, chemical formulae, and tooling contemplated by the present invention addresses both of these issues in a manner heretofore not address by the prior art. 
     In particular, the chemistry for lids is similar to meat trays and microwave bowls discussed above. Specifically, for beverage container lids the present invention contemplates a fiber or pulp-based slurry including a water/moisture barrier and an optional retention aid. In an embodiment, a fiber base of softwood (SW)/bagasse and/or bamboo/bagasse at a ratio in the range of about 10%-90%, and preferably about 7:3 may be used. As a moisture/water barrier, AKD may be used in the range of about 0.5%-10%, and preferably about 1%-4%, and most preferably about 4%. Rigidity may be enhanced by Hercobond 6950 in the range of 0.5%-10% by weight, and preferably about 1%-4%, and most preferably about 2%. Kymene may also be added in the range of 0.5%-10%, and preferably about 1%-4%, and most preferably about 3%. 
     Referring now to  FIG. 13 , an exemplary lid  1300  includes an inclined platform  1302  surrounded by a retaining wall  1303  designed to urge liquid which leaves the inside of the container toward a sip hole  1304 . A small venting aperture  1310  may be disposed on the platform  1302 . A crown  1306  defines a volumetric space between the top of the cup (not shown) and the platform  1302 , and a lock ring  1308  is configured to securely snap around the top of the cup.  FIG. 14  is a top view of the lid shown in  FIG. 13 , including a platform  1402  venting aperture  1410 , and sip hole  1404  for comparison. 
       FIG. 15  is a side elevation view of a lid  1500 , highlighting a negative draft  1522  associated with the lock ring. Conventional wisdom suggests that vacuum molded products may not embody zero or negative draft features, because conventional vacuum mold tooling does not allow the finished part to be removed from the tool, inasmuch as the negative draft feature would “lock” the part to the tool in much the same way as the finished part “locks” itself to its mating component (here, the beverage cup). To overcome this limitation, the present invention contemplates a vacuum mold tool which removes the lid from the mold, notwithstanding the presence of the zero or negative draft locking feature, as described in greater detail below in conjunction with  FIGS. 13-18 . 
     Lid Tooling 
     A tool for making a fiber-based lid having a zero or negative draft comprises a retractable piston having a shape which generally to a mirror image of the lid, and which is configured to extend to unlock the finished lid from that part of the mold which the lid locks to. 
     Referring now to  FIG. 16 , is a perspective view of an exemplary mold assembly for use in manufacturing the lid shown in  FIGS. 13-15  in accordance with various embodiments. More particularly, a mold assembly  1600  includes a mold block  1620  supporting a lock ring mold portion  1608  (corresponding to the lock ring  1308  of  FIG. 13 ), a retractable piston assembly comprising a crown portion  1630  having an inclined platform  1602  (corresponding to the inclined platform  1302  of  FIG. 13 ), and a shaft portion  1640 . In operation, a wire mesh (not shown) surrounds the piston assembly  1630  and lock ring portion  1608 , and slurry is vacuum drawn through a series of holes  1650  to accumulate fiber around the wire mesh in the shape of the lid. In so doing, the lock ring  1308  of the lid locks around the lock ring mold portion  1608 . 
       FIG. 17  is a side elevation view of the mold of  FIG. 16  shown in the retracted position. In particular, the crown portion  1706  of the piston is adjacent the lock ring portion  1708  of the mold block  1720  when the piston is in the retracted position shown in  FIG. 17 . When the lid is formed around the wire mesh surrounding the mold form, the negative draft portion  1522  of the lid (see  FIG. 15 ) locks around the corresponding negative draft portion  1722  of the lock ring portion  1708  of the mold. In order to remove the finished part from the mold, the piston is extended upwardly, forcing the lock ring of the lid to momentarily expand and unlock from the mold. 
       FIG. 18  shows the piston in the extended position. In particular, the shaft  1840  forces the crown portion  1830  away from the lock ring portion  1808 , unlocking the lid from the negative draft feature  1822  of the mold. In an embodiment, the piston is extended pneumatically, and allowed to retract by its own weight once the high pressure air is released. 
     Utility and Shipping Containers 
       FIG. 19  is a perspective view of utility (non-food) container  1900  including sidewall ribs  1902  and a perimeter lip  1904  in accordance with various embodiments. Depending on the nature of the contained material, any one or combination of the aforementioned chemistries may be used in the construction of the container. For example, if the contained liquid includes a water component, a suitable moisture/water barrier may be employed; if the contained material includes an oil component, a suitable oil barrier may be employed, and so on. 
       FIG. 20  is a perspective view of a shipping kit for flat screen televisions, computers, and other electronics and fragile components in accordance with various embodiments. By way of contrast, presently known shipping containers and protective packaging employ air bags, foam blocks, or foam filled bags. The present invention contemplates a bio-friendly, sustainable solution for shipping electronics in the form of a kit which may be used to send a flat screen TV returned by a consumer to a refurbishing center. In the illustrated embodiment, the kit includes: i) a top cover  2002  ii) a screen protector  2004 ; iii) four corrugated pulp corner pieces  2006  fitted over the corners of a flat screen TV  2008 ; iv) a bottom tray  2010 ; and v) one or more pallet straps  2012  for tying the finished assembly together. 
       FIGS. 21-35  illustrate methods and packing components for telescopically enclosing a large screen television, monitor, or other delicate (e.g., electronic, artistic, glass) equipment between left and right corrugated packing components. In various embodiments, the left and right packing components are telescopically aligned to accommodate shipped goods (e.g., TVs) having various lengths using a single, adjustable packaging assembly. Multiple score lines are placed near the top of each of the left and right corrugated components to accommodate different heights of TVs. The combination of the scored height adjustment and telescoping left and right packing components allows for a few packaging assemblies to accommodate a large number of different TV sizes. 
     Referring now to  FIG. 21 , a front view of a packaged assembly  2100  depicts a left telescopic end piece  2102  and a right telescopic end piece  2104 .  FIG. 22  shows the back side of the same assembly, with the left and right end pieces separated.  FIG. 23  shows a subassembly  2300  including a TV  2301 , a top cushion  2304 , a bottom cushion  2306 , and respective corner cushions  2302 . The various cushion components may be vacuum formed from pulp according to the various embodiments described above. The manner in which the foregoing components may be manipulated into a packaged assembly will now be described in conjunction with  FIGS. 24-35 . 
       FIG. 24  shows an exemplary left end piece  2400  in the planar condition, prior to being folded into a sleeve. For reference, a bottom panel  2402  and an end panel  2404  are labeled in the figure.  FIG. 25  shows a panel  2502  folded along an arrow  2504 , and a panel  2506  folded along an arrow  2508 . In  FIG. 26 , a panel  2602  is folded along an arrow  2604 , and a panel  2608  folded along an arrow  2610 . An interlocking section is suitably pushed through a corresponding hole, shown in window  2606 , for added stability. 
       FIG. 27  illustrates a panel  2702  folded along an arrow  2704 , whereupon the end piece is turned upside down and the bottom taped  2710 . The foregoing process is repeated for the right end piece. 
       FIG. 28  is an exploded view of a package assembly  2800  including a flat screen  2801 , a left end piece  2802 , a right end piece  2804 , a top cushion  2806 , a bottom cushion  2808 , and respective corner cushions  2810 . In the illustrated embodiment, the flat screen and surrounding components are suitably inserted into the telescopically aligned end pieces such that the back side  2813  of the flat screen is exposed to an open back  2811  defined between the left and right end pieces. The manner in which the foregoing components are assembled into a final configuration for shipping will now be described in conjunction with  FIGS. 29-35 . 
       FIG. 29  illustrates an exemplary corner cushion  2900  including a concave part  2902  for receiving a corner of the flat screen, and a support part  2904  separated by a fold line  2906 . The support part  2904  may be manually folded along the arrow  2908  into the folded position  2910 .  FIG. 30  shows the left and right sleeves  3002 ,  3004  being telescopically adjusted along the arrow  3001  to accommodate the length of the TV being packaged.  FIG. 30  further depicts the two bottom folded corner pieces  2910  and bottom cushion  2808  being inserted into the aligned sleeves, as indicated by the arrows  3003 . 
       FIG. 31  shows the TV being inserted into the assembled sleeves, followed by a final adjustment of the sleeves along arrow  3102  to ensure a snug fit, followed by the packing of the top corner cushions  2910  and top cushion  2806 . 
       FIG. 32  shows respective end flaps  3202  being folded inward along arrows  3203 .  FIG. 32  shows top flaps  3302  being folded down along arrows  3303 , and top flaps  3304  being folded down along arrows  3305 .  FIG. 34  shows the folded flaps being taped in place at positions  3402 .  FIG. 35  shows the packaged assembly being wrapped in stretch wrap  3502 . 
     The present application also provides an environmentally responsible, sustainable solution for packaging flat screen televisions, monitors, and other delicate (e.g., electronic, artistic, glass) equipment already packed in its own box. This solution uses corrugated and fiber materials and, thus, avoids the use of non-renewable, single use plastics. In contrast to the telescopic configuration described above, the ensuing “end cap” solution provides a system for packaging rectangular boxes of virtually any size, using three different end cap sizes to accommodate different TV box heights, in combination with four different fiber corner cushions, using a sizing system which includes score lines on the end caps. 
     In an embodiment, each end cap comprises a rectangular corrugated component having two pulp cushions, and score lines for adjusting the height of the finished end cap. The end caps are placed on either end of the original design manufacturer (ODM) box. A corrugated screen protector assembly including fiber “feet” is placed over the top middle of the box to protect the underlying screen from breakage during shipment. The ODM box, along with the end caps, screen protector, and corner cushions, is then assembled and surrounded with stretch wrap or palette straps to hold the entire pack together. 
     Various methods and materials for packaging TVs using this end cap solution will now be described in conjunction with  FIGS. 36-51 . 
       FIG. 36  is an exploded view of an exemplary end cap solution including an ODM box  3601  with a TV inside, respective end caps  3602  and corner cushions  3604 , and a corrugate screen protector assembly  3606  having one or more molded fiber feet arrays  3610  disposed on an inside (screen facing) surface  3608  of the screen protector assembly. 
       FIG. 37  is a matrix guide mapping a plurality (e.g., four) of fiber cushion  3702  sizes to a plurality (e.g., three) of end cap  3704  sizes to yield a plurality of assembly  3706  configuration combinations (e.g., twelve). 
       FIG. 38  is a graphical guide  3800  for assisting shipping personnel in selecting the appropriate end caps and fiber corners for a given ODM box size according to the invention. In the illustrated embodiment the guide  3800  includes an end cap selector  3802  and a corner selector  3804 . 
       FIG. 39  shows an ODM box  3901  being compared to the end cap selection guide  3802 . In particular, the end cap selector includes a first zone  3902  corresponding to an end cap A, a second zone  3904  corresponding to an end cap B, and a third zone  3906  corresponding to an end cap C. by lining up the ODM box with the end cap guide, the user can visually determine whether an A, B, or C end cap should be selected. 
       FIG. 40  shows the ODM box being compared to the fiber corner guard selector  3804 . Specifically, by lining up a right edge  4002  of the box with a guide line  4004  on the selector chart, the width  4006  of the box determines which one of a plurality of corner guard sizes should be selected for the particular box under inspection. Having selected the optimum end caps and the optimum corner guards, the manner in which they are assembled around the ODM box will now be described in conjunction with  FIGS. 41-51 . 
       FIG. 41  shows a planar corrugate  4100  prior to being folded into an end cap. The corrugate  4100  includes a plurality of height score lines  4110 , width score lines  4112 , and a support feature  4102  having one or more tabs  4104 ,  4106 , described in greater detail below. 
       FIG. 42  illustrates how the support tabs facilitate taping the end cap flaps. In particular, the thickness of a corner cushion may be defined by dimension  4201 . For a thinner cushion, the end cap may be folded along an inner score line  4204 ; for a thicker cushion, the end cap may be folded along an outer score line  4202 . When using the outer score line, the side flap rests on an edge  4205  (with the tab  4206  bent at a 90° angle, as shown) during taping. However, when using the inner score lint, the side flap does not rest on edge  4205 , and thus may be unstable during the critical taping operation. Accordingly, when using the inner score line  4204 , the tab  4206  is not bent, to thereby provide a stable support for the side flap during taping. Those skilled in the art will appreciate that and number of score lines and associated stepped tabs may be employed to provide stability when taping for any one of a plurality of corner guard thicknesses (and corresponding score lines). 
     Using the aforementioned support tabs, the bottom flaps may be taped together as shown in  FIGS. 43 and 44 . As shown in  FIG. 45 , a corner guard  4501  may then be placed in the bottom area of each end cap  4502 . 
       FIG. 46  shows the ODM box  4601  being inserted into the respective end caps with the bottom corner guards (not shown) installed.  FIGS. 47 and 48  illustrate the installation of the top corner guards. Note the plurality of height adjustment score lines  4802  on the top flaps of the end caps.  FIG. 49  shows the end flaps being securely folded along the appropriate score lines over the corner guards. 
       FIG. 50  illustrates respective end caps  5002  secured to the ODM box  5001 , whereupon a screen protector  5004  (having molded fiber feet, not shown) is installed over the box by folding the screen protector along appropriate score lines  5003 . The final assembly may then be securely wrapped in stretch paper  5102  ( FIG. 51 ) or, alternatively, secured with pallet straps  5202  ( FIG. 52 ). 
     While the present invention has been described in the context of the foregoing embodiments, it will be appreciated that the invention is not so limited. For example, the various geometric features and chemistries may be adjusted to accommodate additional applications based on the teachings of the present invention. 
     A method is thus provided for manufacturing a produce container. The method includes: forming a wire mesh over a mold comprising a mirror image of the produce container; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh from the slurry bath; wherein the slurry comprises a moisture/water barrier component in the range of 1.5%-4% by weight. 
     In an embodiment the slurry comprises a moisture barrier component in the range of about 4%. 
     In an embodiment the moisture barrier component comprises alkyltene dimer (AKD). 
     In an embodiment the moisture barrier component comprises alkyltene dimer (AKD) 80. 
     In an embodiment the slurry comprises a fiber base of OCC/NP at a ratio in the range of 0.5/9.5. 
     In an embodiment the slurry further comprises a starch component in the range of 1%-7% by weight. 
     In an embodiment the starch component comprises a cationic liquid starch. 
     In an embodiment the slurry further comprises a wet strength component such as Kymene (e.g., Kymene 577) in the range of 1%-4% by weight. 
     In an embodiment the mold comprises a rolled edge including a vertically descending skirt. 
     In an embodiment the moisture/water barrier comprises AKD in the range of about 4%; the slurry comprises a cationic liquid starch component in the range of 1%-7%; and the mold comprises a rolled edge including a vertically descending skirt, at least one bottom rib, and at least one sidewall rib. 
     A produce container manufactured according to the foregoing methods is also provided. 
     In a vacuum mold assembly of the type including a wire mesh surrounding a mold form having a substantially vertical insert configured to provide a vent hole in a finished container, a directional rinse assembly is provided. The directional rinse assembly includes: a water supply conduit; a manifold connected to the water supply conduit; and a spray nozzle connected to the manifold and configured to direct a spray of water at the insert along a vector having a horizontal component. 
     In an embodiment the mold includes a plurality of substantially vertical inserts, and the directional rinse assembly further includes a plurality of spray nozzles, each configured to direct a spray of water at respective inserts along respective vectors each having a horizontal component. 
     A method is also provided for manufacturing a zero or nearly zero porosity food container. This method includes a wet press procedure as the first step, followed by an extra surface coating procedure for applying a thin layer of water based long chain fluorine-containing polymers such as Daikin S 2066, in the range of about 0.5%-6% by weight, and preferably about 1%-5%, and most preferably about 4%. 
     A method is also provided for manufacturing a microwavable and/or oven worthy food container. The method includes: forming a wire mesh over a mold comprising a mirror image of the microwavable food container; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh from the slurry bath; wherein the slurry comprises a moisture barrier component in the range of 0.5%-10% by weight, an oil barrier in the range of 0.5%-10% by weight, and a retention aid in the range of 0.05%-5% by weight. 
     In an embodiment the moisture/water barrier component is in the range of about 1.5%-4%, the oil barrier is in the range of about 1%-4%, and the retention aid is in the range of about 0.1%-0.5%. 
     In an embodiment the moisture barrier component comprises alkyltene dimer (AKD). 
     In an embodiment the moisture barrier component comprises alkyltene dimer (AKD) 79. 
     In an embodiment the slurry comprises a fiber base of SW/bagasse at a ratio in the range of 0.5/9.5. 
     In an embodiment the slurry further comprises a rigidity component in the range of 1%-5% by weight. 
     In an embodiment the rigidity component comprises a dry inorganic salt. 
     In an embodiment the oil barrier comprises a water based emulsion. 
     In an embodiment the oil barrier comprises TG 8111. 
     In an embodiment the retention aid comprises an organic compound. 
     In an embodiment the retention aid comprises Nalco 7527. 
     In an embodiment the moisture/water barrier comprises AKD in the range of about 4%; the slurry comprises bagasse and a dry inorganic salt; the oil barrier comprises a water based emulsion; and the vapor barrier comprises an organic compound. 
     A microwavable container manufactured according to the foregoing methods is also provided. 
     A method of manufacturing a meat tray is provided, the method including: forming a wire mesh over a mold comprising a mirror image of the meat tray; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh from the slurry bath; wherein the slurry comprises a moisture/water barrier component in the range of 0.5%-10% by weight and an oil barrier in the range of 0.5%-10% by weight. 
     In an embodiment the moisture/water barrier component is in the range of about 1%-4% and the oil barrier is in the range of about 1%-4. 
     In an embodiment the moisture barrier component comprises alkyltene dimer (AKD). 
     In an embodiment the moisture barrier component comprises alkyltene dimer (AKD) 79. 
     In an embodiment the slurry comprises a fiber base of SW/bagasse at a ratio in the range of 1/9. 
     In an embodiment the slurry includes a rigidity component in the range of 1.5%-4% by weight. 
     In an embodiment the rigidity component comprises a dry inorganic salt. 
     In an embodiment the oil barrier comprises a water based emulsion. 
     In an embodiment the oil barrier comprises TG 8111 in the range of about 1.5% by weight. 
     In an embodiment the moisture/water barrier comprises AKD in the range of about 4%; the slurry comprises bagasse and a dry inorganic salt; and the oil barrier comprises a water based emulsion. 
     A meat tray manufactured according to the foregoing methods is also provided. 
     In an embodiment the meat tray includes at least one sidewall rib and at least one bottom rib. 
     A method of manufacturing a lid for a beverage container is also provided. The method includes: forming a wire mesh over a mold comprising a mirror image of the lid; immersing the wire mesh in a fiber-based slurry bath; drawing a vacuum across the wire mesh to cause fiber particles to accumulate at the wire mesh surface; and removing the wire mesh from the slurry bath; wherein the slurry comprises a moisture/water barrier component in the range of 0.5%-10% by weight, a rigidity component in the range of 1%-4% by weight, and a polycationic component in the range of about 1%-4%. 
     In an embodiment the moisture/water barrier component is in the range of about 1%-4% and the oil barrier is in the range of about 1%-4. 
     In an embodiment the moisture barrier component comprises alkyltene dimer (AKD). 
     In an embodiment the moisture barrier component comprises alkyltene dimer (AKD) 80. 
     In an embodiment the slurry comprises a fiber base of SW/bagasse at a ratio in the range of 1/9. 
     In an embodiment the slurry further comprises a rigidity component in the range of 1%-4% by weight. 
     In an embodiment the rigidity component comprises a dry inorganic salt. 
     In an embodiment the moisture/water barrier comprises AKD in the range of about 4%; the slurry comprises bagasse and a dry inorganic salt; and the slurry comprises a polycationic material in the range of about 1%-4% by weight. 
     A lid manufactured according to the foregoing methods is also provided. 
     In an embodiment the lid further includes a lock ring having a non-positive draft. 
     A vacuum tool is also provided for manufacturing a fiber-based beverage lid having a crown and a lock ring including a negative draft. The tool includes: a mold block supporting a lock ring mold portion corresponding to the lid lock ring; a retractable piston assembly comprising a crown mold portion corresponding to the lid crown and a piston shaft; and a pneumatic actuator configured to extend the piston shaft to thereby remove the lid lock ring from the lock ring mold portion. 
     In an embodiment the vacuum tool further includes a wire mesh removably surrounding the crown mold portion and the lock ring mold portion. 
     A shipping container kit is also provided for a flat screen TV. The kit includes: a top cover; a screen protector; four corrugated pulp corner pieces configured to fit over respective corresponding corners of the flat screen TV; a bottom tray configured to nest with the top cover; and a pallet strap configured to secure the TV, screen protector, corrugated pulp corner pieces within the nested top cover and bottom tray. 
     An adjustable assembly for packing flat screen devices is also provided. The assembly includes: a left corrugated end piece; a right corrugated end piece configured to be telescopically received within the left corrugated end piece; a top, U-shaped fiber cushion configured to be placed over the flat screen device; a bottom, U-shaped fiber cushion configured to be placed underneath the flat screen device; and respective fiber corner pieces configured to be placed on respective corners of the flat screen device; wherein the top cushion, the bottom cushion, and the fiber corner pieces are vacuum formed using a fiber-based slurry. 
     In an embodiment, the slurry comprises at least one of: softwood (SW); bagasse; bamboo; old corrugated containers (OCC); and newsprint (NP). 
     In an embodiment, the left end piece comprises a bottom panel, an end panel, and an interlock configured to maintain the end panel substantially orthogonal to the side panel. 
     In an embodiment, the interlock comprises a tab configured to be manually pushed through a corresponding hole. 
     In an embodiment, the tab is disposed on a third panel adjacent the side panel, and the hole is disposed on a fourth panel adjacent the bottom panel. 
     In an embodiment, two of the corner pieces comprise bottom corner pieces, each comprising a concave portion configured to receive a corresponding corner of the flat screen device, and a support portion. 
     In an embodiment, the concave portion and the support portion are separated by a fold line. 
     In an embodiment, the concave portion and the support portion are vacuum molded as a single piece on a single mesh mold. 
     In an embodiment, the support portion is configured to be manually folded underneath the concave portion in a locked position. 
     In an embodiment, the end panel comprises a plurality of height score lines configured to allow a user to select a particular one based on a corresponding height of the flat screen device when received within the left end piece. 
     In an embodiment, the left end piece further comprises a fifth panel, and wherein the fifth panel and one of the third and fourth panel further comprise a plurality of height score lines configured to allow a user to select a particular one based on a corresponding height of the flat screen device when received within the left end piece. 
     In an embodiment, the fifth panel comprises a top panel which, when folded orthogonally with respect to the fifth panel, is disposed horizontally over the flat screen device. 
     In an embodiment, the assembly is configured to be assembled such that the right corrugated end piece is configured to be slidably received within the left corrugated end piece to thereby adjust the length of the assembly to correspond to the length of the flat screen device. 
     In an embodiment, the top and bottom cushions comprise a plurality of fiber feet configured to cushion the flat screen device. 
     A method of packing a flat screen device for shipment is also provided. The method includes: providing a left corrugated end piece and a right corrugated end piece configured to be telescopically received within the left corrugated end piece; providing a top U-shaped fiber cushion configured to be placed over the flat screen device and a bottom U-shaped fiber cushion configured to be placed underneath the flat screen device; and providing respective fiber corner pieces configured to be placed on respective corners of the flat screen device; wherein the top cushion, the bottom cushion, and the fiber corner pieces are vacuum formed using a fiber-based slurry. 
     In an embodiment, the slurry comprises at least one of: softwood (SW); bagasse; bamboo; old corrugated containers (OCC); and newsprint (NP). 
     In an embodiment, the left end piece comprises a bottom panel, an end panel, and a plurality of height score lines displayed on the end panel; and the method further comprises: selecting a particular one of the height score lines based on a corresponding height of the flat screen device when received within the left end piece; and folding the end panel along the selected height score line to thereby secure the flat screen device within the left end piece. 
     In an embodiment, the method of further includes manually sliding the right end piece within and along the left end piece to thereby adjust the length of the assembly to correspond to the length of the flat screen device. 
     In an embodiment, the method of further includes manually placing four corner pieces adjacent corresponding corners of the flat screen device. 
     In an embodiment, the method of further includes securing the flat screen device, the top and bottom cushions, and the corner pieces for shipping using at least one of stretch paper and pallet straps 
     As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations, nor is it intended to be construed as a model that must be literally duplicated. 
     While the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing various embodiments of the invention, it should be appreciated that the particular embodiments described above are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. To the contrary, various changes may be made in the function and arrangement of elements described without departing from the scope of the invention.