Patent Description:
Fiber opening systems have traditionally been designed for and have been used in the textile industry. Exemplary fiber openers are disclosed for example in the documents <CIT> and <CIT>.

A standard textile bale opener such as a <NUM>+<NUM> bale breaker with a lift apron features a vertically inclined belt with wooden strips which have sharp needles for opening of the fiber. The inclined belt lifts the fiber to a stripper belt which controls flow of the fiber and removes oversized pieces of the fiber. An adjustable gap exists between the stripper belt and the inclined belt. The wider the gap, the less fiber opening results. On the other hand, tightening the gap results in greater fiber opening, but the volume of input fiber can be restricted. The <NUM>+<NUM> bale breaker and other conventional textile bale breakers are designed to open textile fiber and thus are not capable of opening wood and/or bark fiber to sufficiently lower density of such fiber, especially in higher volumes of input fiber.

Wood and/or bark fiber is useful, for example, in preparation of growing media, mulches, and hydraulically-applied growing media and mulches. Since growing media and mulches are sold based on volume, the lower the weight of the growing media, the greater the value of the growing media and their components. Thus, it is desirable to lower density of the components of the growing media, especially the density of a highly compressed wood and/or bark fiber.

Therefore, it would be desirable to provide a fiber opening apparatus which is capable of lowering density of wood and/or bark fiber which is highly compressed, i.e. having a compressed density of about <NUM> to about <NUM> lbs/ft<NUM> (about <NUM>/m<NUM> to about <NUM>/m<NUM>), by at least <NUM>%, more preferably by at least <NUM>%, even more preferably by at least <NUM>%. It would be further desirable that such fiber opening apparatus is capable of handling large volumes of input fiber.

The document <CIT> describes fiberizing bales of pulp into substantially dry fibers and fiber aggregates, i.e., dry fluff, and metering the resulting dry fluff to a receptacle or other process, such as an airlaid process for making disposable absorbent articles. An apparatus includes a bale support member for supporting a bale of pulp, the bale support member defining two openings; two rotatable fiberizing assemblies having disrupting elements protruding through the openings an adjustable distance above the bale support member to contact a surface layer of the bale of pulp, the surface layer having a dimension parallel to the longitudinal axis of the fiberizing assembly, each disrupting element extending longitudinally and substantially continuously along the fiberizing assembly for a distance of <NUM>% or more of said surface-layer dimension. A transportation assembly moves the bale of pulp back and forth along the bale support member and over the openings so that the disrupting elements contact a surface layer in the bale to form substantially dry, individual fibers and fiber aggregates. An adjustable reciprocating assembly provides a motive force for moving the transportation assembly. The adjustable reciprocating assembly permits adjustment of the frequency by which the transportation assembly moves back and forth over the opening; and a conduction assembly for conducting the dry fluff to a hopper or the like.

The document <CIT> describes separation of bast and core fibers from herbaceous fiber producing plants using a series of pre-separation cleaning and conditioning steps. The steps place the bast and core fibers in a better condition for separation before they are actually separated. The harvested fiber plants are cut at a specified length. These fibers are then introduced into a conditioning apparatus which breaks up and dries, but does not yet separate the bast and core fibers. The conditioned fibers are then introduced into an auger and feeder which distributes the dried fiber over up to four identical separation lines. Each line includes at least one core separator made up of a large rotating spiked cylinder partially surrounded by a spiked, grated housing, a smaller rotating spiked cylinder which produces an air flow. An upwardly moving inclined conveyor has openings therein. The heavier woody core fiber is thrown, shaken or dropped through the grated housing and/or conveyor openings and removed to the core cleaner. The remaining bast fiber is then introduced into a second identical core separator where this separation process is repeated, or is introduced into the multi-saw bast fiber opener with a non-positive feed control.

The document <CIT> describes cleaning of cotton, flax and kenaf and related materials in a ginning process. Inclusion of an additional saw cylinder in the saw type lint cleaner allows separating the cotton out of the rejected fiber from the passage through the first saw tooth lint cleaner. The additional saw is doffed by the same brush cleaner that doffs the primary saw cylinder.

The document <CIT> describes a fiber processing assembly that includes a fiber processing machine having an inlet and an outlet. An arrangement is for introducing fiber material into the fiber processing machine through the inlet. A fiber opening and cleaning machine has an inlet and an outlet and is disposed underneath the fiber processing machine. A further arrangement is for advancing the fiber material from the fiber processing machine to the fiber opening and cleaning machine substantially solely by gravity.

The document <CIT> describes textile machinery for opening cotton material with devices featuring knives.

The document <CIT> describes carding textile machinery with devices featuring angled teeth for continuously separating partially opened fibrous material into individual fibers, and for conveying these fibers out of the machinery.

The document <CIT> describes carding textile machinery with devices featuring fine and closely spaced wire teeth for producing sample slivers from fibrous materials for testing purposes.

The document <CIT> describes crusher machinery used in crushing operations for recycling reuse of used spun yarn products containing spun yarn comprised of heat-resistant and high-performance fiber such as wholly aromatic polyamide fiber. The crusher has a chassis with upper crushing rollers, a lower crushing roller, screw-like crushing blades and a counter knife forming hooks and an auxiliary guide.

The document <CIT> describes machinery for leather trimming using needles.

The documents <CIT> and <CIT> describe a bale opener.

An embodiment of the invention provides a fiber opening apparatus for opening a compressed growing medium including fibers, the fiber opening apparatus comprises: at least one section having at least one set of adjacent rotating members with projections and a fiber opener section having opener rotating members, each of the opener rotating members having a surface including at least one wire wound around at least a portion of the surface and ridges on the surface the at least one wire being secured within the ridges. The wire includes a plurality of projections shaped as pyramid projections, each pyramid projection having a triangular cross-section, forming a wide base which gradually narrows at a top of the pyramid projection, the pyramid projection being capable of engaging the growing medium and the opener rotating members being positioned relative to each other to provide at least one pinch point between adjacent opener rotating members, the opener rotating members being capable of separating fibers from the growing medium passing through the at least one pinch point so that the density of passing fiber is lowered by at least <NUM>%, relative to the density of the input fiber of the compressed growing medium.

In an embodiment of the invention, the at least one section is a bale breaker having at least one set of rotating beater members with projections.

In an embodiment of the invention, the distance between the adjacent rotating members is adjustable.

In an embodiment of the invention, each opener rotating member has a width, wherein the at least one wire comprises at least six rows of wire with a plurality of pyramid projections per length of <NUM> (<NUM> inch) of the width.

In an embodiment of the invention, the wire includes at least three pyramid projections per length of <NUM> of wire length.

The bale breaker is located upstream of the fiber opener section and the plurality of projections engaging the compressed growing medium to separate the growing medium into pieces of fiber.

In an embodiment of the invention, the fiber opening apparatus comprises at least one of: a component input section for supplying additional components to the growing medium, a transportation section, a mixing section and a packaging section.

The invention also has as an object, a method of lowering density of a compressed growing medium including fibers, the method comprises: supplying the compressed growing medium comprising wood and/or bark fiber to a fiber opening apparatus as exposed in one of the above embodiments; the plurality of pyramid projections in the fiber opener section the pieces of fiber to expand and open them when passing through the at least one pinch point between the opener rotating members and separate them into a plurality of strings of fiber, and discharging the lowered density opened fiber.

In an embodiment of the invention, the method further comprises: having the compressed growing medium supplied in the form of at least one bale with a density of about <NUM>/m<NUM> to about <NUM>/m<NUM>, passing the at least one bale of the compressed growing medium through the bale breaker of the fiber opening apparatus; engaging the growing medium with the projections of the at least one set of adjacent rotating beater members of the bale breaker that are rotating at a rotational speed of at least about <NUM> rpm; and creating partially opened fiber by separating the bale into pieces of fiber.

In an embodiment of the invention, the method further comprises: said fiber opening apparatus comprises a mixing section and the growing medium comprises wood and/or bark fibers dyed with pigments and said method further comprises supplying to the growing medium optional components including at least one of fertilizer(s), macronutrient(s), micronutrient(s), mineral(s), chemical binder(s), natural gum(s), interlocking manmade fiber(s), soil, and seed to the opened fiber; and mixing the growing medium with the optional components in said mixing section.

It has now been surprisingly and unexpectedly discovered that a fiber opening apparatus employing a plurality of rotating members including a wire wound around the rotating members, the wire including projections, wherein the rotating members are engaging fiber and tearing the fiber apart, is capable of lowering the fiber density by at least <NUM>%, thus providing higher volume of the fiber which results in increased value of the fiber as well as of a product including the fiber as a component such as a growing medium or a mulch.

The fiber opening apparatus of the invention may be used to lower the density of highly compressed fiber to increase its value as a component of a growing medium or mulch. By lowering density of the fiber, the density of the growing medium or mulch is lowered as well, and the value of the growing medium or mulch increases. The input fiber comprises wood and/or bark fiber. The typical compressed density of the input fiber preferably varies between about <NUM> to about <NUM> lbs/ft<NUM> (about <NUM>/m<NUM> to about <NUM>/m<NUM>). The density of the input fiber will be lowered by at least <NUM>%, relative to the density of the input fiber.

The fiber opening apparatus is capable of lowering the density of the highly compressed wood and/or bark fiber, in the order of increasing preference, by about <NUM>% or more, or <NUM>% or more. The fiber opening apparatus is capable of lowering the density of the highly compressed wood and/or bark fiber by at least about <NUM>% to <NUM>%, <NUM>% to <NUM>%, or <NUM> to <NUM>%. Table <NUM> provides a comparison of density reduction per ft<NUM> and m<NUM> achieved by a conventional bale breaker and fiber opener, specifically the <NUM>+<NUM> bale breaker with a lift apron, and by the fiber opening apparatus of the disclosure. As Table <NUM> illustrates, the fiber opening apparatus of the disclosure achieves significantly higher fiber density reduction.

The fiber opening apparatus with wire rotating members may lower the density of the highly compressed fiber from about <NUM>-<NUM> lbs/ft<NUM> (<NUM>-<NUM>/m<NUM>) to about <NUM>-<NUM> lbs/ft<NUM> (<NUM>-<NUM>/m3) or <NUM>-<NUM> lbs/ft<NUM> (<NUM>-<NUM>/m<NUM>), depending on the type of fiber which is being opened by the apparatus. Table <NUM> provides a comparison of compressed bale density with the density of opened fiber for wood and/or bark fiber after passing through the fiber opening apparatus of the invention. As can be seen, the reduction for several materials is greater than <NUM>%.

While reducing the fiber density, the fiber opening apparatus is expanding the volume of the wood and/or bark and/or peat fiber. For example, while conventional apparatus may expand a compressed bale of sphagnum peat in a ratio of <NUM>:<NUM> of unexpanded to expanded fiber, the fiber opening apparatus of the present disclosure is capable of expanding the highly compressed sphagnum peat in a ratio of <NUM>:<NUM> of unexpanded to expanded fiber. Other highly compressed fiber may be expanded in a ratio of at least <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, or even a better ratio of unexpanded to expanded fiber such as <NUM>:<NUM> may be achieved. For example, highly compressed wood and bark fiber may be expanded in a ratio of at least <NUM>:<NUM> and <NUM>% wood fiber may be expanded in a ratio of at least <NUM>:<NUM> of unexpanded to expanded fiber.

The fiber opening apparatus may receive input fiber from bales of compressed wood and/or bark fiber or other compressed fiber such as, but not limited to, sphagnum peat. The input fiber may originate from a vertical or a horizontal compressed bale. An exemplary compressed bale may have a density of about <NUM> lbs/ft<NUM> (about <NUM>/m<NUM>), another exemplary bale may have a density of about <NUM> lbs/ft<NUM> (about <NUM>/m<NUM>), but other densities are contemplated, typically falling between a range of about <NUM> to about <NUM> lbs/ft<NUM> (about <NUM>/m<NUM> to about <NUM>/m<NUM>). Compressed bales with densities below <NUM> lbs/ft<NUM> (about <NUM>/m<NUM>) and bales with densities above <NUM> lbs/ft<NUM> (about <NUM>/m<NUM>) are also contemplated. The input fiber comprises wood fiber, bark fiber, or both. The input fiber may be extracted from hardwood (deciduous) trees and/or softwood (coniferous) trees. The wood and/or bark fiber may include, but is not limited to, wood and/or bark from pine, oak, walnut (Juglans cinerea), mahogany (Swietenia macrophylla, Swietenia mahagoni, Swietenia humilis), hemlock, Douglas fir, Colorado fir, alder, elm, birch, Sitka spruce, eucalyptus, sycamore, maple, cedar, sweetgum, crab apple, ash, weeping willow, sassafras, mulberry, the like, and combinations thereof. Examples of wood and/or bark fiber bales <NUM> may be seen in <FIG> as well as in <FIG>.

It is contemplated that the input fiber may originate from other sources such as cotton, wool, flax, jute, coconut, hemp, straw, grass, and other fibers available directly from natural sources such as peat, as well as chemically modified natural fibers, for example chemically modified cellulose fibers, cotton fibers, azlon, regenerated cellulose products including cellulose xanthate (rayon), cellulose acetate, cellulose triacetate, cellulose nitrate, alginate fibers, casein-based fibers; abaca, cantala, caroa, henequen, istle, Mauritius, phormium, bowstring, sisal, kenaf, ramie, roselle, sunn, cadillo, kapok, broom root, coir, crin vegetal, and piassaua. This list of fibers is illustrative and not limiting.

The wood and/or bark fiber bale may include about <NUM> to about <NUM> weight % of the tree bark and about <NUM> to about <NUM> weight % of the wood components, based on the total weight of the bale. Alternatively, the wood and/or bark fiber bale may include about <NUM> to about <NUM> weight % of the tree bark and about <NUM> to about <NUM> weight % of the wood components or about <NUM> to about <NUM> weight % of the tree bark and about <NUM> to about <NUM> weight % of the wood components, based on the total weight of the bale.

The bale of fiber may further include about <NUM> to about <NUM> weight % of additional components that are combined with the wood and/or bark fiber, based on the total weight of the bale. Examples of such additional components include but are not limited to fertilizers, macronutrients, micronutrients, minerals, chemical binders, natural gums, interlocking manmade fibers, and the like, and combinations thereof. In general, these components are present in an amount of less than about <NUM> weight % of the total weight of the wood and/or bark fiber bale. The additional components in total may be present in an amount from about <NUM> to about <NUM> % of the total weight of the fiber. Additionally, soil may be added in an amount of about <NUM>% or less, about <NUM> % or less, or about <NUM> % or less of the total weight of the growing medium. The soil may be present in an amount of about <NUM> to about <NUM> weight % of the total weight of the growing medium. Soil may also be absent from the growing medium.

Fertilizers such as nitrogen fertilizers, phosphate fertilizers, potassium fertilizers, compound fertilizers, and the like may be used in a form of granules, powder, prills, or the like. For example, melamine/formaldehyde, urea/formaldehyde, urea/melamine/formaldehyde and like condensates may serve as a slow-release nitrogenous fertilizer. Fertilizers having lesser nutritional value, but providing other advantages such as improving aeration, water absorption, or being environmental-friendly may be used. The source of such fertilizers may be, for example, animal waste or plant waste.

Nutrients are well-known and may include, for example, macronutrients, micronutrients, and minerals. Examples of macronutrients include chloride, magnesium, phosphorus, potassium, and sodium. Micronutrients are also well-known and include, for example, boron, cobalt, chromium, calcium, copper, fluoride, iodine, iron, magnesium, manganese, molybdenum, selenium, zinc, vitamins, organic acids, and phytochemicals.

The binders may be natural or synthetic. For example, the synthetic binders may include a variety of polymers such as addition polymers produced by emulsion polymerization and used in the form of aqueous dispersions or as spray dried powders. Examples include styrenebutadiene polymers, styrene-acrylate polymers, polyvinylacetate polymers, polyvinylacetate-ethylene (EVA) polymers, polyvinylalcohol polymers, polyacrylate polymers, polyacrylic acid polymers, polyacrylamide polymers and their anionic- and cationic-modified copolymers, i.e., polyacrylamide-acrylic acid copolymers, and the like. Powdered polyethylene and polypropylene may also be used. When used, synthetic binders are preferably used in aqueous form, for example as solutions, emulsions, or dispersions. While binders are not ordinarily used in growing media, they may be useful in hydraulically applied mulches and hydraulically applied growing media.

Thermoset binders may also be used, including a wide variety of resole and novolac-type resins which are phenol/formaldehyde condensates, melamine/formaldehyde condensates, urea/formaldehyde condensates, and the like. Most of these are supplied in the form of aqueous solutions, emulsions, or dispersions, and are generally commercially available.

The natural binder may include a variety of starches such as corn starch, modified celluloses such as hydroxyalkyl celluloses and carboxyalkyl cellulose, or naturally occurring gums such as guar gum, gum tragacanth, and the like. Natural and synthetic waxes may also be used.

A fiber bale may include about <NUM> to about <NUM> % of tree bark mixed with about <NUM> to about <NUM> weight % of wood components, based on the total weight of the bale. The term "wood components" refers to wood chips, wood fiber, or their combination. The wood components may be derived from coniferous and deciduous trees and may be prepared by any convenient manner, for example as disclosed in document <CIT>. Any type of wood chip may be used, but wood chips of the softwood varieties such as yellow poplar, cedar such as Western red cedar, fir such as Douglas fir, California redwood, and particularly, pine such as Ponderosa, Sugar, White, and Yellow varieties of pine are preferred. Typically, the wood components are lighter in color than the tree bark before processing. The wood components may be dyed by one or more pigments and/or pigment precursors of a tree bark when the wood components are being formed into fibers through a refiner such that the growing medium or mulch has a natural brown coloring for visual monitoring.

The term "mulch" as used herein means a layer of fibrous material that is applied to a soil to reduce erosion, to improve water retention, and/or to hold a seed in place on the soil surface long enough for the seed to germinate and for the root to develop within the soil below the mulch. Hydraulic mulches are mulches applied by spraying with water through a hydraulic seeder or similar device.

The term "growing medium" refers to a soil-free substrate or a substrate with soil, or a combination of materials used to provide physical support, water retention, aeration, and/or nutrient supply for plant growth so that a plant can establish its root system within the growing medium and allow for root growth, as the roots grow in spaces between individual particles of the growing medium.

The bark may contain one or more natural pigments or pigment precursors that give color to its layers. Some bark, (for example eucalyptus bark and sycamore bark) may be light-colored initially, but darken after its pigments are oxidized. Pigments included in the bark may include, but are not limited, to tannins such as tannic acid (e.g., quercitannic acid and gallotanic acid). Non-limiting examples of useful tree barks containing one or more pigments are named above. In addition, during heat treatment, additional pigments may develop in the bark, in the wood, or in both, which contribute to the color of the fiber product. This is what is meant by "pigment precursors.

The amount, age, moisture, and/or other properties of the bark used may influence hue and/or intensity of the imparted color. For example, low quantities of bark may result in light brown color of the mulch composition or growing medium while high quantities of bark may result in dark brown color. At least about <NUM> weight %, about <NUM> weight %, preferably about <NUM> weight % of bark may be needed to obtain mulch or growing medium dyed by the bark pigments. To color-change the mulch or growing medium, about <NUM> to about <NUM> weight % of bark may be included in the initial composition, based on the total weight of the initial composition. Additional bark may be added during the process of producing mulch or growing medium so that the final color of the fiber product may be adjusted to the desired hue. Concerning the age of bark, the bark from the most recently debarked trees generally provides for the most intense color change of the wood components. Moisture of the bark may be about <NUM> to <NUM> %, measured by ASTM D4442-<NUM>, to provide adequate color change of the wood components.

The fiber composition may have a color with a dominant wavelength from about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> to about <NUM>, or about <NUM> to about <NUM> relative to a white illuminate. The term "dominant wavelength" refers to a way of describing polychromatic light mixtures in terms of monochromatic light that evokes an identical perception of hue. It is determined on the International Commission on Illumination (CIE)'s color coordinate space by a straight line between the color coordinates for the color of interest and the coordinates for the illuminate. The intersection at the perimeter of the coordinate space nearest the color of interest is the dominant wavelength. The fiber composition may have a red to brown to black color. The fiber composition may have hsl color coordinates such that the "h value" (hue) is from about <NUM> to about <NUM>, the "s value" (saturation) is from about <NUM> to about <NUM>, and the "<NUM> value" (lightness) is less than about <NUM>. The l value may be from about <NUM> to about <NUM>.

The fiber composition may further include a non-permanent dye that is eventually removed, or which eventually fades, after the composition is opened by the fiber opening apparatus and applied in the field. Preferably, the non-permanent dye is non-toxic so that no toxic chemicals are leached from the opened fiber product into the environment. The non-permanent dye may comprise natural and/or synthetic compounds. The non-permanent dye may comprise compounds derived from plants, fungi, lichens, invertebrates, insects, minerals, the like, or a combination thereof. Any part of the plant may be utilized to provide the dye such as roots, petals, leaves, stems, shoots, stalks, hulls, husks, ripe and/or unripe fruit, seeds. Exemplary sources of plant dyestuffs include tree varieties named above; vegetables such as carrots, beetroot, red cabbage, artichoke, spinach, celery; fruit such as pomegranate, strawberries, avocado, cherries, raspberries, mulberries, elderberries, blackberries, grapes, peach; turmeric, fennel, basil, paprika, saffron, tea plants, coffee plants, barberry, bloodroot, lilac, coneflower, dandelion, goldenrod, hollyhock, ivy, St John's Wort, yellow dock, rose, lavender, cornflower, hyacinth, Queen Anne's Lace, hibiscus, daylily, safflower, camellia, snapdragon, nettle, milkweed, peony, Black-eyed Susan, hydrangea, chamomile, alfalfa, crocus, marigold, or the like. Exemplary mineral-based dyestuffs include iron oxide and carbon black. Exemplary useful non-permanent dye includes ELCOMENT BLACK <NUM> commercially available from Greenville Colorants. Another exemplary type of non-permanent dye may include green pigments.

The non-permanent dye may be combined with the bark alone and/or with the components alone before the initial composition is formed, with the initial composition, with the processed fiber composition, afterwards, or in more than one step. At least about <NUM> to about <NUM> weight % of non-permanent dye may be added to the initial composition to cause color change of the wood fiber, based on the total weight of the initial composition. About <NUM> to <NUM> weight % or more, about <NUM> to <NUM> weight %, about <NUM> to <NUM> weight % of the non-permanent dye may be added to the initial composition, based on the total weight of the initial composition. At least about <NUM>-<NUM> pounds (<NUM>-<NUM>) of non-permanent dye may be added per ton of the final fiber composition to achieve color change.

Typically, the removable non-permanent dye imparts a darker color on the fiber composition than when the non-permanent dye is absent therein. The non-permanent dye may be washed away after several days such as about <NUM> to about <NUM> days or after a more extensive time period after being applied in the field. The non-permanent dye may fade away or begin to fade away (e.g., from exposure to sunlight or other environmental conditions) after several days such as about <NUM> to about <NUM> days or after more extensive time period after the bale is opened and the fiber-containing product is applied in the field. The fiber composition may have a light-fastness, in order of increasing preference, of at least up to <NUM> day, <NUM> days, <NUM> days, <NUM> days, <NUM> month, <NUM> months, or <NUM> months or more, with minimal fading, measured according to ASTM D4303-<NUM>. The light-fastness of the dyed mulch or growing medium may be about <NUM> to <NUM> days, about <NUM> to <NUM> days, about <NUM> to <NUM> days. The term "minimal fading" refers to any visually discernable extent of fading. The term "light-fastness" as used herein refers to the resistance of a pigment to color change upon exposure to light.

The fiber-containing product with the non-permanent dye may have a color with a color with a dominant wavelength from about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> to about <NUM>, or about <NUM> to about <NUM> relative to a white illuminate. The color of the fiber composition including the non-permanent dye may vary. The fiber-containing product with the non-permanent dye may have a red to brown to black color. But other colors such as green, blue, yellow, orange, purple, or gray hues are contemplated as well. The type and amount of dye determine intensity of the color. Typically, the removable non-permanent dye imparts a darker color on the fiber-containing product than when the non-permanent dye is absent therefrom. Alternatively, the fiber-containing product with the non-permanent dye may have a lighter color than when the non-permanent dye is absent therefrom. The fiber-containing product may have a lower "h value" than the fiber-containing product without the non-permanent dye. The fiber-containing product may have hsl color coordinates such that the "h value" (hue) is from about <NUM> to about <NUM>, the "s value" (saturation) is from about <NUM> to about <NUM>, and the "<NUM> value" (lightness) is less than about <NUM>. The <NUM> value may be from about <NUM> to about <NUM>.

The fiber composition may be dyed by bark pigments and/or by one or more natural non-permanent dyes in order to comply with organic standards and secure a certificate from the Organic Materials Review Institute (OMRI).

The fiber composition advantageously can provide balanced air and water holding capacity at about <NUM>-<NUM> volume % each, preferably between about <NUM>-<NUM> volume % each, more preferably about <NUM>-<NUM> volume % each, based on the total volume of the growing medium, measured in a container having dimensions <NUM> x <NUM> x <NUM> (<NUM> inches x <NUM> inches x <NUM> inches). The air and water holding capacity may each be without limitation, about <NUM> volume % or more, <NUM> volume % or more, <NUM> volume % or more, <NUM> volume % or more, <NUM> volume % or more, <NUM> volume % or more, <NUM> volume % or more, <NUM> volume % or more, <NUM> volume % or more, or <NUM> volume % or more, of the total volume of the fiber composition, when measured in <NUM> x <NUM> x <NUM> (<NUM> inches x <NUM> inches x <NUM> inches) container. Balanced air (non-capillary) and water (capillary) holding capacity provides ideal growing conditions to plants. The volume of air space is important for root systems and plants in general, as without oxygen, roots cannot grow and absorb water or minerals. The more oxygenated the roots are, the more efficient the plants become in converting sugars into energy for plant growing. Likewise, sufficient water retention of the fiber composition is important to ensure that the roots have access to proper amount of water for photosynthesis, root growth, and efficient uptake of water by the growing plant without being oversaturated. Conventional growing mixes usually do not achieve balanced air and water retention as typically, when the volume % of water retention rises, it is at the expense of air retention and vice versa.

Water and air holding capacity, as referred to herein, are measured according to "<NPL>, which is referenced herein. The water holding capacity is measured by a Container Capacity test which measures the percent volume of a substrate that is filled with water after the fiber composition is saturated and allowed to drain. It is the maximum amount of water the fiber composition can hold. The drainage is influenced by the height of the substrate, this property is thus dependent on container size. The taller the container, the more drainage it will cause, and the less capacity of the substrate to hold water. The oxygen holding capacity is measured as percent volume of a substrate that is filled with air after the fiber composition is saturated and allowed to drain. It is the minimum amount of air
the material will have. It is affected by the container height in reverse fashion to container capacity; i.e., the taller the container, the more drainage and therefore more air space.

The sum of water and air holding capacity equal total porosity for a given density and moisture content. Total porosity defines the total volume of pores and refers to percent volume of a substrate that is comprised of pores, or holes. It is the volume fraction which provides the water and aeration in a substrate. The total porosity + the percent solids = <NUM>%. Total porosity of the fiber composition may be about <NUM> to about <NUM> volume %, about <NUM> to about <NUM> volume %, about <NUM> to about <NUM> volume %, about <NUM> to about <NUM> volume %. Total porosity of the fiber composition may be about <NUM> vol. % or more, <NUM> vol. % or more, <NUM> vol. % or more, <NUM> vol. % or more, <NUM> vol. % or more, <NUM> vol.

The water holding capacity (WHC) of the fiber composition may be also measured by ASTM D7367-<NUM>, a standard test method for determining water holding capacity of fiber mulches for hydraulic planting. According to ASTM D7367-<NUM>, the water holding capacity (WHC) of the fiber composition may be about <NUM> to about <NUM> weight %, about <NUM> to <NUM> weight %, about <NUM> to <NUM> weight %, based on the total weight of the fiber composition.

An additional advantage of the fiber composition is lower dry bulk density as well as wet bulk density when compared to prior art substrates. High density may impose transportation limits on the growing substrates as such substrates may reach their weight limit before they reach the volume limit feasible for transportation. When compared to higher density media, the lower wet and dry bulk densities of the fiber composition provide greater volume of the fiber composition to the end user at the same weight. The low density fiber composition may be added as a component to prior art media and thus lower their transportation costs by about <NUM>% or more, <NUM>% or more, <NUM>% or more, or <NUM>% or more, as compared to the prior art media alone. Additionally, a consumer may find it easier to purchase and utilize the fiber composition because of its lower weight. The dry bulk density of the fiber composition may be, in order of increasing preference, about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) or less, <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) or less, <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) or less, or <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) or less. The dry bulk density of the fiber composition may be about <NUM> lb/ft<NUM> (<NUM>,<NUM>/ m<NUM>) to about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>), about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) to about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>), about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) to about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>). The wet bulk density of the fiber composition may be, in order of increasing preference, about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) or less, <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) or less, <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) or less, <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) or less, <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) or less, <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) or less, or <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) or less. The wet bulk density of the fiber composition may be about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) to about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>), about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) to about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>), about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>) to about <NUM> lb/ft<NUM> (<NUM>,<NUM>/m<NUM>).

Table <NUM> below illustrates test results for one embodiment of a fiber composition comprising about <NUM>% wood components and about <NUM>% tree bark and another embodiment comprising <NUM>% pine wood fiber, based on the total weight of the fiber composition, in comparison to prior art growing media.

The data in Table <NUM> was collected by JR Peters Laboratory Allentown, PA, USA, using "<NPL>, which is referenced herein.

The percent volume of air space in Table <NUM> refers to the air holding capacity discussed above which was measured as the percent volume of a substrate that is filled with air after the material is saturated and allowed to drain. It is the minimum amount of air the material will have. The measuring container had the following dimensions: <NUM> x <NUM> x <NUM> (<NUM> inches x <NUM> inches x <NUM> inches).

The bulk density in Table <NUM> refers to the ratio of the mass of dry solids to the bulk volume of the substrate. The bulk volume includes the volume of solids and pore space. The mass is determined after drying to constant weight at <NUM>°F (<NUM>), and volume is that of the sample in cylinders.

The moisture content in Table <NUM> refers to the percent moisture found in a sample on a wet mass basis. This is calculated by: [(Wet weight - Dry weight)/Wet weight] X <NUM>. It denotes how much of a particular sample is comprised of water.

Table <NUM> provides comparison of prior art growing media with two embodiments of the fiber composition, specifically one embodiment of a fiber composition comprising about <NUM>% wood components and about <NUM>% tree bark and another embodiment comprising <NUM>% pine wood fiber, based on the total weight of the fiber composition. The loose bulk density data in Table <NUM> was gained by packing the fiber composition into a container measuring <NUM> x <NUM> x <NUM> (<NUM> inches x <NUM> inches x <NUM> inches) after the fiber composition was expanded by an opener and/or by using a process recommended for the specific kind of fiber composition.

Table <NUM> provides a size classification of the fiber of the fiber composition; the weight % of material passing through various sieve sizes as well as density, WHC, and total porosity are also provided. Total porosity was measured by the porometer testing "Procedures for Determining Physical Properties of Horticultural Substrates Using the NCSU Porometer by Horticultural Substrates Laboratory," as referenced above.

The sieve size of the fiber particles in the fiber composition may range from US sieve size #<NUM> to #<NUM>, but other sieve sizes are contemplated. The size of the fiber in the fiber composition may range from about <NUM> to about <NUM>. Some of the wood components and/or bark may be processed in such a way that they become a powder with a particle size of about <NUM> or smaller to about <NUM> or larger. Generally, the smaller the fiber size, the higher the WHC.

Some data in third and fourth columns of Table <NUM> are not claimed.

A compressed bale comprising wood and/or bark fiber to be opened may be produced by the following method. Tree bark, at least some of which may contain one or more pigments or pigment precursors, one or more wood components, and an optional non-permanent dye, may be combined to form an initial composition. Preferably, the wood components are wood chips. About <NUM> to about <NUM> % of a tree bark may be combined with about <NUM> to about <NUM> weight % of the wood components, based on the total weight of the initial composition. Alternatively, about <NUM> to about <NUM> weight % of the tree bark may be combined with about <NUM> to about <NUM> weight % of the wood components, based on the total weight of the initial composition.

The initial composition is heated to an elevated temperature to kill microbes in a pressurized vessel. Typically, the heating step may be conducted at a temperature in the range of about <NUM>°F (<NUM>) or lower to about <NUM>°F (<NUM>) or higher, about <NUM>°F (<NUM>) to about <NUM>°F (<NUM>), about <NUM>°F (<NUM>) to <NUM>°F (about <NUM>). The heating step may be conducted for a time sufficient to kill microbes. The heating step may be conducted for about <NUM> to about <NUM> minutes or longer under a steam pressure of about <NUM> lbs/in<NUM> (<NUM>/cm<NUM>) to about <NUM> lbs/in<NUM> (<NUM>/cm<NUM>) or about <NUM> lbs/in<NUM> (<NUM>/cm<NUM>) to about <NUM> lbs/in<NUM> (<NUM>/cm<NUM>). For example, the heating step may be conducted at a temperature of about <NUM>°F (<NUM>) for about <NUM> minutes at about <NUM> lbs/in<NUM> (<NUM>/cm<NUM>). The heating step results in a preferably substantially sterile growing medium. Preferably, the heating step results in a substantially sterile growing medium. Some of the pigments and/or pigment precursors may impart its color to at least a portion of the wood components during the heating step. The steam flow rate during the heating step may be from about <NUM> lbs/hour (<NUM>/hour) to about <NUM>,<NUM> lb/hour (<NUM>/hour).

An example of a pressurized vessel and related process is disclosed in document <CIT>, in which wood chips are fed to a pressurized steam vessel which softens the chips. Any type of wood chip may be used in this process, but wood chips of the softwood varieties such as yellow poplar, and particularly pine, are preferred.

The initial composition is subsequently processed through a refiner to form the mulch composition or growing medium. The refiner may use a plurality of disks to obtain the mulch composition or growing medium. The refiner may use two or more disks, one of which is rotating, to separate wood fibers from each other as set forth in document <CIT>. The refiner is generally operated at a lower temperature than the temperature in the pressurized vessel. The refiner may be operated at a temperature in the range of about <NUM>°F (<NUM>) to about <NUM>°F (<NUM>), about <NUM>°F (<NUM>) to about <NUM>°F (<NUM>), about <NUM>°F (<NUM>) to about <NUM>°F (<NUM>). The refiner may be operated under steam. The refiner may be operated at atmospheric pressure or elevated pressures such as pressures of about <NUM> lb/in<NUM> (<NUM>/cm<NUM>) or lower to about <NUM> lb/in<NUM> (<NUM>/cm<NUM>). The refiner may be operated at such temperatures and pressures that enable the pigments and/or pigments precursors in the bark, and optionally pigments and/or pigment precursors in the source of non-permanent dye, to impart its color to the wood fibers. The refiner step is conducted for a time sufficient to impart darker color of the bark and/or the color of the non-permanent dye to the fibers. The refiner produces fibers that are thinner than those that would be obtained without such processing.

A growing medium or mulch is thus prepared which may be further refined while additional components such as fertilizers, as set forth above, may be added. Subsequently, the resulting fiber composition is compressed into the bales for transportation.

The fiber opening apparatus to which the compressed fiber is supplied comprises a plurality of sections. The fiber opening apparatus may comprise at least one or more of the following sections: a transportation section, a fiber bale breaker, a feeder, a fiber opener, an input section, a mixing section, or a combination thereof. Some or all of these sections may be attached to one another, either temporarily or permanently. The plurality of sections may be arranged in more than one order as long as the fiber opening apparatus is capable of lowering density of the highly compressed wood and/or bark fiber, in order of increasing preference, by at least about <NUM>% or more, <NUM>% or more. The fiber opening apparatus may be connected to other production systems, temporarily or permanently. The number and dimensions of each section will depend on requirements of a specific application, especially on the target fiber density. A single section may fulfill a function of one or more sections such as the mixing section may also serve as a fiber opener section.

As can be seen in <FIG>, a fiber opening apparatus <NUM> comprises a plurality of transportation sections <NUM>, a bale breaker <NUM>, a fiber opener section <NUM>, an input section <NUM>, a mixing section <NUM>, and a packaging section <NUM>. <FIG> show a fiber opening apparatus <NUM> comprising a transportation section <NUM> directly connected to the fiber opener <NUM>.

A transportation section <NUM> may deliver a bale of fiber and/or partially or fully opened wood and/or bark fiber to other sections of the fiber opening apparatus <NUM>, for example to the bale breaker <NUM>, the fiber opener <NUM>, or the mixing section <NUM>, to another production system, or outside of the fiber opening apparatus <NUM>. A transportation section <NUM> may comprise any kind of a transportation device capable of fulfilling this function. The transportation section <NUM> may comprise a conveyor <NUM> of any kind, for example a conveyor belt, a screw conveyor, an angled conveyor; or a platform; an auger; a bucket elevator; an apron; the like, or a combination thereof. The surface of the transportation device may be roughened to prevent slipping of the bales and/or fiber, but a smooth surface of a transportation device is contemplated as well. The transportation section <NUM> may be open, at least partially enclosed, or fully enclosed. Non-limiting examples of a transportation section <NUM> are depicted in <FIG>, <FIG>; the transportation section <NUM>, as depicted, comprises conveyor belts <NUM>. As is illustrated in <FIG> and <FIG>, the transportation section <NUM> may include one or more removable guards <NUM> preventing pieces of fiber falling off of the transportation device.

As <FIG> and <FIG> illustrate, the transportation device <NUM> may further include one or more removable inserts <NUM> for adjusting dimensions of an opening <NUM> leading to other sections of the fiber opening apparatus <NUM> such as an opening <NUM> leading to a bale breaker <NUM>, to the fiber opener <NUM>, to the mixing section <NUM>, to the packaging section <NUM>, or a combination thereof. Adjusting the dimensions of the opening <NUM> according to the dimensions of a bale <NUM> helps to guide the bale <NUM> to an adjacent section such as the fiber opener <NUM> in <FIG> and ensures that the fiber opener <NUM> can properly engage the bale <NUM>. <FIG> illustrates that the inserts <NUM> may be installed to create uneven adjustments on each side of the opening <NUM>. For example, the dimensions of each insert <NUM> may differ to better serve requirements of each application. Alternatively, the dimensions of at least one of the inserts <NUM> may be adjustable so that the same inserts <NUM> can be used to accommodate a variety of bales.

To initiate breaking of the input fiber from the highly compressed wood and/or bark fiber bales <NUM>, the fiber opening apparatus <NUM> may comprise a bale breaker <NUM>, examples of which are depicted in <FIG>. The bale breaker <NUM> may receive input fiber in the form of a bale <NUM> or partially opened fiber.

The bale breaker <NUM> comprises beater members <NUM>. The beater members <NUM> are capable of dividing the input fiber into pieces. The beater members <NUM> mechanically divide a bale of input fiber <NUM> into pieces of fiber. The beater members <NUM> are capable of rotating clockwise and/or counter clockwise so that projections <NUM> of the beater members <NUM> may access the bale of input fiber <NUM>, enter the bale <NUM>, tear through the bale <NUM>, remove pieces of fiber from the bale <NUM>, and thus create partially opened fiber.

The beater members <NUM> may have any size, shape, or configuration. For example, the beater members <NUM> may be cylindrical. The beater members <NUM> may have the same or different dimensions. For example, the top beater member <NUM> may have a larger diameter than at least one of the lower beater members <NUM>. Exemplary diameters of the beater member <NUM> may range from <NUM> to <NUM> or more; however, any diameter of the beater members <NUM> is contemplated.

The beater members <NUM> may be arranged one above the other or be arranged in a variety of different configurations so that the beater members <NUM> can remove the input fiber from the bales <NUM> and/or at least partially open the fiber. The beater members <NUM> may be stacked or staggered. <FIG> illustrates three beater members <NUM> comprising two upper cylindrical beater members <NUM> of identical dimensions and a bottom cylindrical beater member <NUM> having a larger diameter than the upper beater members <NUM>. At least one of the beater members <NUM> may be spatially offset from the rest of the beater members <NUM>. As can be seen in <FIG>, the bottom-most beater member <NUM> is offset by being located closer to the opening <NUM> than the remaining beater members <NUM>.

The beater members <NUM> may comprise a plurality of projections <NUM> such as those shown in <FIG>. The beater members <NUM> may be separated by a distance creating a gap <NUM> allowing projections <NUM> of the beater members <NUM> to freely rotate around their axis without encountering projections <NUM> of a neighboring beater member <NUM> while allowing pieces of fiber to pass between the beater members <NUM>. The gap <NUM> may be adjustable and the amount of throughput fiber may be controlled by regulating the size of the gap <NUM>. The input fiber may be received by all of the beater members <NUM> at the same time or by one beater member <NUM> at a time. The input fiber may be first supplied to the bottom-most beater member <NUM> or the top-most beater member <NUM>, depending on the requirements of a specific application and a transportation device supplying the input fiber to the beater members <NUM>.

The plurality of projections <NUM> are capable of separating bales of input fiber <NUM> into pieces of fiber. The pieces of fiber separated by the bale breaker <NUM> may measure about <MAT> inch (about <NUM>) or less to about <NUM> inches (about <NUM>) or more in diameter, more preferably about ⅛ inch (about <NUM>) to about <NUM> inches (about <NUM>) in diameter, even more preferably about ½ inch (about <NUM>) to about <NUM> inches (about <NUM>) in diameter, most preferably about ¼ inch (about <NUM>) to about <NUM> inch (about <NUM>) in diameter.

The projections <NUM> may have any size, shape, or configuration thereof to engage the bales <NUM> and separate the bales <NUM> into pieces of fiber. The projections <NUM> may be shaped like spikes, nails, pins, spears, studs, pegs, screws, the like, or a combination thereof. In <FIG>, the projections <NUM> are shaped like spikes. The projections <NUM> may have sharp or dull edges. The projections <NUM> may have rough or smooth surface or rough and smooth portions. Each beater member <NUM> may have one or more horizontal and/or vertical rows of projections <NUM>. Each horizontal and/or vertical row of projections <NUM> may have one or more projections <NUM>. Preferably, the total number of projections <NUM> is such that the bale breaker <NUM> is capable of dividing the bales of input fiber <NUM> into pieces of fiber. Preferably, the configuration of projections <NUM> is such that the projections <NUM> are equally spaced apart in each row. Even more preferably, the projections <NUM> may be configured in an offset pattern so that the beater members <NUM> may engage the entire area of the bales <NUM>. As is illustrated in <FIG>, each cylindrical beater member <NUM> may comprise eight horizontal rows of projections <NUM>, each row comprising six projections <NUM> which are equally spaced apart in an offset pattern to cover as large of an area of a bale <NUM> to be opened as possible.

<FIG> further illustrates all beater members <NUM> rotating clockwise. But other embodiments are contemplated in which all or at least one beater member <NUM> rotates counterclockwise or in which at least some of the beater members <NUM> rotate in the opposite direction than other beater members <NUM>. The rotation of at least some beater members <NUM> may be adjustable.

The pieces of fiber from the bale breaker <NUM> may be transported to a fiber opener section <NUM> on a transportation device such as a conveyor belt <NUM> illustrated in <FIG>. Alternatively, the bale <NUM> containing input fiber may be transported directly to the fiber opener <NUM>, as is illustrated in <FIG>, and <FIG>. The fiber opener section <NUM> may be open or at least a partially enclosed chamber. <FIG> and <FIG> show a partially enclosed fiber opener section <NUM> having adjustable dimensions due to removable inserts <NUM>. As was already stated, the dimensions of the opening <NUM> may be adjusted with removable inserts <NUM> according to demands of a specific application and especially dimensions of incoming bale <NUM>. The fiber opener section <NUM> comprises fiber opening elements capable of lowering density of the fiber. The fiber density will be lowered by at least about <NUM>% or more, or <NUM>% or more, depending on the requirements of a specific application. The fiber opening elements may have any size, shape, or configuration thereof to fulfill this function. The fiber opening elements are rotating members <NUM>. The rotating members <NUM> are cylindrical rollers covered with wire.

The number of rotating members <NUM> may vary, depending on requirements of a specific application. For example, the fiber opener section <NUM> may contain a series of four rotating members <NUM>, as is depicted in <FIG>, but any number of rotating members <NUM> is contemplated, especially for applications with higher volume of input fiber. The fiber opener <NUM> includes at least two rotating members <NUM>, as is illustrated in <FIG>. The rotating members <NUM> may be positioned one above the other, as is depicted in <FIG>, or in an offset manner, as is illustrated in <FIG>. As <FIG> further illustrates, every other rotating member <NUM> may be offset in relation to the first rotating member <NUM>.

The rotating members <NUM> may be in contact with each other or be positioned in close proximity to one another so that a distance between two rotating members <NUM> defines a gap <NUM>. The "gap" refers to a distance between surfaces of adjacent rotating members without a wire. The gap <NUM> between the rotating members <NUM> may be adjustable and may be increased or decreased depending on the requirements of a specific application so that a percentage by which fiber density is lowered may be controlled. The gap <NUM> may be decreased to open tighter-bound fiber or increased to increase throughput of fiber. Exemplary length of the gap <NUM> may be less than <NUM>, <NUM> or more, <NUM> or more, <NUM> or more, <NUM> or more, or <NUM> or more.

The distance <NUM> between adjacent rotating members <NUM> including wire <NUM> is sufficiently small to create at least one pinch point <NUM>. The adjacent rotating members <NUM> are positioned relative to each other to provide the at least one pinch point <NUM> between the adjacent rotating members <NUM>, the adjacent rotating members <NUM> separate the fibers as the fibers pass through the at least one pinch point <NUM> so that the density of the fiber is lowered by at least <NUM>%.

The "pinch point" is a point between adjacent fiber opening elements in which fiber is engaged by the fiber opening elements at the same time so that the fiber is torn, pulled, shredded, or otherwise rendered open and separated into individual strings of fiber. Fiber is directed to each pinch point <NUM> between adjacent rotating members <NUM> and passed through each pinch point <NUM> to separate the fiber into a plurality of strings of fiber so that the density of the fiber is lowered by at least <NUM>%. In <FIG>, fiber is directed to three pinch points <NUM>; the first pinch point <NUM> being located between rotating members #<NUM> and #<NUM>, the second pinch point <NUM> being located between rotating members #<NUM> and #<NUM>, and the third pinch point <NUM> being located between rotating members #<NUM> and #<NUM>.

<FIG> illustrates a pinch point <NUM> between two rotating members <NUM> located directly above each other. The pinch point <NUM> assists in expanding the volume of the incoming fiber. As the rotating members <NUM> engage the incoming fiber which is advanced to and through the pinch point <NUM>, the surface of rotating members <NUM>, such as a wound wire including a plurality of projections <NUM>, tears the fiber apart. The fiber is thus extensively opened as the fiber passes through each pinch point <NUM> between the rotating members <NUM>.

As is depicted in <FIG>, the fiber opener <NUM> may comprise two sets of rotating members <NUM>, rotating members <NUM> of the first set rotating in the same direction and in the opposite direction than the rotating members <NUM> of the second set. The first rotating member <NUM> may turn counter clockwise into the second rotating member <NUM> and the second rotating member <NUM> may turn clockwise into the first rotating member <NUM>. When third and fourth rotating members <NUM> are included such as is depicted in <FIG>, the third rotating member <NUM> may turn counter clockwise into the fourth rotating member <NUM>, and the fourth rotating member <NUM> may turn clockwise into the third rotating member <NUM>. Additional rotating members <NUM> can be added to the configuration. The direction in which each rotating member <NUM> turns may be altered as desired as at least some of the rotating members <NUM> may rotate clockwise and counter clockwise. Alternatively, as is depicted in <FIG>, two rotating members <NUM> may rotate in different directions and turn into each other. But the rotating members <NUM> may be adjusted so that both rotating members <NUM> rotate in the same direction.

The pieces of fiber or a bale <NUM> are delivered to the fiber opener <NUM> in such a manner that fiber is engaged by at least one rotating member <NUM>. The fiber is subsequently crushed, pressed, squeezed, pushed, and/or torn apart in at least one pinch point <NUM> between adjacent rotating members <NUM> so that the individual fibers are pulled apart and density of the fiber is lowered. The fiber may be further passed onto additional rotating members <NUM> and through at least one additional pinch point <NUM> to further lower the fiber density.

The rotating members <NUM> are made from a material that enables the rotating members <NUM> to lower fiber density. Preferably, the rotating members <NUM> are made from metal such as steel, iron, aluminum, the like, or a combination thereof. Other metals and materials such as thermosetting plastics are contemplated. A wire <NUM> is wound around at least a portion of or around the entire surface area of the rotating member <NUM>.

The wire <NUM> may be made from metal or another material which is sharp enough to tear pieces of fiber apart. The wire <NUM> includes projections <NUM> assisting in lowering the fiber density by engaging the pieces of fiber and tearing them apart. The projections <NUM> may have any size or configuration. The projections <NUM> may have uniform or varying dimensions. Exemplary length and/or height of at least some of the projections <NUM> may be less than about <NUM>, <NUM> or more, <NUM> or more, <NUM> or more, <NUM> or more, <NUM> or more, <NUM> or more, <NUM> or more, depending of requirements of a specific application. The length and/or height of the projections <NUM> may be <NUM> to <NUM>, <NUM> to <NUM>, <NUM> to <NUM>. The length and/or height of the projections <NUM> may be <NUM> to <NUM>, <NUM> to <NUM>, <NUM> to <NUM>. Exemplary width of at least some of the projections <NUM> may be less than about <NUM>, <NUM> or more, <NUM> or more, <NUM> or more, <NUM> or more, depending of requirements of a specific application. The width of the projections <NUM> may be about <NUM> to <NUM>, about <NUM> to <NUM>, about <NUM> to <NUM>.

The projections <NUM> are shaped like pyramids and have a cross-section which is triangular. Each rotating member <NUM> may include more than one kind of projections <NUM>. The projections <NUM> may have sharp or dull edges. The projections <NUM> may have textured edges such as including protrusions to further assist in opening of the fiber. In <FIG> not according to the invention, the projections <NUM>, shaped like hooks, are inclined in the direction of rotation. In <FIG>, the pyramid projections <NUM> have a triangular cross-section, the projections <NUM> having a wide base <NUM> which gradually narrows at the top <NUM>. The top <NUM> may be sharp and pointed or relatively dull. The sides of each projection <NUM> may be smooth or rough. The angle of individual sides of the projections <NUM> may vary. Exemplary angles may be about <NUM>° or less, <NUM>° or less, <NUM>° or less, <NUM>° or less, <NUM>° or less, <NUM>° or less, or more than about <NUM>°.

In addition to projections <NUM>, the rotating members <NUM> may include a plurality of depressions <NUM> which may assist with separation of the fiber into individual strings of fiber. Exemplary depressions <NUM> are depicted in <FIG>.

The type of wire <NUM> wound around the surface of rotating members <NUM> may be the same on all rotating members <NUM> or different. One or more rotating members <NUM> may include at least one type of wire <NUM> with different amount and/or type of projections <NUM> per <NUM> (inch) of wire <NUM> than remaining rotating members <NUM>. Each wire <NUM> may have <NUM> projection per <NUM> (inch) of wire or more, <NUM> projections per <NUM> (inch) of wire or more, <NUM> projections per <NUM> (inch) or wire or more, <NUM> projections per <NUM> (inch) of wire or more, <NUM> projections per <NUM> (inch) of wire or more; preferable are <NUM> projections per <NUM> (inch) of wire. Each wire <NUM> may have <NUM> to <NUM> projections, <NUM> to <NUM> projections, or <NUM> to <NUM> projections per <NUM> (inch) of wire. The rotating members <NUM> may have the following spacing of the projections <NUM> along the length or width of the rotating members <NUM>: <NUM> row of projections per <NUM> (inch) of rotating member <NUM> or more, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or more rows of projections per <NUM> (inch) of rotating member <NUM>. The rotating members <NUM> may have <NUM> to <NUM>, <NUM> to <NUM>, or <NUM> to <NUM> rows of projections per <NUM> (inch) of rotating member <NUM>.

The wire <NUM> is wound spirally around the rotating member <NUM>. In <FIG>, a wire <NUM> is secured on the surface of the rotating members <NUM> by being set within a ridge <NUM>. The ridge <NUM> allows the wire <NUM> to be secured tightly, but also determines spacing and positioning of the wire <NUM> on the surface of each rotating member <NUM>.

In addition to the insertion within a ridge <NUM>, the wire <NUM> may be attached to at least one end of the rotating member <NUM> by welding or by another suitable technique.

The wire <NUM> on at least one rotating member <NUM> may be wound in such a way that the rotating member <NUM> has <NUM> or more rows of wire per <NUM> (inch) of each rotating member's width.

<FIG> shows the rotating member <NUM> having <NUM> rows of wire per <NUM> (inch) of the rotating member's width while <FIG> shows the rotating member <NUM> having <NUM> rows of wire per <NUM> (inch) of rotating member's width.

<FIG> illustrate that winding of a wire <NUM> on the rotating member <NUM> may create gaps <NUM> between rows of the wound wire <NUM>. The gaps <NUM> may have any size, shape, or a configuration. The gaps <NUM> may be symmetrical, asymmetrical, regular, irregular, the like, or a combination thereof. Exemplary width of at least some of the gaps <NUM> may be less than about <NUM>, about <NUM> or more, about <NUM> or more, about <NUM> or more, or about <NUM> or more. The gaps <NUM> may be filled with another type of wound wire <NUM> or a different material. Alternatively, the gaps <NUM> may include one or more depressions <NUM>.

Referring again to <FIG>, the fiber opener section <NUM> may further contain one or more deflectors <NUM> which may assist in guiding individual pieces of fiber to the pinch points <NUM>, to the rotating members <NUM>, or both. The deflectors <NUM> may have any size, shape, or configuration to fulfill this function. For example, the deflectors <NUM> may be shaped like slides and/or angled in such a manner that when pieces of fiber encounter the deflector <NUM>, the fiber is guided to a pinch point <NUM>. The deflectors <NUM> prevent pieces of fiber from passing by the rotating members <NUM> without being engaged by the rotating members <NUM>, and preferably by the wire <NUM> of the rotating members <NUM>. The fiber opener section <NUM> may contain any number of deflectors <NUM>. For example, the fiber opener <NUM> may contain one or more deflectors <NUM> per rotating member <NUM>, as <FIG> illustrates. The deflectors <NUM> may be located on the walls of the fiber opener <NUM>. The deflectors <NUM> may be temporarily or permanently attached to the fiber opener section <NUM>.

Preferably, the opened fiber has the desired density upon exit from the fiber opener section <NUM>. The opened fiber from the fiber opener section <NUM> may continue onto a transportation device which will discharge the opened fiber. Alternatively, the fiber may exit or be transported to another section such as a mixing section <NUM> or a packaging section <NUM>, or to an additional fiber opening section <NUM> to open the fiber further. Alternatively still, the fiber may be transported to an input section <NUM> so that additional desired components such as peat, compost, bark, coir, nutrients, fertilizers, and other components named above, may be added to the opened fiber. An exemplary input section <NUM> is shown in <FIG>. After the fiber is sufficiently opened, moisture can be added to the fiber to reduce dust, facilitate easier transport, or a combination thereof.

<FIG> depicts a mixing section <NUM> comprising at least a partially enclosed chamber for mixing the optional components supplied from the input section <NUM> and/or the partially opened fiber. The mixing section <NUM> may comprise one or more mixing members <NUM>. The one or more mixing members <NUM> may mix individual optional components and/or the fiber. The mixing members <NUM> are capable of rotating clockwise and/or counter clockwise. All mixing members <NUM> may rotate clockwise or counter clockwise. Alternatively, at least some of the mixing members <NUM> may turn in the opposite direction than the other mixing members <NUM>. The rotation of the mixing members <NUM> may be altered as desired. <FIG> depicts three mixing members <NUM>; the first mixing member <NUM> rotating clockwise, the second mixing member <NUM> rotating counter clockwise, and the third mixing member <NUM> rotating clockwise.

All mixing members <NUM> may have the same or different dimensions. The mixing members <NUM> may have any size, shape, or configuration. As is depicted in <FIG>, the mixing members <NUM> may be cylindrical. The mixing members <NUM> may be arranged directly one above the other or in a variety of different configurations as long as the mixing members <NUM> are capable of engaging and properly mixing the optional components and/or fiber. The mixing members <NUM> may be stacked or staggered, as is illustrated in <FIG>. Staggering of the mixing members <NUM> may aid proper mixing. The mixing members <NUM> may be separated by a distance creating a gap <NUM> allowing projections <NUM> of the mixing members <NUM> to freely rotate around the axis without encountering projections <NUM> of a neighboring mixing member <NUM> while mixing the optional components and/or fiber. The gap <NUM> may be adjustable so that the throughput of fiber may be regulated. The optional components and/or fiber may be received by the top or the bottom mixing member <NUM> first.

The one or more mixing members <NUM> may comprise projections <NUM> aiding mixing of the optional components and/or fiber. The projections <NUM> may have any size, shape, or a configuration thereof to engage the optional components and/or the partially opened fiber. The projections <NUM> may be shaped like spikes, nails, pins, spears, studs, pegs, screws, the like, or a combination thereof. In <FIG>, the projections <NUM> are shaped like spikes. The projections <NUM> may have sharp or dull edges. The projections <NUM> may have rough or smooth surface. Each mixing member <NUM> may have one or more horizontal and/or vertical rows of projections <NUM>. Each horizontal and/or vertical row of projections <NUM> may have one or more projections <NUM>. Preferably, the total number and configuration of projections <NUM> is such that the optional components and/or fiber may be properly mixed. The projections <NUM> may be equally spaced apart in each row or configured in an offset pattern.

At least some of the mixing members <NUM> may be designed as rotating members <NUM>, optionally wound with wire <NUM> just like the rotating members <NUM> in the fiber opener section <NUM> to provide further opening of fiber while mixing the fiber and/or optional components at the same time.

The optional components and/or the fiber may be discharged or transported to a packaging section <NUM> directly from the bale breaker <NUM>, the fiber opening section <NUM>, the input section <NUM>, or the mixing section <NUM>. As can be seen in <FIG>, the partially opened fiber and/or optional components enter the packaging section <NUM> located downstream from the mixing section <NUM>. Alternatively, the mixture may be transported by a conventional transport apparatus such as a conveyor to a packaging station remotely located.

The volume of opened fiber may be increased or decreased by regulating the rotational speed of at least one beater member <NUM>, at least one rotating member <NUM>, at least one mixing member <NUM>, or a combination thereof. The frequency of rotation of any of the rotating members <NUM>, <NUM>, and <NUM> may be about <NUM> rpm or more, <NUM> rpm or more, <NUM> rpm or more, <NUM> rpm or more, <NUM> rpm or more, <NUM> rpm, or more, <NUM> rpm or more, or <NUM> rpm or more. The frequency of rotation of any of the rotating members <NUM>, <NUM>, and <NUM> may be <NUM> to <NUM> rpm, <NUM> to <NUM> rpm, or <NUM> to <NUM> rpm.

The invention also pertains to a process for lowering density of highly compressed fiber by opening the fiber and producing a growing medium or mulch including the opened fiber with lowered density. The process may comprise the following steps, wherein the steps may be performed in any order and repeated as desired. The process may include a step of loading one or more bales of fiber onto a transportation device which may supply the bales of highly compressed input fiber to a bale breaker. The process may include a step of passing at least one bale of the compressed fiber through a bale breaker before supplying the fiber to a fiber opener. The bale breaker may divide the one or more bales of highly compressed input fiber into smaller pieces, tearing the fiber apart, as well as beating and pulling apart pieces of fiber from the bale. The process may include a step of creating partially opened fiber by separating the bale into pieces of fiber. The process may further include a step of engaging the one or more bales with the projections of one or more beater members turning clockwise and/or counter clockwise. The process may further include a step of adjusting a gap between two or more beater members by increasing or decreasing the distance between beater members, changing the direction of rotation of at least some beater members, and/or adjusting the speed of rotation of at least some of the beater members. The process may further include a step of transporting the pieces of fiber or one or more bales of fiber to the fiber opener section and opening the fiber by passing the fiber between one or more rotating members of the fiber opener section. The process includes a step of engaging compressed or partially opened fiber with at least some of the plurality of projections of the opener rotating members. The opener rotating members may be rotating clockwise, counter clockwise, or a combination thereof. The process may include a step of adjusting the speed and/or direction of rotation of at least one of the opener rotating members and/or increasing and/or decreasing a gap between the one or more beater members. The process includes a step of pulling fiber apart, expanding and opening compressed or the partially opened fiber as pieces of fiber pass between the opener rotating members, through a pinch point, or both. The process includes a step of passing fiber through a pinch point between adjacent opener rotating members and thus opening the fiber as the fiber is being pressed, crushed, squeezed, pushed, and/or torn apart in the pinch point. The process includes a step of separating compressed or partially opened fiber into a plurality of strings of fiber in the pinch point. The process may include a step of decreasing the gap to open tighter-bound fiber or increasing the gap to increase throughput of fiber. The method may include guiding individual pieces of fiber and/or partially opened fiber to and/or through at least one pinch point by using one or more deflectors. The process includes a step of engaging fiber with one or more projections of one or more opener rotating members of the fiber opener section and opening fiber with wire rollers. The process may include a step of regulating capacity and volume of opened fiber by changing rotational speed of at least one beater member, at least one opener rotating member, at least one mixing member, or a combination thereof. The process may also include a step of supplying optional components from an input section. The process may further include a step of mixing the fiber and/or optional components in a mixing section by one or more mixing members. The process may include a step of packaging the at least partially or fully opened fiber. The process may include discharging the opened fiber. The process may include adding and/or removing one or more sections of the fiber opening apparatus as well as attaching one or more sections of the fiber opening apparatus to one another, for example by bolts, nuts, the like, or a combination thereof, temporarily or permanently. The process may include adding the opened fiber as a component into a growing medium or mulch. The process may include a step of forming a growing medium or mulch including the opened fiber.

This disclosure also relates to a growing medium or mulch prepared by the process described above. The resulting growing medium or mulch includes the fiber opened by the fiber opening apparatus. The resulting density of the mulch or growing medium including the opened fiber is lower than the density of the fiber in a compressed bale by about <NUM>% or more, or <NUM>% or more. The resulting growing medium or mulch may be applied hydraulically. The resulting density of the mulch or growing medium including the opened fiber is lower than the density of the fiber in a compressed bale by at least about <NUM><NUM>%, <NUM> to <NUM>%, or <NUM> to <NUM>%.

Claim 1:
Fiber opening apparatus (<NUM>) usable for opening a compressed growing medium including fibers, the compressed growing medium comprising wood and/or bark fiber; the fiber opening apparatus (<NUM>) comprising:
at least one section (<NUM>, <NUM>) having at least one set of adjacent rotating members (<NUM>, <NUM>) with projections (<NUM>, <NUM>); and
a fiber opener section (<NUM>) having opener rotating members (<NUM>), each of the opener rotating members (<NUM>) having a surface including at least one wire (<NUM>) wound around at least a portion of the surface characterized in that each of the opener rotating members (<NUM>) has ridges (<NUM>) on the surface, the at least one wire being secured within the ridges and in that the wire (<NUM>) includes a plurality of projections shaped as pyramid projections (<NUM>);
each pyramid projection (<NUM>) having a triangular cross-section, forming a wide base (<NUM>) which gradually narrows at a top (<NUM>) of the pyramid projection (<NUM>); the pyramid projections (<NUM>) being capable of engaging the growing medium,
the opener rotating members (<NUM>) being positioned relative to each other to provide at least one pinch point (<NUM>) between adjacent opener rotating members (<NUM>), the opener rotating members (<NUM>) being capable of separating fibers from the growing medium passing through the at least one pinch point (<NUM>) so that the density of passing fiber is lowered by at least <NUM>%, relative to the density of the input fiber of the compressed growing medium.