Methods and systems for producing pressware

A scoring and punching tool which forms a blank from material that is scored and punched, the scoring and punching tool for use with a system which forms a tray from the blank, the scoring and punching tool comprising:

• a top tool including
• a punch and blade backing plate retaining a plurality of punches and a plurality of blades, each punch configured to punch a successive one of a plurality of holes in the material, and each blade configured to press a successive one of a plurality of scores in the material, and
• a punch and blade holder including
• a plurality of punch openings, each punch opening associated with a successive one of the punches and configured to provide a guide for the motion of the punch when the holes are punched, and
• a plurality of blade openings, each blade opening associated with a successive one of the blades and configured to provide a guide for the motion of the blade when the scores are pressed;
• and
• a bottom tool including
• a striker plate having an upper surface that includes a plurality of slug openings and a plurality of score formers, each slug opening associated with a successive one of the punches, each slug opening being an opening configured to receive a successive one of a plurality of slugs that are created when the holes are punched, each score former associated with a successive one of the blades, each score former being an impression on the upper surface in which a successive one of the scores is pressed,
• a striker backing plate supporting the striker plate and through which the slug openings extend in a vertical direction, and
• a slug removal plate supporting the striker backing plate, the slug removal plate including
• a plurality of channels, each channel aligned with a successive one of the slug openings and configured to receive a successive one of the slugs,
• a plurality of air passages through which air flows to move the slugs, at least a portion of the air passages coupled to the channels,
• a slug capture chamber coupled to the channels and configured to receive the slugs from the channels, and
• a slug exit port coupled to the slug capture chamber and through which the slugs pass when the slugs are moved by air flowing through the air passages.

A scoring and punching tool which forms a blank from material that is scored and punched, the scoring and punching tool for use with a system which forms a tray from the blank, the scoring and punching tool comprising:

• a top tool retaining
• a plurality of punches positioned in a quadrilateral shape, with a successive one of four groups of punches being positioned along each side of a perimeter of the quadrilateral, each punch configured to punch a successive one of a plurality of holes in the material, and
• a plurality of blades divided into four groups that are spaced apart from one another, with at least a first portion of the blades of each group positioned to form a quadrant of a circle, each group of blades is configured to press a successive one of a plurality of groups of scores into the material such that each group of scores is shaped to form a successive one of four rounded corners of the tray;
• and
• a bottom tool including a striker plate having an upper surface that includes
• a plurality of slug openings positioned in a quadrilateral shape, with a successive one of four groups of slug openings being positioned along each side of a perimeter of the quadrilateral, each slug opening associated with a successive one of the punches, each slug opening being an opening configured to receive a successive one of a plurality of slugs that are created when the holes are punched, and
• a plurality of score formers divided into four groups that are spaced apart from one another, with at least a first portion of the score formers of each group positioned to form a quadrant of a circle, each group of score formers aligned with a successive one of the groups of blades and each score former associated with a successive one of the blades, each score former being an impression on the upper surface in which a successive one of the scores is pressed.