In-line application of dispersion barrier

A method of forming paperboard products, the method comprising steps of:

• dispensing paperboard material from a supply roll carrier of a coating system;
• delivering a coating onto the paperboard material;
• advancing the coated paperboard material to a forming station of a pressware forming system;
• and
• pressing the coated paperboard material into a desired shape via a forming tool of the forming station.

A system for forming paperboard products, the system comprising:

• a coating system comprising;
• a supply roll carrier configured to dispense paperboard material;
• a powered tensioning pinch roller configured to advance the paperboard material;
• a waterfall dispenser configured to deliver a coating to the paperboard material;
• a supply tank configured to supply the coating to the waterfall dispenser;
• a controlled precision metering pump configured to meter the coating from the supply tank to the waterfall dispenser;
• a plurality of air nozzles configured to deliver air to the coated paperboard material to dry the coating;
• a compressed air source configured to supply compressed air to the plurality of nozzles;
• an air pressure regulator configured to meter the compressed air to the plurality of nozzles;
• an electric heater configured to heat the compressed air upstream of the plurality of nozzles;
• a plurality of idler rollers configured to direct the coated paperboard material near the plurality of air nozzles;
• and
• a control system communicatively connected to the controlled precision metering pump and configured to dictate an amount of the coating delivered onto the paperboard material;
• and
• a pressware forming system comprising:
• a scoring station including a scoring tool configured to score the coated paperboard material after the coated paperboard material has been advanced to the pressware forming system;
• and
• a forming station including a forming tool configured to press the coated and scored paperboard material into a desired shape.