Method for forming corrugated paper container and container made therefrom

A method for molding a corrugated paperboard container having a first layer of flat paperboard to which is attached a second layer of contoured paperboard, said contoured layer having a plurality of flutes, each said flute including a first flute tip and a second flute tip, each flute having a flute rise the flute rise being substantially vertical at the midpoint between said flute tips, the first layer of paperboard having a thickness in the range of 0.3 mm to 1.5 mm, and the contoured layer of paperboard having a thickness in the range of 0.23 mm to 0.5 mm, said forming method comprising;

• providing moisture to said paperboard, the amount of moisture added is substantially within the range of 3% to 11% by weight, said paperboard having folds;
• placing said corrugated paperboard into a stamping die, said stamping die having a male die and a female cavity shaped in the shape in which the paperboard is to be formed said stamping die including a draw ring;
• pressing said paperboard between said die and said cavity to apply substantially four tons of pressure to said paperboard;
• applying heat to said paperboard simultaneously with said application of pressure;
• said heat creating steam within said cavity to steam iron said folds to form container;
• tensioning said paperboard while said paperboard is pressed between said die and said cavity;
• removing said die from said cavity;
• and ejecting said paperboard from said cavity after said die has been removed.