Plate forming die set

A method of converting a forming apparatus for receiving a paper web and press forming multiple blanks into a plurality of three-dimensionally shaped paper products within a single die cavity in each forming cycle into a forming apparatus in which the plurality of blanks are simultaneously shaped into a plurality of three-dimensionally shaped paper products within separate die cavities in each forming cycle, comprising the steps of:

• (a) retrofit installing an existing forming apparatus having a die set that defines a single die cavity with at least one reciprocating die plate, at least one upper die plate and at least one lower die plate in vertically stacked relationship with respect to the die set of the existing forming apparatus so as to form a respective additional die cavity;
• and
• (b) providing a guide means for cyclically transferring a single paperboard blank from a blanking means into each of said die cavities during a first portion of each forming cycle;
• wherein said guide means includes a plurality of stationary guide means, and said providing step includes placing each of said stationary guide means in alignment with a respective one of said die cavities for receiving and transferring a single paper blank into the respective die cavity aligned therewith in each forming cycle;
• and wherein said guide means also includes a movable guide means for receiving each paper blank from the blanking means and for successively moving and transferring said paper blank into each of said stationary guide means, and said providing step also includes installing the movable guide means with an inlet end positioned in proximity to an outlet side of said blanking means and with an outlet end arranged so as to be successively movable into proximity with an infeed side of each of said stationary guide means during each forming cycle.