The Versatility of Molded Pulp Packaging

HEAVY WALL

Manufactured using a single mold. Formed wall thickness from about 3/16 to 3/8 inches (5mm to 10mm) with one surface is relatively smooth and the other side is rough. Oven dried and primarily used for support packaging of non-fragile, heavier items.

TRANSFER MOLDED

Manufactured using one forming mold and one transfer mold. Fiber wall thickness from about 1/8 to 3/16 inches (3mm to 5mm). Surfaces are relatively smooth on one side. Most common uses are for many types of electronic product packaging.

THERMOFORMED

Manufactured using multiple heated molds with fiber wall thickness of about 3/32 to 5/32 inches (2mm to 4mm). Surfaces are smooth and forms are well detailed with minimal draft angles. Due to the hot mold pressing process, the walls are somewhat more dense.

PROCESSED

Processed molded pulp products are those that have undergone a secondary procedure in addition to the core manufacturing process. Secondary processing might include dying, coating, printing, die-cutting, chemical additions, etc.

HYBRID

This type combines molded pulp with outer material variations to achieve specific functions such as moisture resistance or enhanced presentation. Some brands use hybrid formats to elevate shelf appeal while keeping the main structure fiber based.

STEP 1 - MIXING

The first step is to soak the recycled materials in water and mix them until the slurry achieves the right consistency of pulp. This step ensures that the fibers can form a stable structure once they enter the mold and the excess water is returned to the system.

STEP 2 – FORMING

The second step forms the pulp to shape with custom designed tools. The tools are lowered into the pulp mixture and the water is pulled through the mesh with a vacuum. The upper tools press into the lower tools to help shape the pieces. Suction from the vacuum helps bind the fibers.

STEP 3 – DRYING: 

After forming, the parts need to be dried to eliminate the remaining moisture. Parts can either be dried with automated, industrial ovens or through natural evaporation outside. Drying is essential for achieving the proper strength, maintaining shape, and preparing the packaging for later handling.

STEP 4 – PRESSING 

After the pulp is dried, the surface can become uneven. To smooth the surface, each product is pressed onto solid metal tools. In addition to making the pulp parts look better, the pressing improves the consistency of the shape for even stacking and nesting for shipping and storage.

STEP 5 – TRIMMING 

The pressed parts are then trimmed to achieve clean edges and uniformed appearance. All the scraps (cut-offs) are returned to the pulp mixture and are re-used. For specialty and high quality products, the parts may also undergo a variety of after-trimming treatments.

RECYCLED PAPER PULP

Recycled paper pulp remains the primary material due to its wide availability and consistent performance. It is sourced from recovered fibers that can be efficiently reprocessed which makes it one of the most cost effective and environmentally responsible choices for large scale production.

RECYCLED CORRUGATE

Recycled pulp comes from corrugated boxes and paperboard waste. The pulp has longer, stronger fibers that has enhanced compression resistance and greater durability, for deeper or heavier packaging formats. It is often utilized when the molded form must maintain shape under weight or stacking pressure.

WOOD PULP

Wood pulp uses virgin fibers from responsibly managed forests and is known for its purity and consistency. It produces molded pulp packaging with precise detail and uniform color. The fibers are refined to ensure excellent mold-ability and stability.

BAMBOO/BAGASSE FIBER

Bamboo fiber is derived from fast growing bamboo and is known for its excellent surface quality and enhanced durability. 

Bagasse fiber is a natural byproduct from sugarcane production. After extraction, the remaining fibers are cleaned and refined into pulp.

STRAW

Straw pulp is naturally stiff and ideally suited to products that need firm structures. Straw pulp products have smooth surfaces, but because of its shorter fibers, are not as flexible when compared to other materials.

Straw is an ultra-rapidly renewable resource, because crops are harvested two to four times per year in each climate zone.

MYCELIUM

Primarily made from mycelium (the root structure of mushrooms) combined with agricultural waste, this material is fully biodegradable and renewable. Suitable for large and fragile goods, mushroom packaging is dense and provides good protection.