Europe's most innovative production for fiber cast molded parts

pulp production

from renewable raw materials

In the future, it will become increasingly important to be able to rely on reliably deliverable, innovative and safe products and packaging that are sustainably produced in Germany and Europe and are based on the development of the circular economy and a fair production chain. With these quality features and our know-how in research and development, which has been constantly expanding over decades, we are always at your disposal.

What is cast fiber or pulp?

(English terms: Molded pulp, Fiber pulp, Pulp molding)

Molded Pulp is a very environmentally friendly materialmade from waste paper, renewable fibers like hay, straw, hemp or the like Pulp material will be produced. The material Molded Pulp is 100% recyclable, 100% recyclable and/or 100% compostable.

Everyone knows this wonderful fiber cast material, and yet the material is only noticed when a product made of this material is referred to: Egg carton! This packaging protects the sensitive food product "eggs" comprehensively - very simply and absolutely safely.

Unfortunately, this fiber cast material has literally disappeared into obscurity in the last few decades and would probably one day have been replaced by modern, albeit environmentally unfriendly products such as synthetics and plastic. With the emerging topic of "sustainability", a new focus is set in the area of ​​packaging & logistics. As a result, the use of plastic is viewed very critically. The industry is now trying to resort to substitutes such as B. "natural plastics“Which in reality are not natural.

With our 3D concepts, we at PAPACKS have brought the material fiber cast onto the "stage of sustainability". For this we were nominated for the GreenTec Award 2017 among the last 3 candidates. We see this nomination as a tribute to the material Molded Pulp.

Today's made by us Molded Pulp is with the concept egg carton no longer to be compared. Today's special requirements from the industry were the challenge for us as a fiber cast manufacturer and fiber cast producer to further develop and optimize production with the fiber cast material. Fiber forms are meanwhile water resistant, grease repellent and also fireproof and thus usable in a wide range of industries. Of the Automotive industry as transport trays and Packaging of food products the area of ​​application extends to the end customer area.

The molded fiber parts are the ecologically and also economically only answer for packaging and transport questions. With this material pulp the turning point is heralded, To ban plastic from the packaging world. In the field of transport and logistics, fiber cast is processed into transport trays and replaces the expanded trays Polystyrene (EPS) or extruded polystyrene (XPS), as well foams known as well Styrofoam.

A characteristic of the material cast fiber is its versatility. The material itself has a high Shock absorption on. By adding various environmentally friendly fabrics the properties of the raw material can be enhanced or even changed. Nevertheless, these are molded fiber parts biodegradable or directly compostable, however, it is most effective direct reuse about a "green circulatory system' to shred the packaging after use and use this material to make new molded fiber parts.

In addition to the protective function, the Molded Pulp Our 3D packaging also features a new, modern design with a high recognition value.

PAPACKS® Pulp Product Categories

Plastic-free - home compostable - fresh fiber/primary fiber - food grade
Transport trays
charge carrier

PAPACKS® FIBER CASTING Molded parts for one-way transport, made from fresh fibre/primary fibre, ready for circular economy cycles. Optionally with fiber abrasion protection/grease and moisture resistance. Replaces plastic, plastic trays and time-consuming cardboard constructions for delivery, logistics and transport protection.

Product packaging
inlays

PAPACKS® FIBER CAST molded parts for product protection, shipping protection and a sustainable product presentation.
Made from fresh fiber or primary fiber, ready for the circular economy. Optionally with fiber abrasion protection, grease and moisture resistance. Replaces plastic blisters, plastic inlays, complex cardboard constructions, foam and styrofoam inserts.

Food primary packaging

PAPACKS® FIBER CASTING Molded parts for one-way transport, made from fresh fibre/primary fibre, ready for circular economy cycles. Optionally with fiber abrasion protection/grease and moisture resistance. Replaces plastic, plastic trays and time-consuming cardboard constructions for delivery, logistics and transport protection.

Pharma, medicine,
Cosmetics

Certified primary packaging made from PAPACKS® FIBER CAST for the medical/pharmaceutical industry.
Optionally with PAPACKS® ORGANIC COATING for oxygen and water vapor barrier as well as grease and moisture resistance. Certification according to the hygiene standards for packaging manufacturers of primary packaging and other relevant management systems according to ISO 9001.

Advantages of fiber casting

Good for the environment, perfect for your customers!

The biggest advantage we are using Molded Pulp offer is to create a closed Circulatory system for industry and manufacturing companies. We produce useful packaging or transport packaging Molded Pulp for your products in the circulatory system. This generally saves you on the cheap purchase of pulp-suitable material compared to plastic - You save costs for recycling / disposal as well as costs for the constant purchase of new raw materials, since the old ones stay in the cycle and are reused.

Customer satisfaction through sustainability

demonstrably more customer acceptance through sustainable packaging

100% plastic free

no additional charges for using unrecycled plastic in packaging

100% renewable raw materials

100% plastic-free, primary fibre, ISEGA/FSC®-certified, PFAS-free, certified for direct food contact

Less packaging license costs

compared to a plastic tray of the same shape (source: www.licensesero.de)

zero waste

complete composting in home compost

Reduced CO2 emissions

4 times lower CO2 emissions per tray than with plastic

High dimensional stability

Molded fiber molded parts withstand a higher impact of force up to deformation compared to plastic trays.

Recyclable in waste paper

Disposal in waste paper for reuse or composting

Temperature resistant at over +100 degrees

suitable for microwave and refrigerator, flame retardant

Grease-resistant and water-repellent

possible through organic coating

Odorless and tasteless

Pulp is odorless. We use the purest fresh fiber in our production.

PAPACKS® Organic Coating

optional: organic coating application for barrier protection, abrasion coating, water vapour, oxygen barrier and other property enhancements

Save space / save storage costs

Molded fiber parts can be nested inside each other and are therefore more space-saving compared to a folded cardboard solution.

Adaptability of the construction

Products are protected by the individual, specially designed 3D shape and the soft cushioning fibers.

Automated / packable by robot

Pulp molded parts can be used in automated and robot-controlled processes.

Shock absorbing / high transport safety

Pulp molded molded parts are tough or soft and absorb repeated impacts without breaking.

Suitable for sea freight

Molded fiber Molded fiber parts can be used in the area of ​​sea freight.

Independent of raw material

Pulp can be made from various sustainable raw materials, e.g. B. industrial hemp.

Guaranteed throughout Europe — by PAPACKS®

The seal of sustainability

As a company, we have a special responsibility for the preservation of global natural resources and the careful use of resources through our actions. We use natural resources and renewable raw materials and consider the entire value chain.

PAPACKS® PRODUCTIONS IN EUROPE

Production sites in Germany and Europe

PAPACKS® GIGAFACTORY 1

Arnstadt / Thuringia (FOODSAFE / MEDICAL DEVICES)

Molded fiber molded parts of certified primary packaging for the food and medical/pharmaceutical industries. Certification according to the hygiene standards for packaging manufacturers of primary packaging and other management systems according to ISO 9001:2015.

Capacity pa: + 180.000.000 pcs.

PAPACKS® GIGAFACTORY 2

Arnstadt / Thuringia (FOODSAFE / MEDICAL DEVICES)

Commissioning in 2022.
Molded fiber molded parts of certified primary packaging for the food and medical/pharmaceutical industries. Certification according to the hygiene standards for packaging manufacturers of primary packaging and other management systems according to ISO 9001:2015.

Capacity pa: + 180.000.000 pcs. 

PAPACKS® PRODUCTION NETHERLANDS

Netherlands (FOODSAFE)

Molded fiber molded parts of certified primary packaging for the food and medical/pharmaceutical industries. Certification according to the hygiene standards for packaging manufacturers of primary packaging and other management systems according to ISO 9001:2015.

Capacity pa: + 50 million pieces

PAPACKS® R&D Innovation Hub

Cologne / NRW (INDUSTRIAL)

Our place for technical innovations, small series production, further development of our 3D tool technology and raw material research.

Capacity pa: + 5 million pieces

"The show with the mouse" explains our sustainable advent calendars

The mouse shows one of the PAPACKS® fiber cast productions with sustainable advent calendars.

A television production by ARD / Das Erste® and WDR® for "Die Sendung mit der Maus"

How is cast fiber or a molded fiber part manufactured?

Fiber casting is made from waste paper fibers dissolved in water, renewable fibers such as hay, straw, hemp, etc. in a vacuum, pressing and drying process in the desired shape.

  • 1
    Processing fibers
    Paper and cardboard waste is dissolved in a “pulper” (large mixer) and then diluted by a control system and prepared accordingly in various processing basins until the so-called fiber thick matter in the work basin is ready for use.
  • 2
    Tool for fiber molding
    The tools for the corresponding cast fiber parts or fiber molds are complex and resemble a metal screen with a counterpart. These correspond to the shape of the later desired fiber casting. The appropriate tool counterpart and a specially calculated scheme for the screen structure will later influence the water drainage and vacuum suction so that the molded fiber part is formed evenly at all points.
  • 3
    Process of molded part production
    The tools are now immersed in the working basin with the pulp mixture and suck the pulp mixture through the sieves by means of a vacuum. Fibers are retained by the sieves and thus build up the molded part. After surfacing, the molded parts are removed from the sieve using a counter-mold and a vacuum and placed on the drying section.
  • 4
    Drying section
    The drying section consists of a grid-like conveyor belt, which enables air permeability. Drying hoods blow heated air onto the molded parts. At the end, the molded parts are removed and placed on pallets.
  • 5
    Form press and punch
    Depending on customer requirements and the area of ​​application, the molded parts can be re-pressed. The fitting accuracy of the molded parts is stabilized and fixed in a press under the action of heat. In addition, desired embossings and perforations can be incorporated or, if necessary, the molded parts can be punched and cut accordingly.

Cast fiber drop test

Based on our extreme drop test - from a height of approx. 3 m - from a cardboard box with a fiberglass inlay filled with two heavy 0,75 liter bottles, you can see the protection and transport safety that fiberglass offers a product like no other material.
Check out our video!