Europe's 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.

How it works

A manufacturing technique older than plastic, with today's know-how for tomorrow's packaging future.

What is cast fiber or pulp?

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

Molded Fiber 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 Fiber can be reused and can be recycled into waste paper.

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fiber cast material has literally disappeared into obscurity in the last few decades and would probably one day have been replaced by modern, albeit environmentally unfriendly products such as synthetics and plastic.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.

We from the PAPACKS have brought the fiber cast material onto the "stage of sustainability" with our 3D concepts. 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 Fiber.

Today's made by us Molded Fiber 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 basic material can be strengthened or even changed. The most effective is this 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 Fiber Our 3D packaging also features a new, modern design with a high recognition value.

raw materials and materials

PAPACKS® Virgin Fiber — Pulp

Cellulose/Virgin Fiber is a premium raw material in the virgin pulp category, ideal for high specification packaging. This raw material comes from FSC®-certified, sustainably managed forests and thus guarantees an environmentally friendly and responsible origin. The use of cellulose/virgin fiber in packaging solutions helps to reduce the environmental impact while ensuring the quality and functionality of the packaging.

PAPACKS® Industrial Hemp

Commercial hemp is a rapidly renewable source of raw materials that can be harvested in a short time and thus makes an important contribution to sustainability. During growth, hemp plants absorb large amounts of carbon dioxide (CO2) from the atmosphere, thereby actively contributing to the reduction of greenhouse gas emissions and combating climate change. In addition, hemp plants are very adaptable and require less water than many other crops. This makes hemp an environmentally friendly and resource-saving alternative.

PAPACKS® Plant-Based Coating​

A plastic-free solution specifically designed for the OTR (Oxygen Transmission Rate) and WVTR (Water Vapor Transmission Rate) barriers offers additional benefits for sensitive products that require fiber bonding or necessary moisture resistance. This innovative technology makes it possible to eliminate the use of plastics in packaging while ensuring product quality and shelf life. This opens up new possibilities for sustainable packaging designs and materials that meet the needs of different industries and applications.

FOOD PACKAGING

Suitable for direct food contact. Benefit from the strength of native fibers complemented by plant-based ones PAPACKS® coating. Our environmentally friendly packaging solutions meet all barrier properties and food safety requirements and are specifically designed for direct food contact. This ensures both the protection of the environment and the maximum integrity of your product.

CONSUMER PACKAGING

Present your products effectively. Underline the value of your products with our high-quality packaging solutions. They are made from renewable resources and combine aesthetics with functionality. Our packaging ensures a striking appearance and protects your product in an environmentally friendly way.

LOGISTICS PACKAGING

Transport safety guaranteed. Protect the integrity of your products during transport with our robust packaging solutions. We use durable materials and innovative designs to ensure the safe arrival of your products in perfect condition. At the same time, we ensure a smaller ecological footprint and a more efficient supply chain.

INNOVATION PACKAGING

We push the boundaries of packaging technology. Our innovative packaging, made from virgin fibers OR alternative renewable materials and equipped with a plastic-free barrier coating, offers a sustainable solution for a wide range of products - from bottles and cosmetics to medicines and refill systems. The step into the future of environmentally friendly, intelligent packaging.

The most important properties of molded pulp packaging

Sustainability

Our cast fiber packaging is sustainably produced in Germany. We only use renewable raw materials and fibers that are FSC® certified and come from sustainable forestry. Our production facilities are powered by renewable energy. This enables us to achieve an optimal ecological footprint compared to packaging based on fossil raw materials, such as plastic packaging. In contrast to synthetic materials such as EPS, our cast fiber packaging can be recycled into waste paper.

Raw material-independent pulp production

Pulp is a versatile material that can be made from a variety of sustainable raw materials, making it optimally adaptable to different requirements and environmental regulations. An example of such a sustainable raw material is industrial hemp, which is characterized by its rapid regrowth rate and environmentally friendly properties. By using various sustainable raw materials, pulp molding can help to reduce the ecological footprint in production and thus make an important contribution to the protection of our natural resources.

Suitable for sea freight applications

Molded fiber Molded fiber parts are suitable for use in sea freight. Thanks to their robust and resistant nature, they can withstand the special demands of sea transport and ensure safe and efficient transport of goods over long distances and in different environmental and climatic conditions.

Shock absorbing / shock absorbing / dimensional stability

With molded pulp packaging, you benefit from excellent shock absorption, which ensures the safe transport of your products. Depending on the design, the fiber cast molded parts can be easily deformed and still retain the necessary stability, especially when the packaging is impacted directly during transport.

Heat and cold protection

Pulp can be an excellent insulator and, with proper construction, provides some protection to products from heat or cold. Molded pulp does not break on impact like frozen packaging with thermoformed plastic parts. It is temperature resistant in excess of +100 degrees Celsius, making it an ideal choice for applications exposed to high temperatures.

In this way, processes can be accelerated in industry, such as in the glass production of bottles, which as a result do not have to be cooled first before they are placed in transport trays, as is necessary with plastic trays.

Automated and robotic use

Fiber cast molded parts are suitable for use in automated and robot-controlled processes. Their precise and consistent shape allows them to be easily handled and packaged by robots and automated systems. This enables efficient and cost-effective production that meets the needs of modern industries and optimizes the use of molded pulp parts in various industries and applications.

Stackable / nestable

Molded fiber packaging is three-dimensional and designed to save space compared to voluminous fiber materials such as EPS molded parts. Thanks to this construction, our packaging can be easily nested and stacked, which facilitates transport and significantly reduces the storage capacity required.

Diverse and individual

Thanks to its flexibility, molded pulp packaging can be produced in different shapes and sizes, making it a versatile and customized solution for the sustainable design of a wide range of products and applications.

Through various manufacturing processes, we can offer individual degrees of fineness for molded fiber parts - be it for an organic or luxurious feel. The fibers we use give the molded fiber parts a white, high-quality look that highlights your product.

Recyclable / disposal

Cast fiber packaging is completely recyclable and can easily be incorporated into existing recycling systems. Our fiber moldings are PTS (Paper Technology Foundation) tested and therefore suitable for return to waste paper where they can be reused as high-quality raw materials.

Water resistant and abrasion protection

PAPACKS® Plant-Based Coating

Thanks to our innovative coating technology and the PAPACKS® Plant-Based-Coating, molded fiber packaging can be made water-resistant to keep the packaging in shape when exposed to moisture or condensation. Our coating also offers possible abrasion protection for sensitive products.

In order to guarantee the optimal solution for your product, it is important for us to understand the entire packaging process in your workflow. Our experts work closely with you to develop customized solutions that meet your needs.

Made in Germany

Our production site in Germany is one of the largest producers of molded fiber parts made from renewable raw materials in Europe. Through our certification according to the BRCGS standard for packaging materials and DIN9001:2015, we guarantee the highest quality standards and high delivery availability for our customers.

A decision for the future

Pulp packaging is future-proof and environmentally friendly because it is made from renewable raw materials. In contrast to materials made from fossil raw materials, cast fiber offers permanent availability based on the continuous availability of renewable raw materials.

Molded Fiber Production PAPACKS® GIGAFACTORY 1 + 2

Plastic-free packaging from renewable raw materials — Made in Germany

In order to meet industrial requirements, we use modern production processes and solutions for the circular economy. It is time for a global change to make our actions as diverse as our nature does.

We have optimized our appearance for our values, integrity and our mission. For us, diversity also means being in harmony with the diversity of nature and using it sustainably.

Be colorful and diverse with your products and use natural packaging for a way back to nature. It is time to go beyond just the “green” and collectively create global change that can be implemented by all.

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)

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 4

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® pulp production with sustainable advent calendars.
play video

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!

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