Europe's most innovative production for molded fiber cast parts

Moulded Fiber production

from renewable raw materials

In the future, it will become more and more important to be able to rely on reliably deliverable, innovative and safe products and packaging that are sustainably produced in Germany and Europe and that 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 continuously expanded over decades, we are at your disposal at any time.

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 can be 100% recycled, is 100% recyclable and / or 100% compostable.

Everyone knows this wonderful material, fiber casting, and yet the material is only perceived when a product is pointed out, made of this material: Egg carton! This packaging provides comprehensive protection for the sensitive food product “eggs”, very simply and absolutely safely.

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material, cast fiber, has literally disappeared into oblivion in the last few decades and would probably one day have been replaced by the modern, albeit environmentally unfriendly products, plastic and plastic.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

We at PAPACKS have brought the material fiber casting onto the stage of "sustainability" with our 3D concepts. We were nominated for the GreenTec Award 2017 among the last 3 candidates. We see this nomination as an homage for the material "Molded Pulp".

Today's made by us Molded Pulp is with the concept: Egg cartonsno longer to compare. Today's special requirements from the industry were the challenge for us as a fiber casting manufacturer and fiber casting 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 ecological and also economic only answer for packaging and transportation solutions. With this material cast fiber the turning point has heralded "To ban plastic from the packaging world". In the area of ​​transport and logistics, fiber cast is processed into transport trays and replaces the expanded trays Polystyrene (EPS) or extruded polystyrene (XPS) as 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 to use this material for the production of 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® cast fiber product categories

Plastic-free - home-compostable - fresh fiber / primary fiber - food grade
Transport trays
charge carrier
PAPACKS® FASERGUSS molded parts for one-way transport, made from virgin fiber / primary fiber, ready for circular economy cycles. Optional with fiber abrasion protection / fat and moisture resistance. Replaces plastic trays and time-consuming cardboard constructions for delivery, logistics and as 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 circular economy cycles. Optionally with fiber abrasion protection, grease and moisture resistance. Replaces plastic blisters, plastic inlays, complex cardboard constructions, foam and styrofoam inserts.
Primary food packaging
PAPACKS® FASERGUSS molded parts for one-way transport, made from virgin fiber / primary fiber, ready for circular economy cycles. Optional with fiber abrasion protection / fat and moisture resistance. Replaces plastic trays and time-consuming cardboard constructions for delivery, logistics and as 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 resistance to grease and moisture. 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 have Molded Pulp offer is the creation of a closed one 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

Proven more customer satisfaction through sustainable packaging

100% plastic free / 0 € plastic tax

No additional charges for using unrecycled plastic in packaging

100% renewable raw materials

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

4x less packaging license costs

Opposite plastic tray of the same shape (source: www. licenseero.de)

Zero waste - composted in 6 weeks

Complete composting in home compost

4x less CO2 emissions

4 times lower CO2 emissions per tray than plastic

Greater dimensional stability

Fibrous molded parts withstand higher forces until they are deformed compared to plastic trays

100% 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

Cast fiber is odorless and we use the purest fresh fibers in our production

PAPACKS® Organic Coating

Optional option: organic coating application for barrier protection, abrasion coating, water vapor and oxygen barriers and other property enhancements

Save space / save storage costs

Molded fiber parts can be plugged into one another and are therefore more space-saving compared to a folded cardboard solution

Adaptability of the construction

Products are protected by the individually specially designed three-dimensional shape and the soft, cushioning fibers

Automated / packable by robot

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

Shock absorbing / high transport security

Cast fiber Molded fiber parts are tough or soft and absorb repeated impacts without breaking

Suitable for sea freight

Cast fiber molded fiber parts can be used in the field of sea freight

Independent of raw material

Cast fiber can be made from various sustainable raw materials, e.g. industrial hemp

The seal of sustainability

100% recyclable - 100% controlled origin of the raw materials - 100% compostable - Made in Germany
Guaranteed across Europe
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 cast 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 pieces.

PAPACKS® GIGAFACTORY 2

Arnstadt / Thuringia (FOODSAFE / MEDICAL DEVICES)

Commissioning in 2022.
Molded fiber cast 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 pieces. 

PAPACKS® PRODUCTION NETHERLANDS

Netherlands (FOODSAFE)

Molded fiber cast 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 calendar

The mouse shows one of the PAPACKS® cast fiber 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 meters, from a cardboard box with a cast fiber inlay filled with two heavy 0,75l bottles, you can see the protection and transport security that cast fiber offers a product like no other material.
Check out our video!

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