Molded fiber production
Europe's innovative production for molded fiber castings made from renewable raw materials
In the future, it will become increasingly important to be able to rely on innovative and safe products and packaging that are produced sustainably in Germany and Europe, can be supplied reliably and are based on the development of the circular economy and a fair production chain. With these quality features and our expertise in research and development, which has been continuously expanded over decades, we are always at your disposal.
Your packaging of the future: sustainable, individual and resource-saving
Imagine packaging that is perfectly tailored to your products and at the same time made from renewable raw materials.
As Molded fiber manufacturer We develop and produce tailor-made, three-dimensional, three-dimensional Molded fiber partsthat combine quality and sustainability. Benefit from molded fiber packaging that reduces your ecological footprint and positions your company as an environmentally conscious brand.
What is molded fiber / moulded pulp or fiber pulp?
(English terms: Molded pulp, Fiber pulp, Pulp molding)
Molded Fiber is a Very environmentally friendly materialmade from waste paper, renewable fibers such as hay, straw, hemp or similar Pulp material is produced. The material Molded Fiber can be recycled and is recyclable in waste paper.
Everyone is actually familiar with this wonderful material, fiber casting, and yet the material is only noticed when a product made from this material is mentioned: Egg carton! This packaging provides comprehensive protection for the sensitive food product "eggs" - quite simply and absolutely safely.
Unfortunately, this molded fiber material has literally disappeared into oblivion in recent decades and would probably one day have been replaced by the modern, albeit environmentally unfriendly, products of plastic. With the emerging topic of "sustainability", a new focus is being placed on packaging and logistics. As a result, the use of plastic is being viewed very critically. The industry is now trying to fall back on substitutes, such as "natural plastics", which in reality are not natural.
With our 3D concepts, we at PAPACKS have brought the material fiber casting to the "stage of sustainability". We were nominated for the GreenTec Award 2017 as one of the last 3 candidates. We see this nomination as a tribute to the material Molded Fiber.
The one we produce today Molded Fiber is with the concept Egg carton can no longer be compared. Today's special requirements from the industry were the challenge for us as a fibre casting manufacturer and molded fiber producer to further develop and optimize production with the material molded fiber. Fiber molds are now water resistant, grease-repellent and also fireproof and can therefore be used in a wide range of industries. From the Automotive industry as transport trays up to the Packaging of food products for the end customer sector.
The molded fiber parts are the ecological and also economic the only answer to packaging and transportation issues. This molded fiber material heralds a turning point, Banning plastic from the packaging world. In the area of transport and logistics, fiber casting is processed into transport trays and replaces the trays made of expanded polystyrene. Polystyrene (EPS) or extruded polystyrene (XPS)also as Foams known, and Styrofoam.
Molded Fiber is characterized by its versatility. The material itself has a high Shock absorption on. By adding various environmentally friendly materials the properties of the base material can be enhanced or even changed. The most effective is the Direct reuse about a "green circulation system" to shred the packaging after use and use this material for the production of new molded fiber parts.
In addition to the protective function, the Molded Fiber in our 3D packaging also has a new, modern design with a high recognition value.
Properties of cast fiber packaging
Advantages for your product packaging
Sustainability
Our cast fiber packaging is produced sustainably 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 is recyclable in waste paper.
Fiber casting production independent of raw materials
Fiber casting is a versatile material that can be made from a variety of sustainable raw materials, making it ideally suited to different requirements and environmental regulations. One 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, fiber casting can help to reduce the ecological footprint of production and thus make an important contribution to conserving our natural resources.
Suitable for sea freight applications
Molded fiber castings are suitable for use in the sea freight sector. Thanks to their robust and resistant nature, they can withstand the special requirements of sea transportation and ensure the safe and efficient transport of goods over long distances and under various environmental and climatic conditions.
Shock-absorbing / shock-absorbing / dimensional stability
With cast fiber packaging, you benefit from excellent shock absorption, which ensures the safe transport of your products. Depending on the design, the molded parts made of cast fiber can be easily deformed and still retain their necessary stability, especially in the event of impacts directly on the packaging during transport.
Heat and cold protection
Cast fiber can be an excellent insulating material and, with the right design, can protect products from heat or cold to a certain extent. Cast fiber does not break on impact like frozen packaging with thermoformed plastic parts. It is temperature resistant at over +100 degrees Celsius, making it an ideal choice for applications exposed to high temperatures.
This can speed up processes in industry, such as in the production of glass bottles, which do not have to be cooled before they are placed in transport trays, as is necessary with plastic trays.
Automated and robot-controlled use
Molded fiber castings are suitable for use in automated and robot-controlled processes. Due to their precise and consistent shape, they can be easily handled and packaged by robots and automated systems. This enables efficient and cost-effective production that meets the requirements of modern industries and optimizes the use of moulded fibre castings in various industries and applications.
Stackable / nestable
Molded fiber packaging is three-dimensional and space-saving compared to bulky fiber materials such as EPS molded parts. Thanks to this design, our packaging can be easily nested and stacked, which makes transportation easier and significantly reduces the storage capacity required.
Diverse and individual
Thanks to their flexibility, molded fiber packaging can be produced in various shapes and sizes, making them a versatile and individual 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 - whether for an organic or luxurious feel. The fibers we use give the molded fiber parts a white and high-quality look that makes your product stand out.
Recyclable / disposal
Molded fiber packaging is fully recyclable and can be easily incorporated into existing recycling systems. Our molded fiber parts are PTS (Paper Technology Foundation) tested and therefore suitable for return to waste paper where they are reused as a high-quality raw material.
Water-resistant and abrasion protection
PAPACKS® Plant-Based-Coating
Thanks to our innovative coating technology and the PAPACKS® Plant-Based-Coating, cast fiber packaging can be made water-resistant to keep the packaging in shape in the event of moisture or condensation. Our coating also offers potential abrasion protection for sensitive products.
To ensure the optimum 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 requirements.
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. Thanks to our certification in accordance with 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
Cast fiber packaging is future-proof and environmentally friendly as it is made from renewable raw materials. In contrast to materials made from fossil raw materials, cast fiber offers long-term availability based on the continuous availability of renewable raw materials.
Renewable raw materials used
Your packaging in the future without additional plastic and without felled trees
Our goal at PAPACKS is to create a future where packaging is environmentally friendly without using plastic or cutting down trees. Through our continuous research and development in molded fiber production and new raw materials, we work every day to achieve this goal and protect the diversity of our nature.
PAPACKS® Virgin Fiber (FSC®)
A premium raw material for high-quality food and non-food packaging
PAPACKS® Industrial Hemp
The innovative raw material without felled trees for fiber raw materials
PAPACKS® Plant-Based-Coating
Protection without additional plastic for sophisticated food packaging
Decentralized production in Europe
Sustainability through short delivery routes - risk minimization, flexibility and adaptability
PAPACKS® GIGAFACTORY 1
Arnstadt / Thuringia
PAPACKS® GIGAFACTORY 2
Arnstadt / Thuringia
PAPACKS® GIGAFACTORY 3
Appingedam/Netherlands
PAPACKS® R&D INNOVATION HUB
Cologne/NRW
PAPACKS® Molded Fiber License
DGNB Gold certification
How is fiber casting or a molded fiber part produced?
Fiber casting is produced by machine from waste paper fibers dissolved in water, renewable fibrous materials such as hay, straw, hemp, etc. in a vacuum, pressing and drying process to the desired shape.
- Preparation fibersPaper and cardboard waste is dissolved in a "pulper" (large mixer) and then diluted by a control system and prepared accordingly in various processing tanks until the so-called pulp thickener is ready for use in the working tank.
- Tool for fiber formThe tools for the corresponding fiber castings or fiber moulds are complex and resemble a metal sieve with a counterpart. These correspond to the shape of the desired later fiber casting part. The water drainage and vacuum suction are later influenced by the matching tool counterpart and a specially calculated diagram for the screen structure, so that the molded fiber part is formed evenly at all points.
- Molding production processThe tools are now immersed in the work tank with the pulp mixture and suck the pulp mixture through the screens using a vacuum. Fibers are retained by the sieves and thus build up the moulded part. After emergence, the molded parts are removed from the screen by means of a counter mold and vacuum and deposited on the drying section.
- Drying sectionThe drying section consists of a grid-like conveyor belt that allows air to pass through. Drying hoods blow heated air onto the molded parts. At the end, the molded parts are removed and placed on pallets.
- Forming press and punchDepending on customer requirements and the area of application, the molded parts can be repressed. The moulded parts are stabilized and fixed in a press under the influence of heat. In addition, desired embossing and perforations can be incorporated or, if required, the molded parts can be punched and cut to size.
Packaging for food
Suitable for direct food contact. Benefit from the strength of native fibers, complemented by the plant-based PAPACKS® coating. Our environmentally friendly packaging solutions meet all requirements for barrier properties and food safety and are specially designed for direct food contact.
Consumer packaging
Logistics packaging
Innovative 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.
"Die Sendung mit der Maus" explains our sustainable Advent calendars
The mouse shows one of the PAPACKS® fiber casting productions with sustainable Advent calendars.
A television production by ARD/Das Erste® and WDR® for "Die Sendung mit der Maus"
Fiber casting drop test
Our extreme drop test - from a height of approx. 3 m - of a cardboard box with a cast fiber inlay filled with two heavy 0.75 l bottles shows the protection and transport safety that cast fiber offers a product like no other material.
Take a look at our video!