Europe's innovative production for molded fiber

Molded fiber production

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 know-how in research and development, which has been continuously expanded over decades, we are always at your disposal.

How it works

A production technique that is older than plastic, with today's know-how for the packaging future of tomorrow.

What is molded fiber or molded pulp?

(Molded pulp, Fiber pulp, Pulp molding)

Molded Fiber is a very environmentally friendly material that is made from waste paper, renewable fibrous materials such as hay, straw, hemp or similar cellulose material. The molded fiber material can be recycled and is recyclable in waste paper.

Everyone knows this wonderful material, molded fiber, and yet the material is only noticed when a product made of 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this molded fiber material has literally disappeared into oblivion in recent decades and would probably one day have been replaced by the modern, albeit environmentally unfriendly, products plastic & plastic.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.

We at PAPACKS have brought the material molded fiber to 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.

The molded fiber we produce today can no longer be compared with the concept of egg carton . Today’s special requirements from the industry were the challenge for us as a molded fiber manufacturer and molded fiber producer to further develop and optimize production with the material molded fiber. Fiber moulds are now water-resistant, grease-repellent and also refractory and can therefore be used in a wide range of industries. The field of application ranges from the automotive industry as transport trays to the packaging of food products for the end customer sector.

Molded fiber parts are the only ecological and also economic answer to packaging and transport issues. This molded fiber material heralds the turning point in banning plastic from the world of packaging. In the field of transport and logistics, molded fiber is processed into transport trays and replaces trays made of expanded polystyrene (EPS) or extruded polystyrene (XPS), also known as foams, and styrofoam.

A characteristic feature of molded fiber is its versatility. The material itself has a high shock absorption. By adding various environmentally friendly substances, the properties of the base material can be strengthened or even changed. The most effective method is direct reuse via a “green recycling system” in order 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 enables a new, modern design with a high recognition value.

Raw materials and materials

PAPACKS® Virgin Fiber

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

PAPACKS® Industrial-Hemp

Industrial hemp is a rapidly renewable source of raw materials that can be harvested in a short time and therefore makes an important contribution to sustainability. During growth, hemp plants absorb large amounts of carbon dioxide (CO2) from the atmosphere, actively contributing to the reduction of greenhouse gas emissions and combating climate change. In addition, hemp plants are highly 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 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 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. This ensures both environmental protection and maximum integrity of your product.

CONSUMER PACKAGING

Present your products effectively. Emphasize 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 transportation 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 environmental 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 variety 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 fiber packaging

Sustainability

Our molded 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 molded fiber packaging is recyclable in waste paper.

Molded fiber production independent of raw materials

Molded fiber 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, molded fiber 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 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 different environmental and climatic conditions.

Shock-absorbing / shock-absorbing / dimensional stability

With molded 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 molded 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

Molded fiber can be an excellent insulating material and, with proper construction, can protect products from heat or cold to a certain extent. Molded fiber does not break on impact like frozen packaging with plastic thermoformed 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 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 molded fiber 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.

Recyclebar / Entsorgung

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, molded 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

Molded 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, molded fiber offers long-term availability based on the continuous availability of renewable raw materials.

Faserguss Produktion PAPACKS® GIGAFACTORY 1 + 2

Plastic-free packaging thanks to renewable raw materials - Made in Germany

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 image to reflect our values, integrity and 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’s time to go beyond ‘green’ and work together to create global change that can be implemented by everyone.

PAPACKS® PRODUCTIONS IN EUROPE

Production sites in Germany and Europe

PAPACKS® GIGAFACTORY 1

Arnstadt/Thuringia (FOODSAFE/MEDICAL DEVICES)

Molded fiber 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 p. a.: + 180,000,000 pcs.

PAPACKS® GIGAFACTORY 2

Arnstadt/Thuringia (FOODSAFE/MEDICAL DEVICES)

Molded fiber 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 p. a.: + 180,000,000 units  

PAPACKS® GIGAFACTORY 4

Netherlands (FOODSAFE)

Molded fiber 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 p. a.: + 50 million units

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 materials research.

Capacity p. a.: + 5 million units

"Die Sendung mit der Maus" explains our sustainable Advent calendars

The mouse shows one of the PAPACKS® Molded fiber productions with sustainable Advent calendars.
Play Video

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

How molded fiber parts produced?

Molded fiber 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.

  • 1
    Preparation 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 tanks until the so-called pulp thickener is ready for use in the working tank.
  • 2
    Tool for molded fiber packaging solutions
    The tools for the corresponding molded fiber or fiber moulds are complex and resemble a metal sieve with a counterpart. These correspond to the shape of the desired later molded fiber 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.
  • 3
    Molding production process
    The 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 dipping, the molded parts are removed from the screen by means of a counter mold and vacuum and deposited on the drying section.
  • 4
    Drying section
    The 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.
  • 5
    Forming press and punch
    Depending 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.

Molded fiber drop test

Our extreme drop test – from a height of approx. 3 m – of a cardboard box with a molded fiber inlay filled with two heavy 0.75 l bottles shows the protection and transport safety that molded fiber offers a product like no other material.
Watch our video!

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