Custom packaging: your shape in molded fiber Developed together — from shape sample to ongoing production
Design based on your product, shape sample, tool making with patented tooling concept and series production — for food and non-food.
Designed to your specifications, tested on the shape sample with your product — design, tool and series production from a single source.
Why PAPACKS
One team for your idea, all the way to series production
You bring your product, we bring the development through to series production — and you approve every step.
Contact
One project manager, one team
After the first conversation, your advisor hands over to your dedicated project manager, who supports you through to ongoing production; behind them, design, tool making, manufacturing and quality assurance work on your molded part.
Approval
You decide at every step
Shape sample, prototype, pre-production run: you test each stage with your product and approve it before the next one begins. The production tool is only built after your approval.
Applications
Designed for food and non-food
Consumer goods, electronics, cosmetics, industry, primary or secondary packaging, promotion and DIY. We define formulation, wall thickness, coating and all necessary tests based on your requirements.
We design the shape to your specifications, test it on the shape sample with your product and only then build the production tool. You will find the documents for your supplier approval in the download area.
Development
From budget price to ongoing production
Six services, each completed with your approval: from the budget price before design to the batch that runs like the initial sample.
Feasibility
Budget price before design
From product, volume and timeline, we derive process, feasibility and budget price. The budget quote lists development, tool and unit price separately — before design begins.
Design engineering
Designed for your line
The CAD model is created from your product, your file or your sample — with demolding, wall thickness and tolerances for the right process. Following our design guidelines, we design your molded part for automated handling; this is confirmed in the line trial.
Shape sample
Fit tested before the tool
A 3D-printed shape sample shows your molded part before a tool is made. You test shape and fit with your product; we incorporate changes into the CAD model.
Tool shop
The tool for your shape
If your shape is suitable, we build the tool — planned at 8–10 weeks. Five-year warranty, plus storage and repair during the production period — under the terms in your quote. How the tool price is made up is set out in your quote.
Tests
Test report before your approval
Drop test, climate and storage test according to the standard we define with you, line trial on your equipment. We define scope and test reports together; for food contact, the declaration of conformity summarizes the results.
Series production
Every batch like the initial sample
The pre-production run and initial samples come from the production tool, together with the data sheet for your molded part. In series production, every batch is traceable; if product or requirements change, we define with you how the molded part is requalified.
Examples
Every idea gets its own shape
Your molded part is created the same way as these examples — you specify shape, compartments and surface; we carry existing dimensions and outer packaging over into the design (Switch packaging).
Seasonal
Calendar insert
Every door gets its compartment, and the insert fits your calendar box. We design compartments and layout according to your product range.
Sports
Free-form insert
The contour follows your component, even with free forms and curves. Your product sits firmly in the carton — designed for your shipping route.
Premium
Box insert
Every item sits in its compartment, and the insert fits your box. We design compartments and contour according to your products.
DIY
Paint tray
Reservoir, scraper ribs and brush rest in one molded part. We design shape and rest according to your roller and your brush.
Special shape
Free geometry in series production
Deep contours and fine details, every piece from the same tool. Whatever can be designed and demolded, we manufacture in series.
Cosmetics
Sample tray
Tubes, sachets and folding cartons each sit in their own compartment, sorted for set or display. We design the compartments according to your products.
With Custom Engineering, we develop your molded fiber packaging for exactly your product — inserts, trays, bowls and hollow bodies made of virgin fiber, for food and non-food. We clarify in the consultation what is possible for your product; dimensions, coating and material data are later listed in the data sheet for your molded part.
At a glance
Orientation in the first conversation
We develop custom molded parts together with you. Volume, format, timeline and tooling as guide values — the budget quote after the initial meeting for orientation.
Minimum quantity
100,000 units per year
From this annual volume, we develop your own shape. The volume counts per molded part.
Molded part format
The shape follows your product
Set inserts, trays, bowls and molded parts up to 690 × 430 × 160 mm in Wet Molding — wall thickness 1 to 5 mm to your specification. Larger formats in Thermoforming, hollow bodies on the PAPACKS Model S10.
Timeline
Around 12 weeks from your approval
First shape sample: around 4 weeks after the kickoff. From your approval, tool, pre-production run and start of production follow in around 12 weeks; the tool itself is delivered after 8–10 weeks (planned value).
Tooling costs
We contribute
How we share your tooling costs depends on annual volume and term — in Wet Molding, up to full coverage. The terms and the five-year warranty on tools from our tool shop are set out in your quote.
From first conversation to series production
How your molded part is made
Four steps from the first question to ongoing production. If your packaging needs a coating for barrier or abrasion protection, a development phase is added: we define the requirements with you and test coating, molded part and your product together — you give the approval for series production.
01
Initial consultation
You tell us your product, idea, requirements, line, volume and target date. You receive feasibility, a budget quote and a timeline as a guide — the binding quote follows after development. Within a few days.
02
Samples and examples
Sample parts from our development, matched to your project: you assess material quality, feel and appearance on a real molded part.
03
Design and prototype
Design and CAD based on your product and your line, shape sample for the shape and fit test, prototypes in quantity for the line trial — then your approval. Around 4 weeks after the kickoff.
04
Tool and series production
Production tool made in-house, pre-series and initial samples from the production tool, then ongoing series production — stacked on pallets, delivered according to your call-off schedule. Around 12 weeks from your approval.
The times are planning estimates; they depend on your approvals, the capacity of our teams and the scope of your project. Your project team at PAPACKS presents the detailed plan around 1–2 weeks after the kickoff. You receive the process and budget quote as a guide after our initial call — with development, tool and unit price; the binding quote follows after development.
Do you have a seasonal deadline? We will tell you in our conversation whether it still works.
Evidence
Certificates and documents for your approval
Certificates with certification body and scope, the declaration of conformity for your molded part — the documents for your quality assurance in one place.
Product contact
Conformity per molded part
If your molded part comes into contact with food, you receive our declaration of conformity according to Regulation (EC) 1935/2004 with scope — type of food, temperature and contact time, tested as delivered with coating if present. For non-food, we supply material composition and material data for your own assessment.
Declaration of conformity according to Regulation (EC) 1935/2004 — prepared individually for each molded part with food contact, with initial sampling from the production tool
Substances
Material declaration per molded part
We do not add PFAS in the formulation, coating or process. The declaration of conformity for your molded part documents compliance with the PFAS limits that apply to all food contact packaging (Art. 5(5) Regulation (EU) 2025/40) and the test for optical brighteners (BfR XXXVI). For non-food molded parts, the material composition lists the substances used.
Declaration of conformity for your molded part — prepared individually
Disposal
Recyclability per molded part
For packaging, we have recyclability assessed product-specifically by cyclos-HTP — as delivered, with coating; we commission the report for your item on your request. For products such as the paint tray, the data sheet provides the disposal information.
Test method: cyclos-HTP according to the ZSVR minimum standard and DIN EN 13430 — assessment per item on request
Production
BRCGS Grade A
Molded parts from our BRCGS-certified plant are manufactured according to the BRCGS Global Standard Packaging Materials, HACCP included. Your quote states which plant manufactures your molded part; your quality assurance receives the certificate with scope.
BRCGS Packaging Materials, Issue 7, Grade A · TÜV Rheinland Cert GmbH — Download documents
Quality
ISO 9001:2015
Documented processes from inquiry to delivery; every batch traceable back to raw material receipt.
ISO 9001:2015 · TÜV Rheinland Cert GmbH — Download documents
Raw material
FSC® Mix Credit
Virgin wood fiber from responsible sources: FSC® Mix Credit, a volume balance across the supply chain.
License FSC-C125098 · applies to items identified as FSC® Mix Credit on the invoice and delivery note — Download documents
Frequently asked questions
What customers ask before the first sample
Next step
Let's talk about your idea
Step 1
Consultation
You tell us your product, idea, requirements and annual volume. You receive feasibility, a budget quote and a timeline as a guide — the binding quote follows after development.
Consultation →Samples
Request samples
Sample parts from our development, matched to your project, so you can assess material quality, feel and look.
Request samples →Form
Send inquiry
Describe your project in the form — dimensions, annual volume, ideally with a drawing or sketch as a PDF — no appointment needed. We review your details and get back to you with an initial assessment and the next steps.
Send inquiry →