Molded fiber cosmetic and personal care packaging Packaging designed around your product and your brand
Set inserts, refill caps, razor handles, pet care containers, tubes and blisters for OTC products — logo embossed in the tool, abrasion protection for lacquered primary packaging on request, documentation per molded part.
Designed to your specifications, tested on the prototype with your product — design, tool and series production from a single source.
Why molded fiber
Packaging people want to touch
We develop every molded part together with you, based on your requirements: unboxing as a brand moment, your products protected until they are unpacked, one material across your entire range.
Unboxing
Feels like your brand
The fiber surface is warm, matte and tactile; logo and texture are molded in, and you choose the color — with food coloring directly in the fiber pulp. The moment your customers open the box belongs to your brand.
Protection
Arrives as packed
The compartments follow the contour of your product, as tight or as loose as your product needs — on request with an anti-abrasion coating for lacquered surfaces; we test the effect on the prototype with your product.
Range
One material, from set to refill
Gift set, refill caps, razor handle or container: one material language across your entire range, developed around your product. We supply the documentation for your approval — material data and, for food contact, the declaration of conformity for exactly your molded part.
We define surface, wall thickness and coating with you — based on your product, your primary packaging and your line. We design the shape to your specifications, test it on the prototype with your product and only then build the production tool. You will find the documents for your supplier approval in the download area.
Examples
Every product gets its own shape
Your molded part is created the same way as these examples — you specify dimensions, compartments and surface; we carry existing dimensions and outer packaging over into the design (Switch packaging).
Refill
Refill caps
Developed for your jar and your formulation. We define coating and sealing paper together, and you test the prototype with your product.
Gift set
Set inserts
Every product sits in its own compartment, and the box opens as a finished set. Your folding carton stays: we carry over outer dimensions and compartments from your current insert or your CAD file.
Shaving
Disposable razor handle
Handle and blade rest made of molded fiber, with the holder designed to the snap-fit dimensions of your blade head. We emboss logo and grip texture directly in the tool.
Pet care
Containers for pet care
Container and lid molded to your product, sleeve or label to match your brand. We define shape and closure with you.
OTC
Tubes and blisters for tablets
In the tube, the tablets sit in a row; in the blister, each sits in its own compartment. We specify the inner coating according to the moisture sensitivity of your tablets and test the barrier on the prototype (WVTR).
Filling
Trays for filling
Every bottle stands upright in its own compartment, with the neck clear for filling. We design the compartments from the CAD model of your bottle.
Molded fiber cosmetic and personal care packaging consists of molded set inserts, trays, refill caps, containers, tubes and blisters made of virgin fiber — and, with the razor handle, the product itself. PAPACKS develops them around your product and your primary packaging and manufactures them in its own plants; we define surface, embossing and coating with you for each application. 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 and blisters up to 690 × 430 × 160 mm in Wet Molding — wall thickness 1 to 5 mm according to your specification and load.
Timeline
Around 12 weeks from your approval
First prototype: around 4 weeks after the kickoff. From your approval, tool making, pre-production run and start of production follow in around 12 weeks. With coating development, your budget quote states the timeline.
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 abrasion protection or barrier, 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, primary packaging, surface, formulation, 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, prototypes for your test — coated for abrasion protection or barrier on request, 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. For cosmetics and skin contact, we supply material composition and raw material documentation for your safety assessment under the Cosmetics Regulation or your risk assessment under the GPSR.
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 formulation, coating or process. The declaration of conformity for your molded part documents compliance with the PFAS limits that apply to all packaging with food contact (Art. 5(5) Regulation (EU) 2025/40) and the test for optical brighteners (BfR XXXVI).
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 razor handle, 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 product
Step 1
Consultation
You tell us your product, primary packaging, surface, line 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 →