Molded fiber protective packaging Protection designed around your product and your shipping route
Product inserts, shipping cushioning and end caps — designed around your product and your outer packaging, with every accessory in its own compartment.
Designed around your product, fit tested on the prototype with the real product — design, tool and series production from a single source.
Why a molded part
Designed for the journey from packing table to recipient
Your product passes through packing table, parcel network and delivery. A molded part that holds it, absorbs impacts and gives every accessory its own compartment makes your shipping predictable: when unpacked, everything is in its place.
Hold
The product sits firmly
The holder is created around your product — from your CAD data or from the original product. Product and molded part interlock as soon as the outer packaging closes.
Clearance
The product keeps its distance
Supports, corners and ribs keep the product at a distance from impacts and edges. We define on the prototype with your product where and how much material is placed.
Accessories
Everything has its compartment
Power supply, cable, bracket and instructions each get their own recess. The recipient unpacks and finds every accessory in its place.
What your molded part looks like depends on weight, sensitive surfaces and shipping route. The shape is designed around your product, the fit tested on the prototype with the real product, and only then is the production tool built. Already shipping? Your carton stays, and the molded part is designed to its inner dimensions — for how the switch works while shipping continues, see Switch packaging.
Examples
Every product gets its own shape
What needs protecting determines the shape. Yours is created the same way as the following examples.
The basics
Bicycle shipping protection
A molded part grips the seat tube and keeps the frame at a distance from the carton wall. It is in place before the carton closes.
Fork
Protection for the fork
The tray holds the fork steerer in a holder. The fork stands upright and is cushioned and protected in the carton.
Product with accessories
Everything in one shape
Product, cylinder and bottles get their own recesses in the same molded part. The recipient takes everything out the way it belongs in.
Rolls
End caps for rolls
Two caps hold the roll at its ends and keep it centered in the long carton. The web itself remains free.
Cushioning
One-piece cushioning
One molded part fills the outer packaging: the product sits in the recess, and the edges absorb impact and stacking pressure.
Household appliance
Base and cap
Two molded parts hold the product at the base and top. It sits protected in the carton, and the control panel stays clear.
Protective packaging made of molded fiber comprises inserts, cushioning, end caps and edge protectors made of virgin fiber that secure your product during shipping. Plus product inserts with compartments for power supply, cable and instructions, and set trays for several items in one shipment. We clarify in the consultation what is possible for your product — dimensions, compartments and process are later listed in the data sheet for your molded part.
At a glance
Predictable from the first conversation
You know in advance what your molded part needs and when it arrives — volume, format, timeline and tooling terms as planning values, binding with your quote.
Minimum quantity
100,000 units per year
From this annual volume, we develop your molded part as a shape of its own — precisely fitted to your product, in Wet Molding from Arnstadt.
Molded part format
The shape follows your product
Product inserts and shipping cushioning up to 690 × 430 × 160 mm in Wet Molding — wall thickness 1 to 5 mm according to product weight and cushioning.
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.
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.
01
Initial consultation
You tell us your product, weight, sensitive surfaces, shipping route, outer packaging if any, volume and target date — a product or a photo is enough, CAD data if available; for several models or sizes, the list is enough. You receive feasibility, a budget price and the quote for the start of development. Within a few days.
02
Samples and examples
Samples that match your project — similar molded parts from existing projects or standard products: you assess material quality, feel and look on a real molded part.
03
Design and prototype
Design and CAD based on your product and your outer packaging, a prototype for the fit test with the real product, with a drop test on request, then your approval. Around 4 weeks after the kickoff.
04
Tool and series production
Production tool made in-house, pre-production run and initial samples from the production tool, then ongoing production from Arnstadt — stacked nested on pallets, delivered according to your call-off schedule. Around 12 weeks from your approval.
These times are planning values; they depend on your approvals, our teams' workload 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 the quote after our initial meeting; binding dates are set out in your detailed plan.
Evidence
Certificates and documents for your approval
Certificates with certification body and scope, specifications with data sheet — the documents for your supplier assessment in one place.
Protective effect
Drop test for your molded part
We have the drop test according to the ISTA test series in your specification carried out for you in a testing laboratory, or you test yourself. Either way, you receive the test report for your internal approval; the result is also listed in the data sheet for your molded part, with scope and costs in the quote.
Test method: ISTA test series according to your specification, product-specific per molded part
Surface
Coated contact surfaces
On request, we coat the surfaces that touch displays, paint or high-gloss finishes. We test on the prototype with the real product whether your surface remains undamaged; the result is listed in the data sheet.
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
Disposal
Recyclability
We have the recyclability of your molded part tested product-specifically with cyclos-HTP; we commission the report for your item on your request.
Test method: cyclos-HTP according to the ZSVR minimum standard and DIN EN 13430
Labeling
Material marking
We emboss material marking and item number directly into the molded part — permanently, in the production tool, with every molded part. Further markings on request, for example for traceability.
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, weight, shipping route and annual volume. You receive feasibility, an initial price estimate and the timeline.
Consultation →Samples
Request samples
Samples that match your project — similar molded parts from existing projects or standard products, 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 →