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Europe's most innovative production

for molded fiber parts made from renewable raw materials

Expansion and production sites

In the future it will become more and more important to be able to rely on reliably deliverable, innovative and safe products and packaging that are sustainably produced in Germany and Europe and that 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.

Paper fiber molded parts for certified primary packaging for the food and medical / pharmaceutical industries. Certification according to the hygiene standards for packaging manufacturers of primary packaging according to ISO 9001 and other relevant management systems.

Capacity pa: + 180.000.000 pieces (2021)
+ 360.000.000 pieces (2022)

PAPACKS® GIGAFACTORY 1
Arnstadt / Thuringia
(FOODSAFE / MEDICAL DEVICES)

Location for technical innovations, continuous further development of our 3D tool technology and raw material research for transfer to existing and new production locations.

Fiber processing & raw material research 

Capacity pa: + 5.000.000 pieces.

PAPACKS® R&D Innovation Hub
Cologne / North Rhine-Westphalia
(INDUSTRIAL)

Production method: thermoforming

Capacity pa: + 50.000.000 pieces.

PAPACKS® PRODUCTION NETHERLANDS
Netherlands
(FOODSAFE)

PAPACKS® GIGAFACTORY 1

Arnstadt / Thuringia (FOODSAFE / MEDICAL DEVICES)

Paper fiber molded parts for certified primary packaging for the food and medical / pharmaceutical industries. Certification according to the hygiene standards for packaging manufacturers of primary packaging according to ISO 9001 and other relevant management systems.

Capacity pa: + 180.000.000 pieces (2021) / + 360.000.000 pieces (2022)

What is cast fiber or pulp?

(English terms: Molded pulp, Fiber pulp, Pulp molding)

Molded Pulp is a very environmentally friendly materialmade from waste paper, renewable fibers like hay, straw, hemp or the like Pulp material will be produced. The material Molded Pulp can be 100% recycled, is 100% recyclable and / or 100% compostable.

Everyone knows this wonderful material, fiber casting, and yet the material is only perceived when a product is pointed out, made of this material: Egg carton! This packaging provides comprehensive protection for the sensitive food product “eggs”, very simply and absolutely safely.

Unfortunately, this material, cast fiber, has literally disappeared into oblivion in the last few decades and would probably one day have been replaced by the modern, albeit environmentally unfriendly products, plastic and plastic. With the emerging topic of "sustainability", a new focus is set in the area of ​​packaging and logistics. As a result, the use of plastic is viewed very critically. The industry is now trying to use substitutes, such as "natural plastics“Which in reality are not natural.

We at PAPACKS have brought the material fiber casting onto the stage of "sustainability" with our 3D concepts. We were nominated for the GreenTec Award 2017 among the last 3 candidates. We see this nomination as an homage for the material "Molded Pulp".

Today's made by us Molded Pulp is with the concept: Egg cartonsno longer to compare. Today's special requirements from the industry were the challenge for us as a fiber casting manufacturer and fiber casting producer to further develop and optimize production with the fiber cast material. Fiber forms are meanwhile water resistant, grease repellent and also fireproof and thus usable in a wide range of industries. Of the Automotive industry as transport trays and Packaging of food products the area of ​​application extends to the end customer area.

The molded fiber parts are the ecological and also economic only answer for packaging and transportation solutions. With this material cast fiber the turning point has heralded "To ban plastic from the packaging world". In the area of ​​transport and logistics, fiber cast is processed into transport trays and replaces the expanded trays Polystyrene (EPS) or extruded polystyrene (XPS) as foams known as well Styrofoam.

A characteristic of the material cast fiber is its versatility. The material itself has a high Shock absorption on. By adding various environmentally friendly fabrics the properties of the raw material can be enhanced or even changed. Nevertheless, these are molded fiber parts biodegradable or directly compostable, however, it is most effective direct reuse about a "green circulatory system“To shred the packaging after use and to use this material for the production of new molded fiber parts.

In addition to the protective function, the Molded Pulp Our 3D packaging also features a new, modern design with a high recognition value.

The show with the mouse explains our sustainable advent calendar

The mouse shows one of the PAPACKS® cast fiber productions with sustainable advent calendars
A television production by ARD / Das Erste® and WDR® for "Die Sendung mit der Maus"

How is cast fiber or a molded fiber part manufactured?

Fiber casting is made from waste paper fibers dissolved in water, renewable fibers such as hay, straw, hemp, etc. in a vacuum, pressing and drying process in the desired shape.

  • 1
    Processing 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 basins until the so-called fiber thick matter in the work basin is ready for use.
  • 2
    Tool for fiber molding
    The tools for the corresponding cast fiber parts or fiber molds are complex and resemble a metal screen with a counterpart. These correspond to the shape of the later desired fiber casting. The appropriate tool counterpart and a specially calculated scheme for the screen structure will later influence the water drainage and vacuum suction so that the molded fiber part is formed evenly at all points.
  • 3
    Process of molded part production
    The tools are now immersed in the working basin with the pulp mixture and suck the pulp mixture through the sieves by means of a vacuum. Fibers are retained by the sieves and thus build up the molded part. After surfacing, the molded parts are removed from the sieve using a counter-mold and a vacuum and placed on the drying section.
  • 4
    Drying section
    The drying section consists of a grid-like conveyor belt, which enables air permeability. Drying hoods blow heated air onto the molded parts. At the end, the molded parts are removed and placed on pallets.
  • 5
    Form press and punch
    Depending on customer requirements and the area of ​​application, the molded parts can be re-pressed. The fitting accuracy of the molded parts is stabilized and fixed in a press under the action of heat. In addition, desired embossings and perforations can be incorporated or, if necessary, the molded parts can be punched and cut accordingly.

Advantages of cast fiber / molded paper fiber parts

The biggest advantage we have Molded Pulp offer is the creation of a closed one Circulatory system for industry and manufacturing companies. We produce useful packaging or transport packaging Molded Pulp for your products in the circulatory system. This generally saves you on the cheap purchase of pulp-suitable material compared to plastic - You save costs for recycling / disposal as well as costs for the constant purchase of new raw materials, since the old ones stay in the cycle and are reused.

  • Cheaper than plastic / plastic
    Due to packaging taxes and disposal costs as well as the upcoming plastic tax, cast fiber / molded paper fiber parts are significantly cheaper than deep-drawn plastic parts overall.
  • Recyclable, compostable, flexible to use
    Cast fiber is made from waste paper, fresh fiber or natural fibers such as industrial hemp, is compostable and can be disposed of worldwide without special surcharges
  • Space saving
    Molded fiber parts can be plugged into one another and are therefore more space-saving compared to a folded cardboard solution
  • time-saving
    Molded fiber parts minimize the handling time compared to complex cardboard inserts or the like
  • Shock absorbing / high transport security
    Molded fiber parts are tough and absorb repeated impacts without breaking
  • Protective
    Molded fiber parts protect both large stable and small fragile products
  • Adaptable
    Molded fiber parts protect products through three-dimensional adaptation to the contour
  • Automatically packable
    Molded fiber parts can be used in automated packaging processes
  • Flame retardant
    Molded fiber parts can be flame retardant
  • Grease and water repellent
    Molded fiber parts can be grease and water repellent
  • Suitable for sea freight
    Molded fiber parts can also be used for sea freight without any problems

Cast fiber drop test

Based on our extreme drop test, from a height of approx. 3 meters, from a cardboard box with a cast fiber inlay filled with two heavy 0,75l bottles, you can see the protection and transport security that cast fiber offers a product like no other material.
Check out our video!

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