Switching existing packaging to molded fiber Designed for your dimensions, your carton and your line — in molded fiber
We take over outer dimensions, inner contour and carton dimensions — plus prototypes for your line trial and documents for your requalification.
Designed to your drawing, tested on the prototype on your line — design, tool and series production from a single source.
Clarify first
Three questions before design
Dimensions, line, approval checklist: your answers determine feasibility, budget price and schedule — for the complete switch or one molded part as a pilot.
Dimensions and outer packaging
Will it fit your carton?
Außenmaß, Innenkontur und Palettenraster übernehmen wir aus Ihrer Zeichnung oder einem Muster und konstruieren das Formteil für Ihren Karton; die Passung prüfen Sie am Formmuster. Ab 100.000 Stück im Jahr je Formteil entwickeln wir Ihre Form.
line
Will it run on your line?
Manual or automatic, gripper, denesting: tell us the manufacturer, model and cycle rate of your system. We design gripping surfaces, draft angles and stacking pitch accordingly; on the prototype, you check denesting and gripping on your system — more on this under Automated Line & Filling.
Requalification
What does your approval checklist require?
Your approval checklist names certificates, tests and documents. In the initial consultation, we cross-check it against our documents; for food contact, we prepare the declaration of conformity according to Regulation (EC) 1935/2004 for your molded part.
Switching existing packaging to molded fiber means: the outer dimensions, inner contour, carton and pallet dimensions and stack height of your current packaging go into the design of a molded part made of molded fiber, manufactured from virgin fiber. We design to your drawing, supply prototypes for your line trial, build the production tool and manufacture the series. You will find the documents for your supplier approval in the download area.
Getting started
What you provide, what you receive
Your dimensions are the starting point. You receive prototypes for your line and documents for your requalification.
Your information
What you provide
- Drawing, specification or sample of your current packaging with outer dimensions and inner contour
- Carton or pallet dimensions and the stack height
- Your approval checklist: required certificates, tests and documents
- Annual volume and the date by which your line should be switched over
- Line details: manual or automatic, manufacturer, model and cycle rate
Our deliverables
What you receive
- Feasibility, budget price and schedule as a guide within a few days
- Prototypes for the line trial on your system — we set the quantity in the initial consultation based on your trial
- The data sheet for your molded part with dimensions and tolerances
- Documents for your requalification: certificates and, for food contact, the declaration of conformity for each molded part
- How we share your tooling costs depends on annual volume and term — in Wet Molding, up to full coverage; the terms are set out in your quote (Custom Engineering)
From first conversation to series production
How the switch works
Four steps from the first question to running series production — design starts directly from your drawing. You give approval at three points: development after the budget quote, the production tool after the line trial, the start of production after the pre-series.
01
Initial consultation
You tell us dimensions, outer packaging, line, approval checklist, volume and date. You receive feasibility, budget quote and schedule 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 to your drawing, shape sample for the fit test in your carton, prototypes in quantity for your 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.
Products for this starting point
Which product adopts your dimensions
Trays, protective packaging, inserts or food packaging — each product page shows examples, key parameters and evidence. Choose by your product.
Industry
Industrial Packaging & Trays
Workpiece carriers and transport trays, nestable and stackable — designed for your line and your pallet pattern.
View product →
Protection
Protective packaging
Cushioning, end caps and inserts in your carton dimensions — designed for your shipping route.
View product →
Consumer goods
Product packaging
Inserts for your folding carton or retail box: each product sits in its own compartment.
View product →
Food
Food Service
Bowls, cups and inserts designed for your contents — with a declaration of conformity for each molded part.
View product →Frequently asked questions
What customers ask before the switch
Next step
Let's talk about your switch
Step 1
Consultation
You tell us dimensions, outer packaging, line, approval checklist and annual volume. You receive feasibility, budget quote and schedule 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 appearance. Prototypes in your dimensions for the line trial follow in step 03.
Request samples →Drawing
Request a budget quote
Give us outer dimensions, inner contour and annual volume, and send your drawing along. Based on your drawing, you receive feasibility, budget price and schedule as a guide within a few days — the binding quote follows after development.
Request a budget quote →