Molded Fiber Production The right process for every molded part
Wet Molding, Thermoforming, Dry Molding and Bottle — four processes in our plants, from design to series production from a single source. We recommend the one that suits your molded part in a consultation.
At a glance
Ten lines, three plants — capacity for your series production
Four molded fiber technologies at sites in Germany and the Netherlands, a patented tooling concept and certifications for producing your molded fiber packaging.
3 plants + R&D
PAPACKS Gigafactories 1 + 2 in Arnstadt and PAPACKS Netherlands in Appingedam (Thermoforming) — developed and managed from Cologne.
10 lines
Five Wet Molding lines, three Thermoforming lines, one Dry Molding line and the Bottle line of the PAPACKS Model S10.
4 technologies
Wet and dry forming, Thermoforming and Bottle — complemented by Finishing & Advanced Coating on our own coating lines.
Tool shop
In-house tool shop, patented tooling concept. How we share your tooling costs depends on annual volume and contract term — in Wet Molding, up to full coverage. The terms and the five-year warranty are set out in your quote.
BRCGS Grade A
Production in the Gigafactories in Arnstadt is certified to BRCGS Global Standard Packaging Materials, Issue 7, Grade A — with traceability of every batch from raw material to delivery.
TÜV Rheinland Cert GmbH · Scope: Gigafactory 1 + 2 Arnstadt
ISO 9001 · FSC®
Quality management according to ISO 9001:2015 for Cologne and Gigafactory 1 + 2 Arnstadt, certified by TÜV Rheinland — and virgin paper fiber from responsible sources, FSC® Mix Credit, license code FSC-C125098.
ISO 9001 · FSC-C125098 — Download certificates
120+ IP rights
Patents, designs and trademarks protect processes, products and tools — the result of molded fiber development since 2013 that continues to advance every line and every formulation.
50+ Awards
From the WorldStar Packaging Award and the Dieline Awards to the Deutscher Verpackungspreis (German Packaging Award) — most recently in 2026 for the Fiber Box. All awards.
Awarding bodies WPO, Dieline, dvi and others; documented by year, 2021–2026
Manufacturing
How is molded fiber made?
In six steps, fiber stock becomes a molded part — in the wet process, Wet Molding.
Step 1
Fiber preparation
Virgin paper fiber or industrial hemp is dissolved in water in the pulper, diluted and adjusted to the formulation in preparation tanks — until the fiber stock in the working tank is ready for use.
Step 2
Tool
The forming tool is a screen in the contour of the future molded part, with a matching counterpart. The screen design determines how the water drains — so that the wall thickness is right at every point.
Step 3
Forming
The tool dips into the fiber stock. Vacuum draws the fibers onto the screen, the water drains off, and the molded part builds up layer by layer. The counter-mold lifts it off the screen and places it on the drying line.
Step 4
Drying
On an air-permeable belt, the molded part passes through the drying line. Hoods blow heated air until the residual moisture is right. At the end, the molded parts are removed and palletized.
Step 5
After-pressing & die-cutting
Depending on requirements, molded parts are after-pressed under heat. This fixes the fit accuracy, smooths the surface and allows embossing, perforations and die-cuts.
Step 6
Finishing
On the coating lines, molded parts receive a functional coating as needed: it reduces permeability to grease, water, oxygen and water vapor — by spray or rotation, matched to product and application.
Thermoforming combines forming and drying in the heated tool: smooth surfaces on both sides, precise contour, tighter tolerances. In Dry Molding, the fibers are formed and compacted directly — for dedicated product classes such as lids and closure caps. The Bottle line of the PAPACKS Model S10 forms hollow bodies with undercuts in a single step.
The material
What is molded fiber?
Molded fiber refers to molded parts made of fiber material that take their shape in the tool. In wet molding, that means: dissolve fibers in water, draw them into the mold, dry. The result is three-dimensional and gets its protective function from its geometry.
At PAPACKS, the fibers come from virgin paper fiber and industrial hemp — individually or combined. Everyone knows the best-known molded part: the egg carton, which protects a fragile food with nothing but its geometry. Which raw materials PAPACKS uses and where they come from is covered on Raw Materials & Material Cycle.
The molded fiber PAPACKS makes today shares only the principle with the egg carton. Formulation, fiber density, tool making and post-processing determine whether a molded part runs as a transport tray in the automotive industry, holds electronics as an insert or works as packaging in direct food contact. Four processes cover this range — each with its own machine generation.
The terms are used side by side: in German, Faserguss, Faserformteil and Faserform refer to the finished product, Faserzellstoff to the raw material — in English, molded fiber, molded pulp, moulded fibre and pulp molding. As a molded fiber manufacturer, PAPACKS makes both: the fiber stock to its own formulation and the molded part on its own lines.
The formulation defines what the material can do: fiber type, fiber density and additives determine strength, surface and barrier. The design determines how a molded part cushions, stacks and runs in the machine. And because the shape is created in the tool, the molded part carries contours, chambers and lettering right along with it — protection and brand recognition in one molded part.
Technologies
The right line for every molded part
Each technology has its own machine generation — developed and built by PAPACKS.
Wet Molding
PAPACKS PP300
The workhorse of production: five lines form molded fiber components in the wet process — from inserts to transport packaging.
Wet Molding Afterpress
PAPACKS Press Station
After drying, molded parts are after-pressed under heat — dimensionally accurate, with embossing, perforation and die-cutting as needed.
Thermoforming
PAPACKS TPP-100
Three lines in Appingedam produce molded fiber parts with a smooth surface and precise contour.
Finishing & Advanced Coating
PAPACKS Coating Line
Two processes, spray and rotation, apply the functional coating for each item — in series production, on our own lines.
Bottle
PAPACKS Model S10
Series production of bottles, containers and tubes with complex undercuts.
View the PAPACKS Model S10 →
Dry Molding
PAPACKS Model S50
Dry forming — the fibers are formed and compacted directly. One line in series production in Arnstadt.
Which process suits your requirements?
The molded part determines the design: wall thickness, size and surface narrow down the process. We clarify special cases in a consultation.
→ Swipe the table sideways to see all columns
| Process | Site | Typical products | Wall thickness | Component size | Surface & shape |
|---|---|---|---|---|---|
| Wet Molding · PP300 unpressed | Arnstadt | Inserts, trays, protective packaging, industrial packaging | 1.0–5.0 mm | 690 × 430 × 160 mm | Fiber surface with visible texture, dimensionally stable trays |
| Wet Molding · PP300 after-pressed | Arnstadt | Inserts and trays for precise positioning, product presentation, functional surfaces | 1.0–3.0 mm | 690 × 430 × 160 mm | Embossing possible, dimensionally accurate for automated handling |
| Thermoforming · TPP-100 | Appingedam | Inserts and trays for precise positioning, product presentation, high-volume series | 0.7–1.2 mm | 1000 × 800 × 200 mm | Smooth with precise contour, embossing possible, dimensionally accurate |
| Dry Molding · Model S50 | Arnstadt | Threaded lids and closure caps | up to 1.2 mm | — | Embossing possible, dimensionally accurate |
| Bottle · PAPACKS Model S10 | Arnstadt | Bottles, containers, tubes | 1.5–2.5 mm | ø 80 mm, height approx. 200 mm — approx. 750 ml | Dimensionally accurate |
The PAPACKS Model S10 values reflect the current stage of expansion. For all processes: just-in-time production, framework agreements with short-notice call-offs, moisture protection and grease resistance through our own finishing for technical and food applications. Design ranges — we confirm the values for your molded part and its suitability for overseas shipping after sample testing.
Tooling, minimum quantities and lead times depend on the product class — the guide values are on the page Custom Engineering.
Inside look
How a molded fiber part is made
Tahsin Dag, founder and CEO, explains production step by step — from the fiber blend to the tested molded part.
Properties
What molded fiber parts can do
Material, design and construction set the limits — we test every property for your requirements on the final molded part.
Protection
Shock-absorbing
The fiber structure absorbs impact energy. Ribs and chambers in the design determine where the molded part gives and where it holds.
Dimensional accuracy
Dimensionally stable
After-pressed and thermoformed components hold their dimensions and fit — a prerequisite for trays that run in automated systems.
Logistics
Nestable and stackable
Tapered geometries nest inside each other when empty — how high the stack builds for each molded part is defined in the design.
Process
Automation-ready
Consistent molding allows handling by robots and pick-and-place — from insertion to palletizing.
Temperature
Temperature-resistant
During drying, molded fiber passes through temperatures above 180 °C. We test on the sample what temperature a molded part can withstand in your application.
Barrier
Coatable
Functional coatings reduce permeability to oxygen and water vapor (OTR/WVTR) and make surfaces grease-resistant and abrasion-resistant — we verify suitability for food contact for each product.
Appearance
Surface of your choice
From textured to smooth, white, brown or colored — with embossing in the tool and print on smooth surfaces.
Disposal
Collection in the paper stream
Uncoated molded parts belong in paper collection — labeling PAP 21. For the Fiber Box, cyclos-HTP test report no. 2782-2026-005174 is available; on request, we have an independent testing institute provide the evidence for your custom molded part.
Evidence
We supply what your approval requires
Certificates with their scope, the declaration of conformity for the article and, on request, the supplier audit at the plant.
Certificates
BRCGS, ISO 9001, FSC®
BRCGS Global Standard Packaging Materials, Issue 7, Grade A for the Gigafactories in Arnstadt · ISO 9001:2015 (TÜV Rheinland) for Cologne and Gigafactory 1 + 2 Arnstadt · FSC® Mix Credit, license code FSC-C125098.
View downloads →Conformity
Declared for each item
Food contact according to Regulation (EC) 1935/2004, recyclability in the paper stream, PPWR status — we compile the documents for your molded part on a product-specific basis.
Supplier Approval & PPWR →On site
Visit the plant
For customers and prospects with a specific project: see the lines on which your molded part is made — audit or plant visit in Arnstadt.
Request a plant visit →Frequently asked questions
Questions about molded fiber
Further reading
What comes off these lines
Finished molded parts from ongoing series production — and our latest production system in detail.
Packaging from our own series production
Fiber Box, trays, inserts and custom developments — as finished packaging from ongoing series production.
View products →
PAPACKS Model S10
Line layout, cycle time, variants and sample program — the PAPACKS Model S10 in detail.
View the PAPACKS Model S10 →Want to produce in-house? The production technology is also available as a license for your market — see the licensing program.
Contact
Let's talk about your project
Direct
Consultation
Describe your project — our engineering team will get back to you promptly with a process recommendation.
Consultation →On site
Visit the plant
For customers and prospects with a specific project: see the lines on which your molded part is made — audit or plant visit in Arnstadt.
Request a plant visit →Hands-on
Request samples
Sample parts from our development, matched to your project — check surface, wall thickness and fit in your hand before you decide.
Request samples →