Creating the world’s first Dry Molded Fiber bottle

PA has partnered with us for years to help bring Dry Molded Fiber packaging solutions to life for their global clients. PA primarily work with clients in two ways. They do custom development programs for individual clients to create bespoke Dry Molded Fiber packaging. For broader, more complex industry challenges like blister packaging, they undertake a Collective approach. By inviting multiple members into the Collectives, we can accelerate learning, reduce individual member investment, and maximize industry impact.

The Bottle Collective is focused on a Dry Molded Fiber Bottle which means that there is a significant reduction in water use and energy compared to alternative fiber forming methods. The majority of the materials used are also renewable resources. Our focus is showcasing a bottle that works technically, works for each brands’ ethos and needs, and works at the commercial speed, scale and cost expected from this market.

As we further engage specific brands and their unique needs, material transfer, color and taste profile and fragrance needs will all be addressed. We cannot share this information currently.

We are building a process and template for which multiple barriers (or none if not required) can be used as suitable for each product’s needs. The intention here is to create a scalable solution for applications of all types.

When a liner is used in our bottle, it is not adhered/glued to the fiber layer. Meaning, it is easily separated by almost any mechanical process. We are working with various waste management facilities in various markets around the world to understand what this looks like in practice – not just theory. We are designing for standard kerbside collection and expect the dustcart pressure to easily and quickly separate the liner from the outer layer. In addition, since a liner is being employed the pulp is of a higher grade than alternatives. The liner houses the product and any chemistry of the product keeping the pulp high grade.

This solution is quite different than cardstock. We can produce a myriad of sizes and shapes not possible in either cardstock or wet molded processes today. Emissions work is currently being evaluated but since our process is a Dry Molded process, there is a significant reduction in water use and energy compared to alternative forming methods.

The purpose and mission is creating a lower footprint bottle alternative compared to single-use plastics, glass, and other materials. The stakes are incredibly high and quite critical – sustainability efforts are a global need, and this collective will help further the changes necessary to achieve UN Sustainable Development Goals and Sustainability targets.

We are already bringing Dry Molded Fiber technology to life in packaging solutions across product industries. The technology is highly versatile and a viable alternative for most rigid, single-use packaging.

The Blister Pack Collective is another active initiative. Similar to bottles we — together with PA Consulting and a number of Brand partners — are working together to demonstrate the first Dry Molded Fiber blister packs.