Dry Molded Fiber

Driving packaging sustainability forward

With cost-effective, high-speed, and resource-efficient production that lowers carbon footprint, Dry Molded Fiber is the ideal solution for companies looking to replace single-use plastics or expand their portfolio of responsible packaging.

Fiber was always the best alternative – we just made it better

Like all great innovations, the Dry Molded Fiber technology was the next logical evolution. Instead of creating a fiber slurry, we form a dry web of fibers, minimizing water use in the molding process. This allows us to achieve cycle times as fast as 3.5 seconds, reducing both water and energy consumption while maximizing output and minimizing environmental impact.

DRY MOLDED FIBER

Optimized for efficiency and designed for sustainability

 

aspects of

Dry Molded Fiber process

Main resource is generic and available worldwide

Start with pulp

The pulp is milled and fibers are air-laid into a dry web

Mill-to-web

Barriers are applied to meet product requirements and intended use

Apply barrier

Products are formed using heat and pressure in standard plate press with uniquely designed tools

Mold into product

All excess material is fed back into the process

Recycle waste

LEARN MORE ABOUT THE PULPAC MODULA

Explore Dry Molded Fiber

Complement your existing packaging production

Whether you’re in plastic conversion or traditional fiber forming, Dry Molded Fiber offers benefits and allows you to expand your portfolio with renewable, recyclable, compostable, and biodegradable packaging—helping you meet sustainability goals without compromising on performance.

This technology enables high-speed production in a streamlined process, converting raw material to finished products in a single machine. It offers a unique combination of benefits—whether for large-scale production, custom orders, specific design needs, or optimizing factory footprint.

TECHNOLOGY LICENSING

Implement Dry Molded Fiber in your operations

Our inclusive, future-proof licensing model empowers businesses to adopt Dry Molded Fiber and drive positive change across the packaging industry – with world-leading expertise and support from us and our network of partners included

Access the technology

STANDARDIZED OR CUSTOMIZED

We help you develop your Dry Molded FIber product

Adapt existing product lines or design unique products to provide responsible packaging that meets today’s demands for sustainability and convenience, while offering a scalable solution for tomorrow.

Products

MACHINE PLATFORMS

Order your machinery from our turnkey partners

The versatile PulPac Modula and the compact PulPac Scala are both delivered globally. We help you choose the model that best fits your needs – start small and scale up, or go full factory from the start!

Machinery

How

to get started with Dry Molded Fiber?

Choose type of product

Dive into our

Products

Access the technology

Get familiar with our

Licensing

Order your production line

Discover our

Machine Platform

Start producing Dry Molded Fiber products

Start at your own pace: evaluate the technology, integrate it with existing production, or scale to full capacity.

Yes – I want to get started!

Questions you might have…

What is the cycle time of a system?

For the PulPac Modula, the holding time is under 0.5 or even as low as 0.2 seconds, 11-17 kick-outs/min, and down to 3.5 seconds for the entire cycle. For the PulPac Scala, the cycle time is currently down to 3.8 seconds.

What are the material costs?

Different product demands different types of material (pulp, tissue, barrier) so we need to look more into detail on your specific product to estimate a price. For pulp, you can find a global price index on www.foex.fi. And general cost of the materials refers to market price.

How do you separate the fibers?

The separation of the fibers is done mechanically by milling the raw material. Fibers are then airlaid into a fluffy web and transported on a conveyor belt.

Can you provide an LCA?

There is a third party validated LCA on Dry Molded Fiber cutlery, showing that the climate impact is 2.5 g CO2eq per spoon (3.8g each) or about 0.66 kg CO2eq per 1 kg product. As a comparison, in an LCA by Takou et al. (2019), with focus on single-use plastic products in Denmark, the climate impact of an average polypropylene (PP) cutlery with similar weight was about 15 g CO2eq per piece or about 4.2 kg CO2eq per 1 kg product. You can find more information about this in one of our press releases

How is chemistry best applied in the process?

In the PulPac Modula we can apply the barrier both in the pulp, in the tissue or with an in-line spraying system.

Is it possible to run the process without any barrier?

Yes, the process can run without any barrier. The barrier’s role is to protect the fibers from water, oil, grease, and other substances, and we always design products with their specific purpose in mind.