Dry Molded Fiber
Setting a new world standard for packaging
It’s not the material, or the machine or even the product. It’s a quite brilliant idea, and a revolutionizing technology that turns ordinary pulp into any rigid, three dimensional products, using almost no water. And it’s fast.
is Dry Molded Fiber?
The simple solution to an unnecessary problem
Plato said, “Our need will be the real creator”, and we invented Dry Molded Fiber on exactly that premise — the need for responsible packaging applications.
Like all ingenious innovations, Dry Molded Fiber was that logical next step. Forming fiber into packaging using water is tried and true, but when you rely on water use, you increase environmental and social impact. We managed to take almost all the water out of that equation, which means cost efficiency and shorter cycle times that can compete with production of single-use plastic.
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
Barriers are applied to meet product requirements and intended use
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
you should consider Dry Molded Fiber?
BECAUSE IT MAKES NOTHING BUT SENSE
Unit cost, scalability, and responsibility
There is an alternative for manufacturing packaging products with lower environmental impact available right now. It meets the requirements for versatility, output, affordability and legislation — wouldn’t that be an obvious choice for a new packaging standard?
Dry Molded Fiber uses generic pulp to form almost any three-dimensional packaging product. We based our technology on well-proven systems and made some improvements. It’s unmatched in design possibilities compared to traditional fiber forming, and it matches plastic processing on both price and cycle times.
What is in a name?
Dry Molded Fiber is exactly what it says
A technology to form rigid, three-dimensional products from cellulose fiber that requires almost no water.
STAY IN SHAPE
Dry Molded Fiber fits into current systems
The technology’s unmatched forming capabilities enable product features like undercuts, snapfit, denesting, and stacking is no problem.
Enabling competitive unit economics
Dry Molded Fiber forms cellulose in a unique way and beats other fiber methods when it comes to speed, cost and quality.
DRY MOLDED FIBER IS
10x faster than conventional fiber forming methods
The Coffee Lid
Products in the PulPac Highway program are recyclable, comes with a validated tool design, ready recipe for material and barrier and all the production data you need to build your own business case.
BUSINESS CASE INPUT
CYCLE TIME (S)
OUTPUT PCS / HOUR
do you get started with Dry Molded Fiber?
Choose your packaging type
Dive into our
Access the technology
Get familiar with our
Order your production line
Discover the PulPac Modula
Enjoy all technology improvments, and every benefit that comes with being a part of the global Dry Molded Fiber community.
Regardless of where you are on your journey, we are right there with you, offering full-scale support for your unique project. Through the sampling phase, industrialization, or setting up production, our team of engineers is with you, every step of the way. Together, of course, with representatives from our turnkey machine partners, automation, tooling, input materials, and barrier solutions.
THE PULPAC MODULA
A turnkey solution offered by our partners
Engineered as a modular, industrial production line, capable of manufacturing affordable, food grade products at high volumes. And it’s readily available to order from our turnkey machine partners.
OUR HIGHWAY PROGRAM
A range of standardized products
We tried, failed, tried again, and now we have perfected a range of commercially validated and tested products. The Highway program let’s you get in the fastlane.
The key to competitive fiber packaging
Compared to commonly used fiber forming methods, our dry process opens up new possibilities for applying barriers. Spray, laminating, and other methods applied in-line or post-process.
Questions you might have…
What is the cycle time of a system?
The whole cycle is automated. With a holding time under 0.5 or even as low as 0,2 seconds, 11-17 kick-outs/min, and 3.5 seconds for the entire cycle, this process is up to 10 times faster than traditional fiber forming. And on par with plastics processing, but with significantly lower climate impact.
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 barrier function is to protect the fibers from water, oil, grease, etc, but if you are producing a product that is not exposed to that type of liquid you will not need a barrier.