Dry Molded Fiber

Dry Molded Fiber is the first industrial method that can convert cellulose fibers into packaging – price competitive enough to replace single-use plastics at scale

The Dry Molded Fiber technology delivers true innovation, affordability, flexibility, throughput speed and high-quality outcome.
A PulPac production line can match the throughput speed of commodity plastics processing enabling converters to shift from producing plastic products to high performance sustainable paper products. Conventional pulp converters can increase margins as the PulPac technology has cost, speed, quality and design advantages that are out of reach for traditional fiber molding methods.

High performance fiber products with unmatched possibilities for design and added properties
The material used in Dry Molded Fiber manufacturing is generic and readily available resources, typically wood pulp purchased on the open market. Depending on application, virgin, residue or recycled cellulose can be used. The pulp can be treated to add additional properties, such as water or grease resistance and to increase strength. Design flexibility is high with e.g. possibility to complex geometries and deep drawing, with draft angles far exceeding traditional fiber molding. Barriers and surface decoration, such as color, print, patterns, embossing and debossing, is added in-line, rolling all manufacturing processes into one and removing the need for additional steps.

High Speed Production
Possibility of cycle times of less than a few seconds. The holding time under pressure starts at 0,2 seconds.

Unique Freedom to Design
High flexibility in shape and graphic design. Complex geometries with zero release angle or even undercuts and multi-compartment. Any type of embossing, debossing, color, patterns and print.

Raw Material Flexibility and Enhancement
Bleached or non-bleached fluff pulp and pre-sized paper. Excellent material thickness control. No wet processes involved.

Barriers Tailored for Superior Performance and Sustainability
Standardized or application designed barriers, sprayed, laminated or pre-sized.

A simple and ingenious technology
The basic principle of the Dry Molded Fiber technology is that paper or pulp is fed through a mill that breaks it up into fibers. The fibers are then formed, using air, into a web that is fed into a standard plate press with unique tooling that compacts the fibers into a mold. Any offcuts and excess web are fed back into the system to eliminate manufacturing waste.

Dry Molded Fiber unlocks the full potential of using wood fibers in packaging
Wood pulp is one of the world’s most abundant and globally available raw materials. Unlike bioplastics it isn’t diverting crops away from food production. Pure cellulose is a renewable, recyclable, biodegradable and compostable resource that absorbs carbon dioxide during growth. Dry Molded Fiber makes it possible to use this fantastic raw material in packaging without the drawbacks of traditional fiber forming methods. Besides offering high-speed manufacturing, which makes it a competitive alternative to plastics, Dry Molded Fiber saves water and energy compared to traditional fiber forming. It reduces CO2 emissions compared to both traditional fiber forming and single-use plastic production. Most Dry Molded Fiber applications are fully recyclable as paper, one of the most recycled materials in the world. Products are also compostable, industrially and in household depending on specification. And If a Dry Molded Fiber product ends up in the wrong place, such as landfill or in the ocean, it will degrade – not pollute and harm wildlife. We work actively with only using and promoting certified raw material from sustainably managed forests that balance the needs of the environment, wildlife, and forest communities— conserving our forests for future generations.