PulPac Modula - The world’s first standardized Dry Molded Fiber Production Unit
Following the accelerating progress of the Dry Molded Fiber technology and great interest from the industry, PulPac together with its partners now reveals a standardized production line – the PulPac Modula. Shifting from plastic converting or traditional fiber molding to Dry Molded Fiber is easier than ever, and even more attractive for the converters and brands that want to be leaders in the race for sustainable packaging.
Turnkey providers and components via PulPac's partners
Interested parties are invited to sign up their interest in the PulPac Modula and Dry Molded Fiber via an expression of interest form and request a sample package. Link above and here >>
Designing concepts to distribute technology
The PulPac Modula is engineered as a modular industrial production line, ready for food grade production of high volume and affordable Dry Molded Fiber products. The very first demonstration line has been set up in PulPac’s Tech Center in Sweden, where industrial food grade manufacturing of sustainable spoons made of pure cellulose fibers has begun.
Fiber cutlery ready for production
The versatility, cost structure and market readiness of Dry Molded Fiber opens exciting opportunities for both fiber and plastic converters. In a few years, it will be possible to manufacture Dry Molded Fiber bottles and other complex products. But already today you can commercialize affordable high-volume products like spoons, trays, lids, bowls, – paper products that can hold grease and water without toxic chemicals – which are all ready for production with the PulPac Modula platform. Single-use cutlery is a very interesting segment with billions of units demanded each year, and especially given the EU-wide ban on non-sustainable plastic cutlery coming to effect July 1st this year.
Fast, effective and sustainable production
The dry process enables the PulPac Modula to run extremely fast. Cycle time and production rates is on par with plastic manufacturing, and up to ten times faster than conventional fiber molding. Furthermore, Dry Molding does not waste valuable water resources nor impact the wastewater infrastructure. The process is much more energy-efficient than conventional fiber molding and enables material efficiency of up to 99% with in-line recycling. In summary, these process advantages yield up to 80% lower CO2 emissions at similar unit costs as plastic.
How it works
The PulPac Modula PU300 is based on well-proven technologies and systems. The material used for production is regular pulp, cellulose fiber, a commodity item that is globally available.
Within the PulPac Modula, a mill breaks up the pulp into separate fibers. These fibers are airlaid to a vacuum belt, forming a fluffy fiber web that is coated with non-toxic barrier additives and laminated with tissue. Thereafter, an electric servo press with a 300 tons force, customized for food grade production, molds the products with 0,2 seconds holding time enabling a production cycle of 3,5 seconds. All non-used material is re-circulated, giving close to complete material efficiency.