Questions you might have

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.

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.

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.

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.

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.

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.

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.

The whole cycle is automated. 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 differentiating factor is the cycle time which currently is 5.1 seconds. These processes are up to 10 times faster than traditional fiber forming and on par with plastics processing, but with significantly lower climate impact.

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.

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.

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.

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

We have barrier solutions for products like spoons, trays, lids, bowls, – paper products that can hold grease and water without toxic chemicals. In addition, we are continuously adapting new barrier solutions.

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

Reach out and we’ll set up an introductory meeting. Next step is an NDA, so that we can share details. If we jointly decide to proceed we validate your product, sign a license agreement and you order your machine from one of our turnkey partners. You will have our full support throughout your Dry Molded Fiber journey.

You order your machine from our turnkey machine partners. We will connect you with the most suitable for your needs.

PulPac holds a vast IP portfolio, including patents and front-edge know-how covering the technology of dry molding. PulPac encourages everyone wanting to dry mold fiber commercially to have a license from PulPac to ensure not to infringe on PulPac’s IP.

No, you need to sign a license agreement with us before machine-order.

It all depends, but the normal process from validation of your product, signing of the license agreement, machine-order to production that is up and running commercially is approximately 6-12 months.

Yes, with our business model and together with our turnkey machine partners, we can deliver technology, know-how, and our partners can deliver machinery globally.

Yes, we have a partner supplier network that offer full support on your Dry Molded Fiber journey.

The licensing cost is basically a royalty on sales. When you succeed, we succeed.

The technology can be used to make most types of three-dimensional rigid convenience packaging. To help our license holders to get started, we have a range of standardized and already validated applications that are ready for market. We can also support you in validating your uniquely designed product and making it ready to be produced.

Absolutely, reach out to us on info@pulpac.com

There are a few limitations for what kind of products that the technology can be used for, but there are products that are already validated and there are products remaining to be explored.

Today we have barriers for both cold and hot drinks.

We have barrier solutions for products like spoons, trays, lids, bowls – paper products that can hold grease and water without toxic chemicals.

Yes, we call holes “in mold cutting” and we can make both “buttons” and hinges on products.

We have a network of converters and can connect you with the best-suited partners.

We do not sell any machinery, but we have turnkey machine partners that do so and can help you make the most out of our production.

Depending on the local climate and time of year, the factory needs to be climate-controlled to control the quality of the products.

The number of cavities depends on the size/ depth of the cavity or the tonnage of the press.

The maximum mold area depends on the number of molds, the size of the web and on the tonnage on the press.

The estimated reference value for a PulPac Modula is ≈145 kW, and PulPac Scala ≈ 50 kW.

The estimated reference values for a production line is 1 to 2 FTE for standard operation.

Yes. Our turnkey machine partners, as well as other machinery partners, have extensive experience in delivering automation solutions suited to your individual needs.

As soon as we hear from you, we set up an introductory meet and greet to see if match. If all parties agree, we sign a non-disclosure agreement and proceed. If, after that, we have mutual agreement, we validate your product and take next steps.

Being a PulPac partner means that we recommend you and your solution to new customers when presenting Dry Molded Fiber to them. As a partner you have direct access to our Partnership team that will work with you to ensure that your solution works with Dry Molded Fiber.

We want all partners to bring their best ideas and contribute with either products, solutions, or services that help the Dry Molded Fiber network scale even faster. To do so, it is very important for us that our partners have the supply capacity to provide our joint customers around the world with their product, solution, or service.

By building a global partner network, and working across industries, we stimulate development and speed to market. We know that collaboration is the best way forward, because we see it happen every day.

The primary goal of the Collective is to incorporate the use of sustainable and renewable pulp materials to safely reduce and replace difficult-to-recycle and single-use plastics in tablet blister packs. PA Consulting, PulPac, and all of our Collective Members will be working together to develop both the packs and the industrial-scale manufacturing process that will be necessary to accelerate the transition to more sustainable blister packaging in the consumer health, pharmaceutical, and FMCG industries.

The Dry Molded Fiber technology is a more sustainable and scalable alternative to single-use plastic packaging. The fast dry process offers several design and manufacturing advantages, including high-speed and lowcost mass production.

While each product will have specific requirements, we expect the initial Dry Molded Fiber packs will enable a 90-95% reduction in plastic vs. current blister packaging. There will be some applications where 100% paper-based packs are possible.

Dry Molded Fiber converts renewable and recyclable fibers into packaging. As the name implies, the primary benefit of Dry Molded Fiber vs. wet molding is that it’s a dry process. Very little water is used in production and there is no need for additional energy to drive water off. That leads to two key benefits:

1. A better sustainability profile as water
use drops, as does associated energy.

2. These drive down the per unit production
time and costs, making scale possible.

As sustainability leaders in this space, our Collective Brand Members are proactively investing in blister packaging solutions that can:

1. Reduce overall environmental footprint
2. Reduce or eliminate plastic content
3. Transition away from PVC and materials that’s har to recyclehar to recycle
4. Increase recyclability

Our Dry Molded Fiber blister packs should help address all of those challenges.

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

We expect the current Collective program to develop the foundational blister packs, and the manufacturing process will run through the middle of 2024. Additional scale-up and enhancement of the production process alongside commercial equipment architecture will be critical to ensure broad market access.

The Collective approach allows for multiple parties across industries to all contribute toward solving a massive global challenge. Our Collective partnership will mean accelerated learning and growth in ways that are new and potent. And eventually, a greater collective impact in the market with a faster transition to more sustainable blister packaging.

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.