Packaging capabilities - How does it work?

From molded pulp fiber to solid packaging

Molded fiber or molded pulp has more than proven its strengths as a packaging material. New, innovative applications continue to add value, maintaining a strong emphasis on cost efficiency and our shared responsibility for people and the planet. Molded fiber provides protection, effective product presentation, longer-lasting shelf life for products… and molded pulp packaging is definitely green.

‘Molded fiber' is the collective term used to refer to the process for producing strong, protective material made from 100% recycled paper. Paper waste is dissolved in water until it becomes a homogeneous mass of fibers. This fibrous mass or pulp is sucked into molds and vacuum-shaped, creating the specific molded pulp packaging product – an egg carton or fruit tray – that takes on its final shape under pressure and leaves the production line completely dry. The process uses a closed water system, offering an extra guarantee of sustainable production.

The molded fiber production process, step by step:

  • The conveyor belt1 leads the recycled paper to the pulper2.
  • Water from the water tank3 and recycled paper are processed into pulp and pumped into the 4% pulp tank4
  • The pulp is pumped through an automatic cleaning system5 and consistency regulator into the 1% pulp tank6.
  • The pulp is pumped into the moulding machine7 where products are formed on moulds using vacuum. The hot air hood8 reduces the water contents of the products.
  • The moulded products are blown off on carriers, guided by the intermediate frame9. The carriers take the products through a multi-layer oven10. After drying, the products are deposited on a finished product conveyor.
  • Circulated air is reheated in the airheater11. Exhaust air is reused to heat up the process water in the heat exchanger12.