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Molded Fiber Packaging
THE PROCESS
The process is similar for all types of products. The main differences are in the formation process and the processing after formation.
The Creation
The process begins by collecting newspapers, magazines, boxes, or other items destined for landfills. In a blender, these items are broken down into small fibers that are added to water to create a slurry. This mixture is made to a specific consistency to be added to molds and then formed into the final product.
Depending on the product created, the form will either be pressed and dried in an oven, or pressed and cured without additional drying (thermaformed). A completely sustainable packaging solution, 100% compostable and biodegradable.
The Types
Type 1 - Thick Wall/Heavy-Duty
Example Product Types:
Horticulture trays & pots
Protective packaging: Corner guards
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Manufactured from a single mold with a product wall thickness of 3/16" to 13/32" or 5mm to 10mm. Smooth on one side, rough on the other. Ideal for non-fragile, heavy items (e.g., vehicle parts, furniture, motors). Suitable for horticultural use. Oven dried
Type 2 - Transfer Molded Products:
Product Types:
Consumer product protective packaging.
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Manufactured from a single mold with a product wall thickness of 3/32" to 3/16" or 2mm to 5mm. One smooth side and one rough side. Primarily used for supporting non-fragile, heavy items like vehicle parts, furniture, and motors. Also used in horticulture for plants, floral, and nursery pots. Oven dried.
Type 3 - Thermoformed/Thin Wall Products:
Product Types:
Cups, bowls, plates, and food packaging.
Smooth surfaces, well-detailed forms with minimal draft angles. Wall thickness: 1/32" to 3/32" or 0.5mm to 2mm. No oven curing required; products are dried in the mold. Hot mold pressing results in denser walls. Resemble thermoformed plastic material.
Type 4 - Processed
Product Types:
Custom Containers, Consumer Products
This category includes molded fiber products with additional treatments such as hot pressing, die-cutting, printing, coloring, special molds, slurry formulations, embossing, unique design features, and special additives.
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