Molded Pulp Packaging Design
Economic, Sustainable Shipping
Molded pulp is a 100% recyclable material that has gained traction in replacing some non-recyclable packaging materials. Molded pulp is commonly made from paper, corrugated and natural fibers such as bamboo. The type of material used determines the color, surface texture and properties of the molded pulp.
The biodegradable and compostable nature of these products makes them an ideal choice for environmentally conscious package design. Molded fiber products can be incinerated without harming incinerators, and the manufacturing process recycles both fiber and water, resulting in nearly zero waste.
Case study: Nearly $800,000 annual savings with eco-friendly, sustainable packaging design.
Benefits of Molded Pulp Packaging
This paper-based packaging solution provides value across multiple applications. Providing cushioning material properties for shock events that products often see in small parcel shipping is one of the advantages of molded pulp. Other applications of molded pulp include sophisticated packaging solutions for high end products looking for a memorable unboxing experience.
Environmentally Friendly
Molded fiber products are made from biodegradable and compostable waste paper or other natural fibers. It is recyclable along with other waste paper, further reducing waste.
Durable Protection
Molded pulp is lightweight yet strong, making it an ideal choice for packaging heavier items that may otherwise suffer damage in transit.
Economical
Molded fiber is cost-effective, with the manufacturing process recycling both fiber and water, resulting in almost zero waste.
Adaptable to Many Applications
Finally, molded fiber products are versatile, as they can be used for a wide range of products from egg cartons and trays to plant pots and containers.
BoldtSmith packaging optimization saves huge amounts on annual shipping costs – contact us today to learn more about how our custom molded pulp packaging and molded pulp packaging designs can improve your shipping and handling process.
Molded Pulp vs EPS Foam Packaging
Molded Pulp |
EPS Foam | |
---|---|---|
Recyclability |
100% Recyclable |
Not commonly recycled |
Cushioning |
Great cushioning value |
Great cushioning value |
Material Cost |
Competitive to EPS |
Competitive to Molded Pulp |
Tooling Cost |
Expensive and required for samples |
Expensive but not required for samples |
DC Storage Space |
Nests well and takes up minimal DC space |
Has a large footprint and takes up a lot of space |
Composition |
Paper based material |
Petroleum based |
Consumer Perception |
Sustainable and green |
Not environmentally friendly |
Molded Fiber Products: An Overview of the Four Basic Types
The International Molded Fiber Association (IMFA) breaks molded pulp into four distinct types.
Type-1 Molded Fiber Products – Robust and Thick-Walled
Type-1 molded fiber products are produced using a single mold, resulting in a product with a wall thickness of 3/16 to 3/8 inches (5mm to 10mm). These products have one relatively smooth surface and one rough side, and they are commonly used for support packaging of non-fragile, heavier items like furniture, motors, and vehicle parts. Furthermore, they are employed for floral, plant, and nursery pots and containers. These products require oven-drying.
Type-2 Molded Fiber Products – Transfer Molded
Type-2 molded fiber products are made by utilizing one forming mold and one transfer mold, resulting in a product with a wall thickness ranging from 1/8 to 3/16 inches (3mm to 5mm). These products have a relatively smooth surface on one side, and they are most commonly used for egg cartons and trays. New designs are being developed for electronic product packaging like cell phones and DVD players. Moreover, they are utilized for hospital disposables, tableware, electrical appliances, and fruit and drink trays. These products require oven-drying.
Type-3 Molded Fiber Products – Thermoformed
Type-3 molded fiber products require multiple heated molds, resulting in a product with a wall thickness of 3/32 to 5/32 inches (2mm to 4mm). These products have smooth surfaces with well-detailed forms and minimal draft angles. Products are dried in the mold, requiring no oven curing. Due to the hot mold pressing process, the walls of these products are somewhat denser. Furthermore, type-3 thermoformed fiber products resemble thermoformed plastic material.
Type-4 Molded Fiber Products – Processed
Type-4 molded fiber products refer to products that require some form of secondary or special treatment besides being molded and cured. Examples of Type-4 include hot or after-pressed, die-cut or perforated, printed, colored, special mold, special slurry formulations, embossments, and special design features.
Your Design is Our Only Interest
Unlike many packaging design companies, we don’t sell physical packaging material. Our only concern is optimizing the best design for your product’s packaging. We provide unbiased assessments of materials and designs without the added pressure of selling a specific type of material.
Our main concern is simple: delivering expert insights from an experienced, professional perspective.