Moulded Fibre

BeautyBlue Ocean Closures Screw CapCelluloseColourformCompostableFood & BeverageFood GradeLightweightMeiyume Molded PulpMoisture BarrierMoulded FibreMxG FiberOil ResistantPackagingPapacks Fiber BottlePureFiberRecyclableRefibrRigidThe Beauty LoopThe Fibre Bottle by Cullen

WHAT WE SAY:

Used for packing eggs for over a century, moulded fibre was the unsung hero of plastic-free packaging solutions – until now. The material’s biodegradable, compostable and recyclable qualities, combined with cheap costs of production, are making it so popular that demand is outpacing supply.

Made from renewable raw materials, such as bagasse and bamboo, often derived from agri-waste, moulded fibre is seen as a sustainable alternative to plastics and innovations in pressing technology are helping it imitate the smooth look and feel of plastic too. So much so that luxury brands, such as Chanel and Apple are jumping on the bandwagon. Our main concern, however, is the need for liners and coatings to store liquids – liners and coatings that are predominantly fossil fuel-based. We look forward to significant advancements in this area, which are coming soon.

Moulded fibre egg carton / Source: Shutterstock

WHAT IS MOULDED FIBRE?

Made from pulped raw materials, such as Bagasse, Bamboo, softwood, hardwood, and recycled fibres from cardboard, newspaper and kraft, moulded fibre is an increasingly popular packaging solution that has the potential to wipe out single-use plastics in key industries, such as food, beverage, consumer technology and cosmetics.
Moulded fibre packaging is created when raw feedstocks undergo heat processing to become malleable enough to be moulded into three-dimensional shapes, used as both protective and primary packaging. These shapes are as varied as an egg carton, a clamshell container and a multi-compartment storage box, and are only limited by imagination.
Manufacturing processes vary vastly and not all moulded fibre packaging is created equal. Pulp preparation can be done either mechanically or chemically. Pressing can be done either wet or dry and the resulting grades of moulded fibre vary from thick-walled, rough finishes to thermoformed packaging that’s smoother and sleeker. All processes have different impacts, which we explore below.
At the end of its life, moulded fibre products are recyclable in paper and cardboard curbside waste streams. It must be noted, however, that in 2016 only 20% of US households had access to kerbside recycling programmes that would accept moulded fibre products. While this percentage has likely increased, it does indicate that just because it can be recycled, does not mean it will be. In Europe, most paper recycling programmes accept moulded fibre products.
Moulded fibre is also said to be biodegradable and compostable, but this is entirely dependant on how it is treated, coated and lined. Moulded fibre products have traditionally relied on a thin plastic lining, or the use of fluorochemicals, to be waterproof and grease resistant. The plastic layer is not degradable and the forever chemicals have been found to migrate into food and our bodies, leading to their ban in many parts of the world.
At present, for moulded fibre to be compostable, it must be unlined and uncoated, but solutions are in the works to create entirely plastic-free solutions. This is particularly pressing due to the rise in fibre bottles for drinks, a product being sought after by myriad leading beverage brands. If we cannot perfect the fibre bottle before it is rolled out en masse, paper waste streams will be contaminated with plastic liners.
Moulded fibre packaging is both a scalable and affordable solution for brands of all sizes. According to Smithers, global consumption of the material is forecasted to be over 12.4 million tonnes by 2025. Raw materials account for roughly 35% of the finished goods value and while recycled Paper content dominates the market at present, we expect to see a move to other feedstocks, such as straw, bagasse and recycled Cotton, broadening the market’s potential further.

KEY PROPERTIES:

Compostable
Food Grade
Lightweight
Moisture Barrier
Oil Resistant
Recyclable
Rigid

INDUSTRY:

Beauty
Food & Beverage
Packaging

AVAILABILITY:

Mass Market

DIVE DEEPER:

The first moulded fibre patent was issued in 1903, but until recently the main use for this type of packaging has been the packing of eggs. Thanks to increased demand for sustainable packaging, and technological advancements in the industry, the moulded fibre industry has grown rapidly into a USD 5 billion industry, with growth forecast to continue at a CAGR of 6.5% through 2030, according to World Paper Mill.
Not all moulded fibre is the same, however. The use of raw materials and processes applied to the pulp can greatly vary the sustainability and performance of a moulded fibre product. Two key processes are involved in production of moulded fibre products that determine the quality of it: pulp preparation and moulding.
Pulp preparation can be done either mechanically or chemically. Mechanical pulping sees raw materials blended and treated with warm or hot water to make the fibres swell and break up into pulp, leaving a consistency of runny oatmeal. It is energy intensive and generally produces pulp that is higher yield, but low in strength.
Chemical pulping involves the cooking of fibres in a tank called a digester. There are two methods for this: in a sulfite process, ground wood is cooked in a sulfurus acid and limestone; in a kraft process, ground wood is cooked in sodium sulfide. Chemical pulping produces low yields with high strength. It is said to have less of an impact on global warming, but contributes to acidification.
The moulding process also varies. Wet press technology sees pulp products subjected to pressure and high temperatures in the mould until its moisture evaporates, where dry press technology sees dry fibres formed into a low density cellulose web using air and then pressed into shape. Dry pressing does not use water and the process is generally faster than a wet press, although machinery for the wet press method is much more readily available.
Different processes result in different grades of moulded pulp. Thick-wall or ‘slush’ moulded products have more density, rough surfaces, and are used primarily for heavy item packaging. Wall thickness varies from five to ten millimetres. Transfer moulded products are thin walled - three to five millimetres - smoother and most commonly used today across products, such as drink trays, wine shippers and egg cartons. Thermoformed fibre is a more premium, thin-walled formed fibre created with ‘cure-in-the-mould’ technology, which produces smooth-surfaced pulp products that closely resemble thermoformed plastic alternatives. Wall thickness varies from two to four millimetres.
Secondary processing is common with moulded fibre and finished moulds often go through a process of coating, printing, hot-pressing, die-cutting or trimming. The coating process is of particular interest, as many moulded fibre products are coated or lined in plastic-based materials to create waterproof properties, as mentioned above.
Recent innovations in moulded fibre have lured luxury brands, such as Apple and Chanel to find packaging alternatives that still look sleek and premium. The skyrocketing of demand in the space has meant that demand for moulded fibre has at times outpaced supply.

KEY FACTS:

12.4 million tn

The projected moulded fibre consumption by 2025 is 12.4 million tn.

$5bn

The the global moulded fibre market in 2022 is valued at $5bn.

68%

Of paper and paperboard was recycled, in the US, in 2021.

Key Questions to Ask:

What fibre are you using for your pulp and how does it stand up to environmental scrutiny?

Moulded fibre is made, predominantly, from the waste of other industries – a win in many ways. To make it as environmentally sound as possible, however, you must consider the raw material from which your fibre comes, and the impact the growing and harvesting of it has on the planet. Bamboo, for example, is considered generally sustainable, but it may not grow locally to you and your production premises. It may also be sourced from a supplier, who is clearing land and growing monocultures to meet demand, resulting in a negative impact on biodiversity. Pesticides may also be used to encourage quick growth. There is a variety of considerations for each feed, so do your research and prioritise locally-grown feedstocks to minimise carbon impact.

If chemical pulp processing is used, how do these chemicals impact the environment?

The sulfite chemical pulp process has been both the most used and the most effective, pulping process to date, but it has also been shown to cause serious environmental pollution after being released into the environment. Even with the more updated kraft process byproducts, such as sulfur dioxide, create emissions and often contaminate water streams. The identification of responsible suppliers, who use a low number of toxic chemicals is essential.

How much recycled paper content for pulping is available where you are?

Quantities of recycled paper content for use in moulded pulp packaging varies globally, dependant on regional paper waste recycling infrastructure. In the US, for example, 68% of paper and paperboard was recycled in 2021, whereas in India the rate is just under 30%. In some European countries it is as high as 99.7%. If looking for local waste streams, recycled paper may not be the first port of call for everyone.