PulPac Dry Molded Fiber

Moulded fibre bowls / Source: PulPac

CelluloseEuropeFood & BeverageFood GradeFreezer SafeLeak ProofLow-CarbonMicrowave SafeMoisture BarrierMoulded FibreOil ResistantPackagingPaperPulPac Dry Molded FiberRecyclable

WHAT WE SAY:

Faster, cheaper and better for the environment? PulPac’s Dry Molded Fiber ticks all the important boxes, and is a branded moulded fibre that’s definitely worth checking out if you need high volumes of relatively basic items such as spoons, trays, lids and bowls.

However, while we will be delighted to celebrate the end of single-use plastic cutlery, could you aim one higher and eliminate single use completely?

PulPac Dry Molded Fiber

WHAT IS PULPAC DRY MOLDED FIBER?

Dry Molded Fiber from PulPac offers an alternative to single-use plastic, through a commercially scalable, Cellulose fibre-based, dry pressed product.
Through its dry process, the production cycle is up to ten times faster than traditional wet press Moulded Fibre methods – remember, speed equals scale.
This means that Dry Molded Fiber can offer a cost-competitive replacement for plastic across many disposable product sectors, such as spoons, trays, lids and food bowls.
Most Dry Molded Fiber products are fully recyclable through the Paper waste recycling stream, as well as being compostable and biodegradable.
As PulPac licenses its Dry Molded Fiber technology, production availability is expanding and not limited to a single company or the existing producers.

KEY PROPERTIES:

Food Grade
Freezer Safe
Leak Proof
Low-Carbon
Microwave Safe
Moisture Barrier
Oil Resistant
Recyclable

INDUSTRY:

Food & Beverage
Packaging

AVAILABILITY:

Mass Market

DIVE DEEPER:

Moulded fibre has been one of the key winners in the move away from plastic utensils and food service packaging as consumers increasingly try to avoid single-use plastic.
Yet despite this, the industry faces numerous challenges, primarily around reaching cost parity with plastic, but also with regards to the PFAS chemicals often used to make fibre products water and grease-resistant.
As its name suggests, the material relies on a process of forming 3D objects without the use of water – unlike other fibre moulding techniques.
Paper or pulp is fed into a mill and broken up into fibres. The fibres are laid on a vacuum belt, mixed with barrier additives and laminated, before being compacted under heat and pressure to form a mould. The entire process typically takes under a few seconds, similar to plastic.
The company uses non-toxic additives and its products are PFAS-free.
Any unused material or offcuts can be fed back into the production system.
The company reports that because of the process’ speed and lack of water, its Dry Molded Fiber products can result in up to 80% lower CO2 emissions when compared to plastics and traditional moulded fibre, although no LCA is publicly available to validate the scope of these claims.
While Dry Molded Fiber products can be formed from any cellulosic fibres, wood pulp is typically used which, as PulPac highlights, does not compete with food crops.
PulPac piloted its patented Dry Molded Fiber material in 2020 before releasing its standardised production line, the PU300, in mid-2021. The company operates a licensing business model that outsources production to local partners, a model which it states will allow it to scale fastest.
While the company’s initial focus is on single-use food packaging, it also points to alternative use cases, such as paper clothes hangers.
While it has produced a number of prototype bottles, PulPac is still developing a complete and long-lasting waterproof barrier coating that would enable Dry Molded Fiber bottles to be rolled out at commercial scale.

A Dry Molded Fiber takeaway cup / Source: PulPac

Vacuum forming / Source: PulPac

KEY FACTS:

80%

PulPac reports that its Dry Molded Fiber products result in up to 80% lower CO2 emissions when compared to plastics and traditional moulded fibre.

$7.1mn

The company raised USD 1.2 million in January 2021 in order to further commercialise its technology, taking its total funding to USD 7.1 million.

Key Questions to Ask:

What are the most abundant and renewable sources of cellulose in your market?

Wood pulp sources are significantly more abundant and well-managed in some global locations – if there is limited forestry industry or it suffers from weak protections, then you should consider if another cellulose-based feedstock would be a more favourable option. However, recycled feedstocks cannot typically be used for food contact products.

What coatings and barrier additives will you require?

As always, the devil is in the details. While PulPac’s products might be PFAS-free, you should investigate how the performance demands of your finished product impact its recyclability and/or the residue left behind should it biodegrade in the natural environment.

Can you move away from single use altogether?

While it is great that there is a cost-competitive alternative to single-use plastic, the elephant in the room remains that most Dry Moulded Fiber products today are still single use. Could you reimagine your product or service around a more circular solution?

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