Europe's innovative production for fiber cast molded parts
pulp production
from renewable raw materials
In the future, it will become increasingly important to be able to rely on reliably deliverable, innovative and safe products and packaging that are sustainably produced in Germany and Europe and are based on the development of the circular economy and a fair production chain. With these quality features and our know-how in research and development, which has been constantly expanding over decades, we are always at your disposal.
How it works
A manufacturing technique older than plastic, with today's know-how for tomorrow's packaging future.
What is cast fiber or pulp?
(English terms: Molded pulp, Fiber pulp, Pulp molding)
Molded Pulp is a very environmentally friendly materialmade from waste paper, renewable fibers like hay, straw, hemp or the like Pulp material will be produced. The material Molded Pulp can be reused, is recyclable and compostable.
Everyone knows this wonderful fiber cast material, and yet the material is only noticed when a product made of this material is referred to: Egg carton! This packaging protects the sensitive food product "eggs" comprehensively - very simply and absolutely safely.
Unfortunately, this fiber cast material has literally disappeared into obscurity in the last few decades and would probably one day have been replaced by modern, albeit environmentally unfriendly products such as synthetics and plastic. With the emerging topic of "sustainability", a new focus is set in the area of packaging & logistics. As a result, the use of plastic is viewed very critically. The industry is now trying to resort to substitutes such as B. "natural plastics“Which in reality are not natural.
With our 3D concepts, we at PAPACKS have brought the material fiber cast onto the "stage of sustainability". For this we were nominated for the GreenTec Award 2017 among the last 3 candidates. We see this nomination as a tribute to the material Molded Pulp.
Today's made by us Molded Pulp is with the concept egg carton no longer to be compared. Today's special requirements from the industry were the challenge for us as a fiber cast manufacturer and fiber cast producer to further develop and optimize production with the fiber cast material. Fiber forms are meanwhile water resistant, grease repellent and also fireproof and thus usable in a wide range of industries. Of the Automotive industry as transport trays and Packaging of food products the area of application extends to the end customer area.
The molded fiber parts are the ecologically and also economically only answer for packaging and transport questions. With this material pulp the turning point is heralded, To ban plastic from the packaging world. In the field of transport and logistics, fiber cast is processed into transport trays and replaces the expanded trays Polystyrene (EPS) or extruded polystyrene (XPS), as well foams known as well Styrofoam.
A characteristic of the material cast fiber is its versatility. The material itself has a high Shock absorption on. By adding various environmentally friendly fabrics the properties of the raw material can be enhanced or even changed. Nevertheless, these are molded fiber parts biodegradable or directly compostable, however, it is most effective direct reuse about a "green circulatory system' to shred the packaging after use and use this material to make new molded fiber parts.
In addition to the protective function, the Molded Pulp Our 3D packaging also features a new, modern design with a high recognition value.
PAPACKS® Pulp Product Categories
Plastic-free - Made from renewable raw materials
Transport trays
charge carrier
PAPACKS® FIBER CASTING Molded parts for one-way transport, made from fresh fibre/primary fibre, ready for circular economy cycles. Replaces plastic, plastic trays and time-consuming cardboard constructions for delivery, logistics and transport protection.
Product packaging
inlays
PAPACKS® FIBER CAST molded parts for product protection, shipping protection and a sustainable product presentation.
Made from virgin fiber ready for the circular economy. Replaces plastic blisters, plastic inlays, complex cardboard constructions, foam and styrofoam inserts.
Food primary packaging
PAPACKS® FIBER CASTING Molded parts for one-way transport, made from virgin fibre/primary fibre. Replaces plastic, plastic trays and time-consuming cardboard constructions for delivery, logistics and transport protection.
Pharma, medicine,
Cosmetics
Certified primary packaging made from PAPACKS® FIBER CAST for the medical/pharmaceutical industry.
Optional with PAPACKS® ORGANIC COATING for oxygen and water vapor barrier. Certification according to the hygiene standards for packaging manufacturers of primary packaging and other relevant management systems according to ISO 9001.
Advantages of fiber casting
Good for the environment, perfect for your customers!
The biggest advantage we are using Molded Pulp offer is to create a closed Circulatory system for industry and manufacturing companies. We produce useful packaging or transport packaging Molded Pulp for your products.
Customer satisfaction through sustainability
Customer satisfaction through sustainable packaging
Free of plastic
no additional charges for using unrecycled plastic in packaging
Renewable resources
Plastic-free, primary fibre, FSC®-certified, suitable for direct food contact
Less packaging license costs
compared to a plastic tray of the same shape (source: www.licensesero.de)
High dimensional stability
Molded fiber molded parts withstand a higher impact of force up to deformation compared to plastic trays.
Recyclable in waste paper
Raw material of the packaging for disposal in waste paper for reuse or composting
Temperature resistant at over +100 degrees
PAPACKS® Organic Coating
optional: organic coating application for barrier protection, abrasion coating, water vapour, oxygen barrier and other property enhancements
Odorless and tasteless
Pulp made from primary fibers is odorless. We use the purest fresh fiber in our production.
Shock absorbing / high transport safety
Pulp molded molded parts are tough or soft and absorb repeated impacts without breaking.
Save space / save storage costs
Molded fiber parts can be nested inside each other and are therefore more space-saving compared to a folded cardboard solution.
Automated / packable by robot
Pulp molded parts can be used in automated and robot-controlled processes.
Suitable for sea freight
Molded fiber Molded fiber parts can be used in the area of sea freight.
Independent of raw material
Pulp can be made from various sustainable raw materials, e.g. B. industrial hemp.
Plastic-free packaging from renewable raw materials — Made in Germany
In order to meet industrial requirements, we use modern production processes and solutions for the circular economy. It is time for a global change to make our actions as diverse as our nature does.
We have optimized our appearance for our values, integrity and our mission. For us, diversity also means being in harmony with the diversity of nature and using it sustainably.
Be colorful and diverse with your products and use natural packaging for a way back to nature. It is time to go beyond just the “green” and collectively create global change that can be implemented by all.
PAPACKS® PRODUCTIONS IN EUROPE
Production sites in Germany and Europe
PAPACKS® GIGAFACTORY 1
Arnstadt / Thuringia (FOODSAFE / MEDICAL DEVICES)
Molded fiber molded parts of certified primary packaging for the food and medical/pharmaceutical industries. Certification according to the hygiene standards for packaging manufacturers of primary packaging and other management systems according to ISO 9001:2015.
Capacity pa: + 180.000.000 pcs.
PAPACKS® GIGAFACTORY 2
Arnstadt / Thuringia (FOODSAFE / MEDICAL DEVICES)
Commissioning in 2022.
Molded fiber molded parts of certified primary packaging for the food and medical/pharmaceutical industries. Certification according to the hygiene standards for packaging manufacturers of primary packaging and other management systems according to ISO 9001:2015.
Capacity pa: + 180.000.000 pcs.
PAPACKS® PRODUCTION NETHERLANDS
Netherlands (FOODSAFE)
Molded fiber molded parts of certified primary packaging for the food and medical/pharmaceutical industries. Certification according to the hygiene standards for packaging manufacturers of primary packaging and other management systems according to ISO 9001:2015.
Capacity pa: + 50 million pieces
PAPACKS® R&D Innovation Hub
Cologne / NRW (INDUSTRIAL)
Our place for technical innovations, small series production, further development of our 3D tool technology and raw material research.
Capacity pa: + 5 million pieces
"The show with the mouse" explains our sustainable advent calendars
The mouse shows one of the PAPACKS® fiber cast productions with sustainable advent calendars.
A television production by ARD / Das Erste® and WDR® for "Die Sendung mit der Maus"
How is cast fiber or a molded fiber part manufactured?
Fiber casting is made from waste paper fibers dissolved in water, renewable fibers such as hay, straw, hemp, etc. in a vacuum, pressing and drying process in the desired shape.
- Processing fibersPaper and cardboard waste is dissolved in a “pulper” (large mixer) and then diluted by a control system and prepared accordingly in various processing basins until the so-called fiber thick matter in the work basin is ready for use.
- Tool for fiber moldingThe tools for the corresponding cast fiber parts or fiber molds are complex and resemble a metal screen with a counterpart. These correspond to the shape of the later desired fiber casting. The appropriate tool counterpart and a specially calculated scheme for the screen structure will later influence the water drainage and vacuum suction so that the molded fiber part is formed evenly at all points.
- Process of molded part productionThe tools are now immersed in the working basin with the pulp mixture and suck the pulp mixture through the sieves by means of a vacuum. Fibers are retained by the sieves and thus build up the molded part. After surfacing, the molded parts are removed from the sieve using a counter-mold and a vacuum and placed on the drying section.
- Drying sectionThe drying section consists of a grid-like conveyor belt, which enables air permeability. Drying hoods blow heated air onto the molded parts. At the end, the molded parts are removed and placed on pallets.
- Form press and punchDepending on customer requirements and the area of application, the molded parts can be re-pressed. The fitting accuracy of the molded parts is stabilized and fixed in a press under the action of heat. In addition, desired embossings and perforations can be incorporated or, if necessary, the molded parts can be punched and cut accordingly.
Cast fiber drop test
Based on our extreme drop test - from a height of approx. 3 m - from a cardboard box with a fiberglass inlay filled with two heavy 0,75 liter bottles, you can see the protection and transport safety that fiberglass offers a product like no other material.
Check out our video!
