Innofibre validates HP’s molded fiber tech advantages over conventional tooling

14 Apr 2021 --- Innofibre has released new research data validating HP’s Molded Fiber Advanced Tooling Solution. Based on its testing, the independent Canadian research institute confirms HP’s technology can offer greater precision, along with faster forming and drainage times. 

“Compared to traditional molded fiber tooling, HP’s tools can be changed quickly and easily, with fewer stops in the workflow,” says Tarik Jabrane, Natural Sciences and Engineering Research Council of Canada (NSERC) industrial research chair.

“The speed of iteration and ability to change tools enables more prototyping and ultimately provides a more cost-effective option for the industry.”

It is “no surprise” HP is gaining traction with molded fiber manufacturers in Europe, the US and Canada, according to Mariona Company, global head of HP Molded Fiber Solutions. 

An example of a tooling made to package an HP-owned product.The Innofibre validation is reeling in pulp molding specialists such as Vernacare, Polyco Healthline Group and Eco Pulp.

Pre-existing collaborations include Fiber Innovation, Pacific Pulp Molding, Pulp Moulding Dies, and Western Pulp Products Company. Pulp Moulded Products and Veritiv are currently also working on a variety of new designs.

The results are in
Key findings published by Innofibre confirm the HP solution delivers many stronger parts more quickly than traditional tooling.

• Due to its excellent first pass pulp retention, especially of the longest fibers, HP tooling uses less fiber to make parts with greater strength than equal grammage parts from 50-mesh tooling.
• HP digitally designed screens resist wrinkles, so customers get parts with crisp edges and borders and highly personalized, legible markings.
• HP’s solution saves customers time and money with its superior fiber retention and faster forming. The savings are equivalent to avoiding having to discard every 11th egg tray being produced into whitewater.

“The ability to change over the product is huge. The machines run 24/7: When they’re not running, you’re not making money. Being able to change over a tool in minutes instead of hours is a huge advantage,” asserts Troy Mutton, president at Pulp Moulding Dies.

“It’s not a prototype tool anymore; it’s a functioning production tool that could possibly outlast traditional tooling,” he adds.

The printing customization factor finds favor with Bill Martin, director of operations at Western Pulp Products Company. 

“It’s very beneficial to have screens that can be tailored to a specific customer. To do a branded short run for a specific customer has a lot of capability and promise. In most industries, people will pay more to have their name on products they make and sell.”

Advanced technology unlocks value
Traditional methods have made certain design opportunities impossible due to complex geometries and shallow draft angles.

However, HP’s Molded Fiber Advanced Tooling Solution leverages proprietary HP digital manufacturing software and data intelligence. Its industrial 3D printing technology replaces the need for handcrafted screens, CNC machining and manually drilled form tools.

The two tools involve:

• HP AdvancedPro Transfer Tool: A lightweight transfer tool providing an extra digitally designed screen on the transfer side for improved productivity and process efficiency by reducing forming cycle time and moisture content. The tool improves transfer-side smoothness and enables parts with low draft angles as well as custom markings on the transfer side.
• HP FlowTec SmartScreen: Custom screens algorithmically designed to fine-tune slurry flow and improve molding performance for challenging geometries.

The lightweight Advanced Pro Transfer tool improves transfer-side smoothness and enables parts with low draft angles and custom markings.Eco-friendly pulp
Molded fiber, also known as molded pulp, is typically made from recycled paperboard or newsprint, but can also be made from many plant cellulose fibers, including bagasse, bamboo and wheat straw. 

Renewable molded fiber packaging products are biodegradable and recyclable. They are currently used in handling and packaging thousands of products from food containers to the packaging of household items and electronics to single-use medical service items.

Using molded pulp more efficiently aligns with HP’s 2025 goal to eliminate 75 percent of its own single-use plastic packaging, compared to 2018. 

Innova Market Insights named “Fiber-Based Frenzy” as its third top packaging trend for 2021. According to Innova Market Insights’ 2021 survey, half of US consumers (49%) regard packaging’s recyclability as its most important sustainability credential, followed by reusability (44%) and recycled material use (35%). 

Advanced screen texture possibilities allow for new levels of customizations. Meanwhile, 72 percent of global consumers and 62 percent of US consumers recognize paper’s exceptional recyclability.

Feeding the fiber-based frenzy
Other companies to jump on the pulp molding bandwagon include The Loop Factory, which scored exclusive EU funding to commercialize its Yangi Dry Forming Technology for fiber-based packaging earlier this month. 

Fiber-based packaging is taking hold outside of the consumer electronics and industrial markets as well as in the F&B arena. 

PulPac, the inventor of a novel Dry Molded Fiber technology, recently partnered with PA Consulting and Seismic Solutions to deliver cost-effective, fiber-based alternatives to single-use plastics to global markets, including North America.

Meanwhile, PulPac joined forces with gategroup company deSter to develop and manufacture fiber-based, single-use food packaging for the airline and foodservice industries.

By Anni Schleicher