PulPac pilot line marks industrialization of disruptive single-use fiber
30 Jun 2020 --- PulPac has engineered the first pilot line for its patented Dry Molded Fiber technology, which presents a price competitive alternative to single-use plastics at scale. Touted as the world’s first industrialization of disruptive dry molded fiber technology, the pilot line is a sequential step towards enabling licensees to produce billions of plastic-free and biodegradable fiber products within a few years. PulPac invites manufacturers and brands to set up their own Dry Molded Fiber production as EU Member States seek to impose the Single-Use Plastics Ban by the 2021 deadline.
Invented by PulPac in 2016, Dry Molded Fiber technology is protected by 38 patents and patent applications, covering more than 50 nations. The technology dry molds pulp into solid packaging of any shape, including beverage cup lids, coffee pods and food trays.
“We have invented the first industrial method that converts virgin, residue or recycled cellulose fibers into packaging [and] it is price competitive enough to replace single-use plastics at scale. The pilot line is a sequential step towards our goal to help clients produce their own fiber-based products,” Linus Larsson, CEO of PulPac tells PackagingInsights.
“The next step is to continue to scale and offer our technology to clients. The pilot line allows clients to understand and visualize their production of Dry Molded Fiber,” Larsson says.
PulPac's pilot line marks the “world’s first” industrialization of dry molded fiber.
PulPac expects the first Dry Molded Fiber packaging to reach shelves this fall. The application is a non-food blister packaging for a series of retail products sold on the Swedish market.
Fully automated processing
The pilot line is fully automated. Raw paper pulp is fed through a mill to break it up into fibers, and these are then formed into a web that is fed into a standard plate press. The press is equipped with unique tooling that compacts the fibers into a mold.
“Any offcuts and excess web can be fed back into the system to minimize waste. Barriers and surface decorations are easy to add in-line, rolling all manufacturing processes into one. So, there is no need for additional steps,” Larsson explains.
The dry forming enables high-speed manufacturing of fiber products of almost any shape or use while saving energy and reducing CO2 emissions. The technology also presents many design and tech advantages that traditional fiber molding methods cannot meet, the company indicates.
“Our clients will be able to deliver what the whole world demands, a sustainable replacement to single-use plastics – and they can do so with maintained or even increased margins in several categories. The pilot line lets us showcase the advantages of the technology and fast track industrialization for clients,” Larsson notes.
The dry forming enables high-speed manufacturing of fiber products in almost any shape.
Industry lines up
PulPac describes the industry’s interest in its technology as “significant.” A handful of clients and partners are already implementing the technology. In May, AR Packaging joined the PulPac Technology Pool, aiming to be first-to-market with 3D dry molded cellulose trays and cutlery for the food, on-the-go and foodservice sectors created using the patented technology.
“Our vision is to be a world leader in innovative packaging that is both sustainable and commercially successful. We help clients to disrupt the industry and set a new and sustainable standard for packaging and single-use products,” Larsson concludes.
In December, PulPac secured funding to accelerate the global commercialization of its environmentally sustainable packaging and disposables. PackagingInsights spoke in-depth with Larsson about the full potential of Dry Molded Fiber technology.
By Joshua Poole
