PulPac unveils first Dry Molded Fiber production unit as EU prepares for single-use plastic bans

22 Jun 2021 --- PulPac is unveiling the “world’s first” Dry Molded Fiber standardized production unit for manufacturing cost-effective, fiber-based alternatives to single-use plastics items, including food-grade applications. 

The PulPac PU300 is engineered as a modular industrial high volume production line. The first demonstration line is located in PulPac’s Tech Center in Sweden, where industrial manufacturing of cellulose fiber spoons has begun.

“For sustainable solutions like Dry Molded Fiber, the EU Single-Use Plastics Directive (SUPD) gives urgency to the fact we need to replace plastic with packaging and single-use products that make sense,” Linus Larsson, PulPac’s CEO and co-founder, tells PackagingInsights.

“We see a huge demand for the specific items being subject to the SUPD, and we direct our efforts to offer a truly competitive solution, both from a cost perspective, but mainly from a product quality and customer experience point of view.”

The SUPD will take effect on July 3, banning popular throwaway plastic items like cutlery, plates, straws, beverage stirrers, and beverage cups and containers made of EPS.

PulPac’s starting annual capacity for spoons is 230 million. The first Dry Molded Fiber products will reach the market in various segments this year, primarily in Europe.Dry Molded Fiber can produce 99% material efficiency and 90% lower CO2 emissions than plastic at a similar unit cost, PulPac says.

Fiber-based frenzy
Plastic-alternative, fiber-based solutions like PulPac’s Dry Molded Fiber technology are proliferating in light of impending EU legislation.

For Larsson, PulPac’s high production rates, which are on par with plastic manufacturing, differentiate it from the competition.

“Dry Molded Fiber is up to ten times faster than conventional fiber molding. It is a very energy-efficient process and doesn’t waste valuable water resources.”

“This paired with a product quality and definition beyond what is currently available from other sustainable options leads us to believe that consumers will prefer a dry molded product.”

“It is key to make the sustainable transition seamless from an end consumer point of view. Perception of the products needs to be on point.”

Dry Molded Fiber also enables material efficiency up to 99 percent with in-line recycling and up to 90 percent lower CO2 emissions than plastic at a similar unit cost, the company says.Dry Molded Fiber can replace plastic coffee cup lids, meat trays, deli carry-out containers, cosmetic packaging, bottles and more.

Industrialization challenges
PulPac announced in December 2019 that it had raised the capital to industrialize its technology. One of the biggest obstacles to this goal has been the COVID-19 pandemic, with the company’s network of partners and clients unable to meet physically. Despite this, cooperation has been effectively maintained, says Larsson.

In terms of technical challenges, PulPac took Dry Molded Fiber forward by developing the PL200 – the PulPac PU300 ‘predecessor,’ an automated Dry Molded Fiber pilot line presented a year ago.

“We secured the technology in the pilot line process and standardized it in the PulPac PU300,” explains Larsson.

“As we aim at replacing single-use plastics at scale, the challenge now is scaling the supply chain fast enough to meet the great market demand.”

“We are building a community of partners, converters, machine builders, brands and fiber providers that want to transform the industry together with PulPac and Dry Molded Fiber.”

PulPac has secured several partnerships, including with gategroup company deSter for developing and manufacturing fiber-based, single-use food packaging for the airline and foodservice industries.

Meanwhile, the company has recruited PA Consulting and Seismic Solutions to develop a wide range of technical and commercial applications and scale up the manufacturing process. AR Packaging is also licensing the Dry Molded Fiber technology.

Fiber bottles and more
Dry Molded Fiber’s versatility, cost structure and market readiness make it suitable for numerous products, including fiber bottles and other complex applications.

“Already today, you can commercialize affordable high-volume products like spoons, trays, lids and bowls – paper products that can hold grease and water without toxic chemicals – which are all ready for production with the PU300 platform,” notes Sanna Fager, PulPac’s CCO.

“The PU300 machine platform is a milestone for making affordable fiber-based packaging globally available. To meet the massive interest from brands and converters, we are now scaling supply chains by building a global community of world-leading Dry Molded Fiber suppliers,” Larsson reiterates.

“We welcome converters, machine builders, brands and fiber providers to join us and transform the industry from within.”

PulPac supports its clients with their own Dry Molded Fiber manufacturing as a priority. Its goal is to replace over one million tons of plastic by 2025.

By Joshua Poole