Manufacturing of Molded Pulp

Molded pulp, a blend of paper and water, is perhaps most readily associated with egg packaging and fast-food drink trays. However because pulp can be molded into complex 3-dimensional shapes with the ability to effectively enclose and protect products, molded pulp continues to emerge as the interior dunnage of choice for many packaging applications. An understanding of the paper fibers and how to best process these fibers for each product application requires special skill, and is more art than science.

Molded pulp is the result of combining water and post-consumer secondary fiber - including newsprint, corrugated and other select paper grades - in a large vat to create a slurry of proper consistency. Custom designed production molds, which are attached to a molding machine, are submerged into this slurry. Pulp is drawn onto the screen mold via a vacuum process; paper fibers accumulate to a desired thickness and strength while excess water is removed. The fibrous formed mold is then transferred to an oven rack whereby it is carefully dried, packed and prepared for delivery.

The relatively soft paper fibers of molded pulp cushion and absorb impact while at the same time providing environmentally responsible packaging. Molded pulp offers excellent blocking, bracing and support functions and is highly shock absorbent for interior protective and sustainable packaging purposes.