Discovery Channel Video: “How It’s Made – Molded Pulp Manufacturing Process”
*Video is for educational purposes only and is not an exact representation of Keiding’s processes.
Molded pulp, and the manufacturing process associated with molded pulp, is perhaps most readily identified with egg packaging and fast-food drink trays. Because paper pulp can be molded into complex 3-dimensional shapes with the ability to effectively enclose and protect all types of products, molded fiber has emerged as the interior dunnage of choice for many packaging applications. An understanding of recycled paper fibers and the ability to apply that knowledge to the manufacturing process requires special skill, and is in many ways more art than science.
Molded pulp is the result of combining water and recycled paper – including newsprint, corrugated and other select paper grades – in a vat resembling a large blender to create a slurry of proper consistency. Custom designed tools, which are attached to a molding machine, are submerged into this slurry. Pulp is then drawn onto the screen mold via a vacuum process; paper fibers accumulate to a desired thickness and strength while excess water is removed. When the vacuum process is complete, the fibrous formed part is transferred to an oven whereby it is carefully dried, packed and prepared for shipment.