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Pulp molding creates recyclable packaging from recycled newspaper and cardboard. Four types of products are available, but the process requires significant energy and water. Thick-walled molding is for heavy items, transfer products have thinner walls, and thermoformed fiber produces smooth, strong products. Some products require two stages to complete.
Pulp molding is the process used to create recyclable packaging material. This material is created using only recycled newspaper and corrugated cardboard. Great everyday examples of containers made with pulp molding are trays used to carry multiple drinks in fast-food restaurants, clamshell containers, and food trays. This type of container has become very popular in the last 10-15 years as consumers have started to demand recyclable packaging.
There are four types of pulp molding products available to consumers: thick wall, transfer, thermoformed fiber, and machined. All four methods require significant amounts of energy and pressure to shape the recycled fibers into the required shapes. It is important to note that although the finished product is made from recycled materials, a significant amount of water and energy is required to create the final product. The heavy requirement for resources has led some experts to question whether these products are really better for the environment.
Thick-walled paste molding is used for packing heavy items, molded paste pallet trays and auto spare parts. The product itself is quite rough on one side and slightly smoother on the other. The intended use of this type of pulp molding is for heavy materials. Roughness is not a primary concern, but relative strength is. Many companies design thick-walled products to withstand significant pressure and often rate different products to help people decide which one to use.
Transfer products have thinner walls and are made with a process very similar to papier-mâché sculptures. The process is the most commonly used manufacturing method for pulp molding materials. A mold is created using very fine wire mesh in the reverse shape of the final product. Fibrous materials are sprayed onto the mold, completely covering it; as the material dries, the wire frame is separated from the product and reused. For an example of a product made with this process, look at the beverage trays, cup holders, egg trays, or fruit trays used in stores.
The most recent development in wood pulp molding is thermoformed fiber. This method produces strong products with a smooth surface. Heat is added to the process at specific stages, allowing the material to look and feel like plastic, while being made from recycled fibers.
Some products require two stages to complete: forming and then finishing. These types of products are considered processed. The unit first completes one of the first three processes and is then passed to the processing section. Adding colour, die-cutting, trimming or using additives are all parts of secondary processing.
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