Moulded Pulp Packaging Suppliers

Moulded pulp types and construction processes

Moulded pulp packaging (also called moulded fibre packaging) is produced by forming a slurry of papermaking fibre — most commonly recycled paper, recycled cardboard, or virgin wood pulp — into a three-dimensional shape using a vacuum-forming mould. The resulting product is a rigid, lightweight packaging shape that can be produced in virtually any contoured form, making it ideal for product inserts, egg trays, bottle trays, food service containers, and protective packaging. The four main moulded pulp production processes are: thick-wall (Type 1) moulded pulp — an air-dried product with a rough surface texture on both inner and outer faces; the most economical process, used for standard egg trays, fruit trays, and industrial protective packaging. Transfer-moulded (Type 2) moulded pulp — a thinner-wall product formed on one mould and transferred to a second mould to dry, producing a smoother outer surface and better dimensional consistency; used for consumer electronic inserts, bottle trays, and commercial food service containers. Thermoformed (dry-pressed) pulp (Type 3 and Type 4) — the slurry-formed blank is pressed between heated metal moulds to produce a very smooth, dimensionally precise product with clean surface finish on both sides; suitable for premium food service containers, cosmetic inserts, and branded product packaging where aesthetics matter. Smooth-moulded (premium thermoformed) Type 4 is the premium variant, with the highest surface quality and print capability, used for premium cosmetic packaging and luxury product inserts as an alternative to EPS or plastics.

Fibre grades, applications, and ordering guidance

The fibre used in moulded pulp packaging significantly affects its properties. Recycled newspaper and OCC (old corrugated container) fibres are the most economical option and suitable for non-food-contact protective packaging, egg trays, and industrial inserts — the grey-brown colour is characteristic. Recycled office paper (white) fibre produces a lighter-coloured product with better surface quality. Virgin bagasse (sugarcane fibre), bamboo, and wheat straw pulps are used for premium food service products — producing a whiter, smoother surface and enabling food contact compliance claims for food service applications. Bleached virgin wood pulp is used for the highest quality thermoformed food service containers, providing white surfaces and clean food contact compliance. Food contact compliance for moulded pulp: food service containers must comply with applicable food contact regulations for paper and fibre (EU: BfR XXXVI and relevant national regulations; US: FDA 21 CFR for food contact). For recycled fibre, the main concern is MOSH/MOAH contamination from residual printing inks — virgin or certified-clean recycled fibre is preferred for direct food contact applications. Key applications are: egg and fruit packaging trays (high-volume commodity production), bottle and product inserts for protective transit packaging (electronics, spirits, cosmetics), food service containers (plates, bowls, trays, clamshell containers for hot and cold food), wine bottle packaging (a rapidly growing application as paper-based bottle formats emerge), and premium product inserts replacing EPS or plastic foam. MOQs for standard moulded pulp products (egg trays, standard inserts) are low — often 500–2,000 units for existing tooling. Custom moulded shapes require tooling investment ($500–3,000 per mould) with typical MOQs of 1,000–5,000 units.

Frequently asked questions