Processed Molded Pulp

Overview

Processed molded pulp refers to any molded pulp box inserts that has gone through any additional processes such as dying, coating or hot pressing. This gives you the opportunity to customize your box inserts with molded pulp and creates more high quality results when used for product packaging. Available for all types of molded pulp inserts, processed molded pulp offers brands the opportunity to enhance the unboxing experience through detailed customization.

Manufacturing Process

Blend

Raw material is blended and then mixed with water. Any non-fiber material is removed at this stage to create the pulp.

Mold

The machine pulls pulp onto the molds of your products. The water is then removed by applying a vacuum to set the pulp in place on the mold.

Press

The pulp is pressed and dried by two heated halves of the mold. Dry press thermoforming the product in under 10 seconds.

Dry

All complete dry press molded pulp inserts are inspected for quality control and then stacked on pallets ready for shipping.

Material Composition

Sugarcane Bagasse

A fibrous pulp material that remains after crushing sugarcane and extracting all liquids.

Recycled Cardboard

Recycled cardboard is collected and blended with water to create a reusable fibrous pulp.

Recycled Paper

Recycled paper is collected and blended with water to create a reusable fibrous pulp.

Drypress/Wetpress Comparison

	Dry Press Molded Pulp	Wet Press Molded Plup
Cost	$	$$
Thickness	1.5mm to 6.0mm	0.7mm to 1.2mm
Dimension Range	Within L “120cm” W “80cm” H “15cm”	Within L “70cm” W “60cm” H “12cm”
Surface Finish	Smooth top side, rough bottom side	Very smooth top side, mesh like bottom side
Commonly Used For	Food & drink trays, electronic products, heavy products	Lightweight products, luxury products

Thickness

Insert Material Comparison

	Molded Pulp	Corrugated	Foam
Material Composition	Made from 100% recycled paper	Mixture of virgin and recycled paper	Resin base
Sustainability	Recyclable, biodegradable, compostable	Recyclable	Non-biodegradable or recyclable
Protection	Excellent vibration & cushioning resistance	Moderate vibration & cushioning resistance	Excellent vibration & cushioning resistance
Storage Capability	Stackable	Stackable flat	Not stackable
Climate Tolerance	Temperature & humidity resistant	Humidity affects performance	Temperature & humidity resistant
Static	Static neutral	Static neutral	Only with anti-static foam
Color Availability	White / brown / black	White / brown	White / black

Second Process Options

Screen Printing

Available in a range of colors by addign slurry additives to create a fully dyed custom box insert.

Foil Stamping

Uses heat and pressure to apply metallic detailing to brand logos or artwork designs.

Laser Engraving

Uses heat to carve out logos, brand names or design elements and provides a stark color difference.

Coating

Coatings can be applied to the surface of molded pulp to create smooth and shiny/matte surfaces.