Manufacturing Pulp Packaging

Molded pulp packaging is made with a series of steps. The general manufacturing process is the same for all pulp packaging, with the biggest difference is the amount of automation and complexity of the machinery & tooling.

Manufacturing Steps

Step 1 – Mixing

The first step is to soak the raw materials in water and mix them until the right consistency of pulp is achieved. No waste water is generated in the manufacturing process; all excess water either evaporates during the manufacturing or is returned to the system.

Step 2 – Forming

Next, the pulp material is formed to shape by custom designed tools. The tools are lowered into the pulp mixture and the water is pulled through the mesh with a vacuum. The upper tools press into the lower tools to help shape the pieces. Suction from the vacuum helps bind the fibers. After forming, the parts are wet and need to be dried.

 Tooling

Step 3 – Drying

GreenKraft clamshells and T8 light trays are dried on open air drying racks. Thin-walled (thermoformed) molded pulp products are dried with automatic, high temperature and pressure drying machines.

Step 4 – Cutting and Pressing

Finally, the pulp packaging is pressed to smooth the surface and the edges are trimmed. No material is wasted; all the scraps (cut-offs) are returned to the pulp mixture and re-used. For specialty and high quality products, the packaging undergoes a variety of after-pressing, debossing or other treatments.