Published on: 21.10.2026
Updated on: 21.10.2026

Save up to 30 per cent on costs

Fibre moulding as an alternative to deep-drawn parts

Many companies are currently exploring ways to cut packaging costs, reduce their use of plastic and make their packaging processes more efficient. Fibre moulding offers a cost-effective and sustainable alternative to plastic thermoformed parts.

Have existing packaging checked

The essentials at a glance

Warum Unternehmen Tiefziehteile zunehmend hinterfragen

Viele Unternehmen suchen nach Möglichkeiten, Verpackungskosten zu senken und Kunststoffanteile zu reduzieren. Steigende Kosten, Nachhaltigkeitsziele und effizientere Verpackungsprozesse führen dazu, dass bestehende Tiefziehlösungen häufiger technisch und wirtschaftlich geprüft werden.

Was ist Faserguss?

Faserguss ist eine papierbasierte Verpackungslösung aus geformten Papierfasern. Aus dem Material entstehen passgenaue Formteile, Inlays, Schutzverpackungen und Transportverpackungen für industrielle Anwendungen.

Wann ist Faserguss günstiger als ein Tiefziehteil?

Bei passenden Wandstärken, Stückzahlen und Geometrien kann Faserguss wirtschaftliche Vorteile bieten. Besonders ab Wandstärken von etwa 0,4 mm und Jahresmengen ab rund 15.000 Stück kann sich der Wechsel von Tiefziehteilen zu Faserguss rechnen.

Funktionale Vorteile von Fasergussteilen

Faserguss kann Produkte schützen, fixieren und automatisierte Verpackungsprozesse unterstützen. Das Material ist stoßdämpfend, elektrostatisch neutral, temperaturbeständig und lässt sich individuell an die Produktgeometrie anpassen.

Nachhaltige Verpackung aus Altpapier

Faserguss basiert auf Altpapier beziehungsweise Recyclingpapier. Nach Gebrauch kann das Material in der Regel über den etablierten Altpapierkreislauf recycelt werden und unterstützt Unternehmen bei nachhaltigeren Verpackungslösungen.

Wann Tiefziehteile weiterhin die bessere Lösung sind

Faserguss ersetzt Kunststoff-Tiefziehteile nicht in jeder Anwendung. Bei hohen Transparenzanforderungen, sehr dünnen Wandstärken, speziellen Barriereeigenschaften oder filigranen Geometrien können Tiefziehteile weiterhin sinnvoll sein.

Technische Prüfung: Wo liegt das Einsparpotenzial?

Ob sich der Wechsel lohnt, zeigt sich erst bei der Analyse der konkreten Verpackungslösung. Geprüft werden unter anderem Produktgeometrie, Schutzanforderungen, Wandstärke, Jahresmenge, Handling, Automatisierbarkeit und Prozesskosten.

Why companies are increasingly questioning the use of deep-drawn parts

We are increasingly being approached by customers looking for an alternative to plastic thermoformed parts. The main reason is usually the search for potential cost savings. At the same time, demands are rising in terms of sustainable packaging, material availability and efficient packaging processes. Many existing thermoforming solutions work well from a technical point of view, but incur high material costs or no longer align with current sustainability targets. This is precisely where it is worth taking a closer look at fibre moulding.

As a paper-based packaging solution, fibre moulding can fulfil a similar function to a thermoformed part: securing, protecting, separating or stabilising products for transport. The difference lies primarily in the material, the manufacturing process and recyclability.

What is fibre casting?

Moulded fibre, also known as fibre moulding, is a packaging material made from paper fibres. Many people are familiar with the principle from egg cartons. In industrial applications, however, moulded fibre has been significantly further developed: the material is used to produce precisely fitted moulded parts, inlays, protective packaging and transport packaging.

The fibre-moulding process enables customised geometries that are precisely tailored to the product being packaged. This allows products to be securely positioned and protected during storage, dispatch or handling.

Typical areas of application include:

Inlays for securing products
Protective packaging for sensitive components
Transport protection for industrial goods
Fibre-moulded packaging as an alternative to plastic packaging
Customised packaging solutions for automated processes

When is fibre moulding cheaper than a deep-drawn part?

Particularly for wall thicknesses of 0.4 mm or more, fibre-reinforced moulded parts can often be produced more cost-effectively than comparable deep-drawn plastic parts. Depending on the application, geometry and quantity, savings of up to 30 per cent are possible.

Cost-effective use can become viable from an annual volume of around 15,000 units. The key factor here is not just the unit price of the parts. Process costs, material usage, packaging handling, storage and recyclability should also be taken into account in the assessment.

Individuelles Faserguss-Tray als nachhaltige Alternative zu Tiefziehteilen für technische Bauteile.

Comparison: deep-drawn part and fibre-reinforced moulding

Tiefziehteil vs. Faserguss
Criterion	Thermoformed plastic part	Fibre-moulded packaging
Material basis	Plastic	Paper fibres / waste paper
Product protection	Very good, depending on the design	Very good with suitable geometry
Transparency	Possible	Not transparent
Shock absorption	depends on the material	very well suited
Suitability for automation	possible	possible
Recycling	depends on the plastic and material flow	possible via the waste paper recycling loop
Cost-effectiveness	heavily dependent on material and mould	often attractive from medium to high production volumes
Sustainability impact	depends on the plastic	paper-based and recyclable

Cost savings of up to 30 per cent are possible

“In suitable applications, companies can save up to 30 per cent on packaging costs by switching from deep-drawn parts to fibre moulding – whilst maintaining a comparable level of protection and offering additional sustainability benefits.”

Functional advantages of fibre-reinforced moulded parts

Fibre-reinforced moulded parts offer numerous properties that are relevant to industrial packaging. The material is shock-absorbing, electrostatically neutral, temperature-resistant and can be customised to the geometry of the product. As a result, moulded fibre components can not only replace packaging materials but also optimise packaging processes. Products can be safely guided, secured and processed automatically. This can be a significant advantage, particularly in mass production.

Further advantages:

precise product fit
reliable transport protection
reduced material complexity
good stackability
suitable for automated packaging processes
Recyclable via the waste paper recycling system
Potential support with PPWR requirements

Sustainable packaging made from recycled paper

Faserguss is made from waste paper or recycled paper. After use, the material can usually be recycled via the established waste paper recycling system. Faserguss thus helps companies to reduce their use of plastic and make their packaging more sustainable.

It is important to note that sustainability does not stem from the material alone. The overall packaging solution is what matters. When Faserguss reduces material usage, simplifies processes and improves recyclability, it creates measurable added value for procurement, logistics and sustainability management.

When thermoformed parts remain the better solution

Fibre moulding is not automatically the best choice for every application. Deep-drawn parts remain a viable option when certain requirements take precedence.

This applies in particular to:

high transparency requirements
very thin wall thicknesses
special barrier properties
particularly delicate geometries
applications with very specific plastic requirements

That is why a sensible switch always begins with a technical assessment. Only then can it be determined whether fibre-reinforced moulded plastic can replace the existing packaging.

Technical audit: Where is the potential for savings?

In many cases, it is only through a detailed analysis that the true potential becomes apparent. In doing so, buhl-paperform considers not only the existing thermoformed part, but the entire packaging process.

Among other things, the following are examined:

Product geometry
Protection requirements
Wall thickness
Annual volume
Suitability for automation
Handling during the packaging process
Transport and storage conditions
Sustainability targets
Potential material savings

This provides a sound basis for decision-making. buhl-paperform sees itself not merely as a supplier, but as a development partner. It is not just a matter of manufacturing a moulded part, but of developing a solution that integrates seamlessly into the overall process.

Entwicklung und Gestaltung einer Fasergussverpackung anhand von Mustern

Fibre-reinforced moulded parts as a replacement for thermoformed components

“We are currently seeing many companies scrutinise their packaging costs much more closely than they did a few years ago. Time and again, it is becoming apparent that fibre-moulded parts can replace deep-drawn parts in certain applications – offering the same functionality, but often at significantly lower cost.”

Tailored solutions from buhl-paperform

Be inspired by our successfully completed projects.

Faserguss-Verpackung für sensible medizinische Dialyse-Komponenten.

Medicine / Medical Technology

Padding for dialysis products

Detailansicht eines leeren Faserguss-Trays für Adventskalender mit passgenauen Nestern

various sectors

Advent calendar insert

Detailansicht der Stapelung eines 6er-Fasergusstrays für Becher.

Food industry

Tray for cups

Discover all our packaging solutions