FAQ's

FAQ's - Here you can get help quickly.

What is moulded fibre and how is it made?

Moulded fibre, also known as moulded fibre, is an extremely environmentally friendly packaging material that is durable, flexible and stable at the same time. Moulded fibre is made from up to 100% used cardboard and paper (waste paper) and is therefore the perfect alternative to petroleum-based materials or complex folded blanks.

During production, waste paper is dissolved in water and processed. The paper fibres are then formed using article-specific moulds and placed on a drying belt, where the product hardens, water evaporates and the finished fibre casting emerges at the end. Depending on the planned application, the moulded fibre parts are calibrated in a further work step using pressing tools in order to achieve a high degree of shape accuracy and smooth the surface structure.

How long does it take to produce a moulded fibre part?
 

The realisation time from the enquiry to the first series delivery varies depending on the task and includes the following project steps:

1. Customer requirement: Focus on precise needs analysis and joint exchange of experience to create the buhl-paperform checklist.
2. Budget calculation: Based on the information gathered, a detailed budget offer is prepared, including series part prices, mould, development and sampling budget.
3. 3D concept and presentation: Our specialists create a 3D concept based on the checklist. The digital presentation is discussed together in order to incorporate optimisation potential at an early stage.
4. Sample production (optional): If required, a sample quantity is produced to present the packaging concept and carry out handling trials and packaging tests.
5. Production of series mould: Once the 3D concept and optional samples have been approved, the series mould is produced.
6. Start of series production: After approval, series production begins.

You can find additional information here: Project workflow
 

Are these really just paper fibres or do they contain additives (e.g. adhesive, binder)?

At buhl-paperform, we place the highest value on transparency and environmental friendliness. Our products consist of up to 100% high-quality waste paper, which is carefully processed to ensure the highest quality. We deliberately refrain from using adhesives or binding agents to ensure optimum recyclability in the material cycle.

Our environmentally friendly packaging solutions are manufactured using a production process that does not involve the use of any chemicals or additional compounds. This means you can be sure that every product you receive from us is made from paper fibres. 

What optional functionalities can a moulded fibre part be equipped with?

Moulded fibre can be adapted to a wide range of specific requirements. Various additives can be added to achieve the desired properties of the end product.

For example, fibre castings can be given the following optional properties:

• flame-retardant
• grease-repellent
• moisture-resistant
• special absorbency

Thanks to our state-of-the-art technical equipment and our many years of development experience and expertise in various material areas, we are constantly driving innovation and actively shaping the future of packaging solutions.

Feel free to contact our experienced experts.

Arrange a consultation appointment

What advantages does fibre casting offer compared to other materials?

Fibre casting offers a number of advantages compared to other materials. We use up to 100% recycled paper as a raw material in the production of our fibre cast products. By using our fibre castings as a packaging solution, you become part of the circular economy, as the cushions can be returned to the waste paper cycle after use, from which new products can be made. In this way, you also make a valuable contribution to waste avoidance and resource conservation.

1. established disposal cycle for waste paper: Waste paper has an established disposal cycle worldwide and is one of the most widely collected materials. By using waste paper as a raw material, you are actively contributing to the promotion of a sustainable circular economy.

2. 100% recyclability: Our cast fibre products can be 100% recycled. This enables efficient use of resources and reduces the amount of waste that ends up in landfill.

3. biodegradable and compostable: Should our products accidentally end up in nature, you can be sure that the paper fibres are 100% biodegradable and compostable. Our products decompose within a very short time.

4. low CO2 footprint: Compared to disposable plastic products, our cast fibre products have a significantly lower CO2 footprint. By using waste paper and the recycling process, we significantly reduce greenhouse gas emissions and actively contribute to climate protection. Our production has a certified, CO2-neutral energy use, which ensures a minimised CO2 footprint.

5. cost savings and transport efficiency: fibre casting enables cost savings in logistics and warehousing, as the moulded fibre parts can be nested inside each other and therefore require less space in transport and storage. In addition, the handling effort in the packaging process is minimised compared to blanks that have to be erected, as the 3D geometries adapted to the product contours are already formed on delivery.

6. maximum transport protection: the packaging is adapted to your product with millimetre precision and fills the space securely, regardless of the product shape. Precisely fitting damping elements compensate for defined shocks and vibrations. This ensures maximum transport protection.

7. customisability and automation: We develop packaging formats that can be applied to the logistics processes in various industries. The high-quality feel and look of our products are retained.

Overall, as a sustainable material for packaging, fibre casting offers a wide range of ecological and economic benefits. 

Find out more here: moulded fibre

What areas of application are there for fibre castings?

The following groups are known to use fibre castings:

1. Recovered paper-based packaging (e.g. packaging pads)
2. Fresh fibre packaging (e.g. cosmetics)
3. Food packaging (e.g. egg packaging, fruit trays)
    

At buhl-paperform, we specialise in waste paper-based padding solutions, which we produce in three different manufacturing qualities.

Our in-depth expertise, which we have gained from customer-specific padding projects since 1996, enables us to develop customised fibre casting solutions for a wide range of industries. Thanks to the expertise of our developers, we can successfully realise projects and offer you a wide range of application possibilities. Our impressive track record speaks for itself and should inspire you to explore the full range of our realisation possibilities.

Cross-industry customisation: Regardless of your industry, we are able to create solutions that meet your specific requirements. Our fibre casting products (link to industry solutions) can be used in a wide variety of environments and applications.

Inspiration from successful projects: Take a look at our successfully completed projects (link to industry solutions) to be inspired by the numerous possibilities. From packaging solutions to industrial applications - our diverse references illustrate our ability to turn innovative concepts into reality.

No limits to realisation: Our commitment knows no bounds. Regardless of the complexity of your project, we are ready to turn your ideas into reality. We create solutions that meet your individual needs and exceed your expectations.

With our two fully equipped production sites, we are ideally equipped to handle large orders with high quantities without any problems. We currently produce up to three million fibre castings per month. We plan to double our production capacity by 2029.

Discover the endless possibilities of fibre casting and let our expertise and creativity convince you. Together, we can make every project a success - there is no challenge we cannot overcome.

Arrange a consultation appointment.

Why are buhl-paperform's fibre castings environmentally friendly and sustainable?

Our fibre castings are made from up to 100% recycled paper, which we obtain from regional sources (e.g. supermarket chains). This means that we do not use any agricultural land, unlike fibres made from hemp or grass. We also do not use any forest land for wood fibre production. Our manufacturing processes are not energy-intensive, unlike the cracking process for petroleum-based materials. The use of waste paper enables an efficient recycling process compared to fibre alternatives (e.g. hemp fibres or grass fibres), where this is not always guaranteed. This innovative approach promotes a sustainable circular economy and maximises the life cycle of the resources used.

Recyclability and waste reduction: By using waste paper as the main component of our fibre castings, we enable internationally efficient recyclability. This makes a fibre casting based on waste paper fundamentally different from petroleum-based packaging and cushioning solutions, such as polystyrene and other plastic materials. This helps to reduce the amount of waste that ends up in landfill. Our products therefore actively support efforts to minimise waste and promote environmentally friendly disposal.

Biodegradability and compostability: The paper fibres in our fibre castings are not only recyclable, but also biodegradable and compostable. This means that our products decompose within a very short time without leaving any residue. These environmentally friendly properties contribute to the sustainable use of resources.

Circular economy and resource efficiency: The use of waste paper as a raw material promotes a closed-loop circular economy. Once a moulded fibre part has been used - no matter where in the world - there is a regional recycling option. This avoids the international transport of recycled materials and thus reduces CO2 emissions. Our fibre castings therefore do not become waste after use, but serve as high-quality raw material, which simultaneously protects the environment and reduces greenhouse gas emissions.

Environmentally friendly decision for the future: Your decision to use fibre cast pads as a packaging solution distinguishes you as a responsible, environmentally conscious, sustainable and future-oriented company. The efficiency of recycling and the positive impact on the environment make fibre casting a responsible choice.

At buhl-paperform, we pride ourselves on offering innovative solutions that not only meet the needs of our customers, but also make a positive contribution to environmental protection.

What does buhl-paperform's CO2 footprint look like?

We consistently rely on certified CO2-neutral energy use and ISO 50001-certified energy management processes. These measures are part of our long-standing commitment to minimising CO2 emissions.

Thanks to our locations, we are centrally located in Europe and have very short delivery routes.

What is the average energy and water consumption per part? 

1. Energy consumption:
   Energy consumption varies depending on the weight of the parts and the manufacturing process used.
2. Water consumption:
   Through our internal recycling of process water and the use of rainwater, we ensure that water consumption is kept to a minimum in order to use resources efficiently.

What does a mould cost?

The cost of a mould varies depending on the manufacturing process chosen or required. The size of the part to be manufactured is also a decisive factor. Our development endeavours to design the size of the padded parts as efficiently as possible through intelligent product design.
 

Can moulded fibre packaging be produced in white?

We have made a conscious decision to use recycled paper as the most sustainable of all fibre materials. For this reason, we do not produce white moulded fibre packaging.

Can cast fibre packaging be printed?

Yes, this is possible. Many people are familiar with this process from conventional egg packaging.
 

What product weights can the material be loaded with?

We have packaging in the Portfolie that can carry weights of more than 1000kg.

What is the minimum quantity?

The minimum quantity is based solely on economic considerations.

How does the packaging / moulded fibre behave in damp conditions?

A fibre casting behaves 1:1 comparable to a corrugated cardboard box. However, it can be upgraded to complete water resistance by adding additives.
 

How does fibre casting behave with components that require ESD?

Due to the natural non-conductivity of paper fibres and the impossibility of generating static charge, fibre castings often do not require special ESD equipment.

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