What is moulded fibre? A look into the fascinating world of sustainable packaging solutions.
Moulded fibre, also known as fibre casting, is an environmentally friendly and therefore sustainable packaging material that is also durable, flexible and stable. We produce moulded fibre from up to 100% used cardboard and paper (waste paper), making it the perfect alternative to petroleum-based materials or folding blanks that require time-consuming manual assembly. After use, a fibre-cast part is returned to the raw material cycle, closes the value chain and can be preferably recycled. There are also applications in which the compostability of the fibre cast part is used.
3D-moulded waste paper has been widely known as egg carton since the 1930s. In 1931, the excellent shock-absorbing properties of the moulded fibre inspired the idea of storing and transporting fresh eggs in special packaging. In the 1990s, the use of moulded fibre for industrial and design packaging began. It was during this period that buhl-paperform GmbH was founded and played a key role in the innovative developments.
The very low environmental impact, the excellent cushioning properties, the individual design and the 100% recyclability made moulded fibre (then as now) the ideal packaging material with an almost unlimited number of industrial applications.
Current industry requirements have repeatedly motivated us as a fibre casting manufacturer to continuously develop and optimise production with the natural material fibre casting. Moulded fibre parts are now optionally flame-retardant, grease-repellent, moisture-resistant and absorbent, making them suitable for use in a wide range of industries. Applications range from packaging for the bicycle industry to transport trays for the automotive industry.
As a pioneer among fibre casting producers and a pioneer in the field of sustainable technical upholstery, we are ideally equipped for the future. Our modern technical equipment, first-class production machines and many years of expertise have formed the foundation of our successful and innovative production of fibre-cast upholstery for several decades. Our range of expertise extends from comprehensive design experience in various material areas (plastics processing, metal processing, glass processing), to an understanding of individual customer products, to the optimisation of logistics chains and knowledge of cross-industry series production on the customer side.
Since our foundation in 1996, we have gained extensive experience and have continued to develop. We are proud to be pioneers in the field of fibre casting, continuously driving innovation and sharing our expertise and experience with our customers. The recognition of our innovative achievements is reflected in numerous international property rights and awards.
Der Herstellungsprozess:
Unsere Fasergussverpackungen sind das Ergebnis eines sorgfältigen und aufwändigen Herstellungsprozesses, der aus 6 Schritten besteht.
1. Raw material
First of all, the raw materials (paper and cardboard waste) are collected. Our recovered paper is recyclable and FSC®-certified (FSC-C162663).
2. Paper processing
The raw materials are diluted by adding water and carefully dissolved in a pulper, resulting in a homogeneous, liquid mass.
3. Paper cleaning
Removal of impurities (wood shavings, staples, etc.) to ensure the quality of the end product and avoid irregularities.
4. Molding process
The tool sucks pulp through the sieves to build up the molded packaging products. They are then dried and processed further if necessary.
5. Quality inspection
The last step in production is an inspection of the finished molded fiber products’ quality to ensure that they will safely and reliably protect your products.
6. Storage
The finished molded fiber products are placed on pallets and stored in our warehouse, which has a total of approx. 5,400 rack spaces.
Sustainable cast fibre packaging and its most important properties:
Sustainability and recyclability of fibre casting
At buhl-paperform, we live, develop and produce sustainability every day - and have been doing so since 1996! We focus on closed recycling loops and comprehensive environmental responsibility. Our cast fibre packaging solutions offer a sustainable alternative to petroleum-based materials and handling-intensive folded blanks. At the same time, we attach great importance to the responsible use of resources in the production process, in the form of heat recovery, a closed water cycle and certified CO2-neutral energy procurement.
Why fibre casting is the best choice for our environment? Find out more here.
Product protection
Our moulded fibre solutions offer outstanding product protection thanks to their three-dimensional adaptation to the product contour. Whether you are dealing with large and sturdy products or small and delicate / fragile goods, our moulded fibre packaging offers a customised protective cover that is perfectly tailored to individual product requirements. When developing our packaging, we take into account all your product requirements in terms of transport, storage and handling requirements, which ultimately result in your individual, customised packaging solution.
Shock absorption
Our specially moulded fibre castings offer a unique combination of flexibility and stability that allows controlled shocks to be absorbed effectively during transport. The design of our moulded fibre packaging works with defined crumple zones without losing the stability required to protect your product. This means that our packaging absorbs direct loads during transport to absorb the impact energy and optimally protect your products.
Resistance / heat and cold protection
During transport, products can be exposed to various temperature influences that can cause potential damage. Fibre castings are naturally insensitive to temperature fluctuations. Unlike plastic, which can become brittle in the cold, fibre casting offers reliable protection even at low temperatures.
We attach great importance to finding the optimum solution for your product. Therefore, it is crucial to understand the flow of your entire packaging process. Our experts will work closely with you to develop customised solutions that meet your exact requirements.
Arrange consultation appointment.
Integration into automated and robot-controlled packaging processes
Moulded fibre packaging basically offers all the properties required for smooth integration into automated and robot-controlled packaging processes. Thanks to their high stability and robustness as well as their easy handling and stackability, they fulfil the requirements for efficient processes. Our packaging formats are developed in such a way that they can be used flexibly in handling and logistics processes across all industries and can be easily integrated into inventory automation systems.
We have already successfully realised numerous projects in close cooperation with our customers and automation specialists. This extensive experience qualifies us as experts who you are welcome to contact for a workshop or brainstorming session on the subject of automation.
Stackable / nestability / volume reduction
Moulded fibre parts are nestable, which means that they can be stacked efficiently and therefore take up less storage space and transport volume. Compared to block foams such as EPS, moulded fibre allows optimal use of the available space, so you can save valuable space and therefore costs.
Future viability
Fibre casting is the future-proof packaging solution that meets the growing demand for environmentally friendly packaging thanks to its proven sustainability, resource efficiency and versatility. As an alternative to petroleum-based materials, cast fibre not only offers stability and protection for products, but also the certainty that the raw material waste paper is available in the long term and that used cast fibre parts can be fed into the international recycling cycle worldwide. Fibre casting therefore makes a significant contribution to reducing the ecological footprint of the packaging industry.
Special challenges: sensitive customer products and challenging logistics routes
Our moulded fibre parts are suitable for use in all logistics routes, be it air freight, sea freight and individual and parcel service shipments, and are perfectly tailored to the specific challenges. Due to their stable nature, they reliably protect your product from damage and ensure the safe and efficient transport of goods over long distances and under different environmental and climatic conditions. This not only ensures that logistics complaints are a thing of the past, but also helps to increase your customers' satisfaction.
As an example, we at buhl-paperform have developed a patented solution for the transport of (liquid) hazardous goods: +liqui. In close cooperation with a shipper of laboratory chemicals, we have developed an innovative moulded fibre part that offers a safe solution in combination with the industry-standard absorbent material Vermiculite. In the event of a spill, the pad absorbs the spilled liquid.
Fibre casting is extremely adaptable and can be precisely tailored to a wide range of specific requirements. The desired properties of the end product can be achieved by adding various additives. Fibre casting can therefore be optionally equipped with the following features:
- flame-retardant
- grease-repellent
- Moisture-resistant (ideal for problem-free use in the sea freight sector)
- special absorbency
