Formed paper and moulded fibres – replacing plastic in packaging

Fibre-based products are becoming more formable and the development of these materials and production processes are advancing. When it comes to replacing plastics in packaging, formed paper or moulded fibre packaging products are becoming one of the most attractive renewable alternatives.

RISE is a full-scope development supplier for formed fibre packaging and products, with expertise along the entire value cycle.

The combination of RISE collective expertise in key areas such as fibre science, papermaking, converting, barriers and their analysis, enables development of new fibre formulations, improve the fibre forming process technologies, develop novel product solutions and adapted analysis methods. At RISE, it is possible to study these fibrous materials in industrially relevant and novel forming techniques.

Paper forming and fibre moulding technologies

The formed fibre area, explained by means of operation possibilities, is divided into:

3D-forming of paper - including production of stretchable papers
- Embossing, pressforming, hydroforming, deep drawing, pilot production equipment for stretchable papers
Wet moulding
- Stock preparation, large scale laboratory wet moulding with three press stations, fully automated and continuous wet moulding machine is planned to be launched at RISE in 2023
Dry moulding
- Fibre disintegration at laboratory scale, airlaid mat production at laboratory scale and laboratory equipment for high temperature-high pressure pressing

Focus and opportunities

Our focus is both on material development for enhanced product performance and barrier properties, as well as on process for efficiency and choice of strategy in a wider system of scope. RISE offers opportunities to develop and test new and traditional concepts by use of experimental equipment for moulding and evaluation of products, in terms of for example:

Fibre morphology and formulation effect on processing and product properties.
Impact of process parameters towards a more cost-effective product and enhanced product functionality.
Material, surface and process design towards barrier properties.
Understanding the impact of tool specifics on product and process performance.
Analyses and methods for controlling the process and product quality.

Some of the reference projects are within following areas:

New product development
Material strength improvement
Optimized surface smoothness
Chemical addition in pulp
Coatings and barriers
Printability studies
Forming and casting solutions
Raw material and stock preparation
Benchmarking
Prototyping
Performance verification and standardized measurements
Stretchable paper for forming
Plastic replacement

By combining different technical solutions and expertise along the entire value cycle, RISE can help transforming your packaging from plastic to fibre based or improve the performance or process efficiency in a current fibre based packaging solution.