Most of us have come across molded fiber packaging as items such as egg trays or cup holders from fast food restaurants and other protective packaging in consumer goods. Today, molded pulp-based packaging is increasingly used in higher-value applications, such as packaging for food and beverage, electronics, and cosmetics.

The interest in molded fiber packaging is growing because it offers a combination of benefits. The key driver is sustainability: molded fiber is renewable, recyclable, and a more environmentally friendly alternative to plastic and other non-biodegradable materials. As such, it helps meet the demand coming from both the consumers and regulation.

“In addition, molded fiber provides brand owners an opportunity for highly customized packaging in terms of design, shapes, and sizes. It is a versatile packaging material that can fit many specific end-uses. Currently, the trend to replace plastic is particularly boosting high-end molded fiber packaging made of virgin fiber, intended for demanding end-uses and luxury packages,” says Alexander Beam, Senior Global Business Development Manager for Molded Fiber at Kemira.

Chemistry enables functional and safe molded packaging

When replacing traditional single-use plastic solutions in packaging with new, more sustainable alternatives, the challenge is always to do it without compromising on functionality, safety or cost-efficiency. This is where chemistry comes into the picture, enabling the use of cellulose-based raw materials in different end-use applications.

“Chemistry is the invisible enabler for any type of fiber-based packaging. In molded fiber, chemistry is one of the three main variables in the production process along with fiber choice and machine parameters. Chemistry expertise is key in creating the desired properties for the intended packaging end-use and in ensuring efficient production processes, both in terms of cost and raw material efficiency,” explains Alexander.

Kemira has long experience of cellulose-based processes and products from the traditional pulp and paper industry, from pulping to surface treatment, and has also been involved in the molded fiber industry for years. “With our end-to-end know-how, we can now also support the emerging and developing molded fiber applications and help the value chain develop novel high-quality packaging.”

The broad chemical portfolio of functional and performance additives for molded fiber includes solutions e.g., for creating the required durability, strength, and hydrophobicity for molded fiber packaging and for ensuring hygienic end-products. This is key in creating packages that protect both the goods inside and that are safe for consumers to use. High-performance polymer chemistries have a crucial role in the molding process, contributing to e.g., dewatering and formation performance and efficiency. Special process chemistry helps with production line housekeeping, preventing issues with process runnability and operational efficiency.

“With our chemistry expertise and application know-how, we can find the right solution to solve our customers’ challenges and help optimize their products and production,” says Alexander.

“Kemira also has vast knowledge on regulatory compliance and chemical safety topics in-house, which is crucial especially when dealing with food contact materials.”

Renewable and recyclable barrier technologies

Cellulose-fiber based packaging material is renewable by nature, but they lack the properties that are critical to e.g., food packaging: resistance to grease, oil, moisture, and water. In molded fiber packaging, these barrier properties have traditionally been achieved by using fluorochemicals (per- and polyfluoroalkyl substances, PFAS). With the growing concerns about the environmental and health impacts of PFAS, the value chain is looking for novel, safer, and more sustainable barrier technologies.

Kemira has been working with water-based dispersion barrier coatings for paper and board packaging for years, to provide the fiber-based packaging value chain with solutions that help increase the recyclability and safety of food packages. Now the development focus is on renewable alternatives to fossil-based chemistries and on new solutions that are suited to particularly fit the needs of molded fiber production.

“We’re ready to launch our proprietary advanced oil and grease resistant barrier chemistry, designed specifically for molded fiber applications and food service use. At the same time, we continue our work to develop next generation products, such as 100% renewable barrier coatings and fully biobased polymers for applications such as strength enhancement,” says Alexander.