Molded pulp products for sustainable packaging: Production rate challenges and product opportunities

Molded cellulosic pulp products provide eco-friendly alternatives to various petroleum-based packaging systems. They have a long history of reliable usage for such applications as egg trays and the shipping of fruits. They have recently become increasingly used for the packaging of electronics, wine bottles, and specialty items. Molded pulp products are especially used in applications requiring cushioning ability, as well as when it is important to match the shapes of the packed items. Their main component, cellulosic fibers from virgin or recycled wood fibers, as well as various nonwood fibers, can reduce society’s dependence on plastics, including expanded polystyrene. However, the dewatering of molded pulp tends to be slow, and the subsequent evaporation of water is energy-intensive. The article reviews strategies to increase production rates and to lower energy consumption. In addition, by applying chemical treatments and processing approaches, there are opportunities to achieve desired end-use properties, such as grease resistance. New manufacturing strategies, including rapid prototyping and advances in tooling, provide opportunities for more efficient form factors and more effective packaging in the future.