the common 8 types of pulp molding products

Table of Contents

Pulp molding products include egg trays, fruit trays, food packaging, medical trays, industrial packaging, cup carriers, seed starters, and disposable medical products, offering sustainable and cost-effective solutions across various industries.

Egg Trays/Cartons

The type of product I would like to present is egg trays and cartons made from not plastic but molded pulp. It is a vital solution to the safe and secure transport and storage of eggs. Pulpo molded trays are developed with individual cups or sometimes pockets to accommodate each egg and cover it from impact. The design itself reduces the cause of travelling eggs getting collided with each other. The buildup amount of protection decreases the suffered breakages by approximately up to 70%. The capacity of the tray is usually 30 eggs, covering all the eggs from clashing by the surrounding eggs.

One of the additional advantages of pulp molded egg trays is their environmental friendly nature. The product is 100% of recycled paper, which makes them perfectly biodegradable by putting them into the compost. As a result of the decomposition, they can be recyclable again. The trays do not need additional investments to put them into the landfills and wait for hundreds of years until they will disappear. The plastic trays and cartons unfortunately do not disappear and still can be found at the ground and even sea waste.

With the comparison of the price of the plastic log, the pulp one is around 25% cheaper. Sometimes they range from 0, 05 to 1, 0 dollar per unit of carton, depending on the type and amount of cartons. Pulp-molded egg trays can be ordered to be personalized and to adjust at any size of an egg. From a small to extra large product differentiation, pulp molded egg trays can be used, as well as different size settings can be utilized in the process of destination of the egg.

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Fruit and Vegetable Trays

Fruit and vegetable trays made from molded pulp are used as essential means of safe transport and display. These trays are designed to cushion fruits and vegetables and reduce mechanical damage in terms of bruising and scratching, which is almost inevitable with regular transport. Thus, specific advantages are associated with the intelligent design and structure of the tray on the one hand and the proper materials on the other. Producing these trays is a competitive solution for maintaining the quality and prolonging the shelf life of fresh produce.

As for the structure, produce trays are normally divided into compartments that are usually molded to fit the specific shape of a fruit or a vegetable. The introduction of a regular shape eliminates the risk of movement within the packaging, which is another crucial factor in preventing damage. According to existing research, the use of adequately designed molded pulp trays can reduce the overall damage to transported fruits by more than 60% as opposed to their direct transportation in plastic crates. Molded pulp is a soft material, which ensures the necessary level of shock absorption.

Another factor that makes these trays a perfect solution for business is related to their overwhelming safety features. Molded pulp trays are made from recycled paper and can be composted reducing the necessity for additional expenses associated with the use of non-biodegradable materials. Purchasing a package or a tray from a paper manufacturer, one can easily reduce the carbon footprint and eliminate the use of styrofoam or regular plastic, which is a serious environmental issue. As for the cost of production, it is around $0.07-0.12 per piece, which is more or less affordable. Other advantages include the uniform size of the tray, stackability for retail settings, and convenience in use at home.

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Food Packaging

Pulp molding technology for food packaging has become so revolutionary due to its eco-friendliness, versatility, and affordability. As such, food packaging supply includes a wide range of containers – plates, bowls, and take-out boxes exclusively designed for food preservation applications. In addition, papier-mâché products serve as the perfect alternative for either plastic or foam containers, which are typically blamed due to their negative impact on the environment. Being primarily functional and versatile, pulp molded food packaging is specifically engineered for grease or wet products.

Typically designed to sustain hot soups or stews and cold ice creams or salads, those containers are capable of using grease- and moisture-resistant equipment. Therefore, stable in shape and design, they show no leaking through or falling apart feature. For example, trials reveal that the shape and the stable condition of pulp molded equipment were kept unchanged between 30 and 60 minutes of a full meal – which represents the life span of a regular fast-food snack. Compared to plastic, pulp molded food packaging is characterized by bio-degradability – while plastic may take up to 400 years to decompose, pulp products decay in compost facilities within 90 days.

In addition, papier-mâché products are very affordable to produce. Given the low cost of the source product – raw paper which is frequently recycled – as well as the abundance of the material, pulp molded plates or bowls cost no more than $0.08-$0.15 per unit. If talking about larger orders, the cost decreases even more. Thus, pulp molded food packaging has become an inferior alternative for food service companies who wish to reduce the costs without compromising on the environment. Finally, these products exhibit easy stackability, thus saving considerable storage and transportation room. Being also lightweight, transporting pulp molded food packaging is significantly cheaper.

Medical and Dental Product Trays

Pulp molding is used for making diverse types of packaging items, with one of the most common applications of this technology being for medical and dental product trays. The latter are necessary for the healthcare sector for organizing, sterilizing, and handling medical and dental instruments efficiently. Pulp molded trays allow for the management of tools as they are placed in a precise manner.

This helps ascertain that surgical and dental instruments are taken out of the sterilizer in a certain way and placed back in the tray in the same manner, which is favorable from the perspective of keeping the equipment safe and sterile. Another benefit of pulp molded medical trays is that they can be fitted to match the size of a particular instrument firmly. This feature can be critical in operating rooms or dental surgeries where doctors use a sizeable number of tools, and their placement plays a big role in the speed of the procedure.

For example, a dental tray can have sections for scalers, mirrors, probes, and forceps, each tailored to prevent them from touching one another. Overall, one can argue that equipment trays made of pulp molding are necessary for the healthcare sectors, as they allow instruments to be effectively organized and sterilized, which is not possible to achieve in most cases without the use of pulp molded trays.

Additionally, using them helps make this industry more sustainable, as currently, most dental and surgical equipment trays are made of plastic. These plastic trays cannot be composted and must be discarded, as a result of which they generate considerable waste, as “5.9 million tons of waste is generated in the health care industry a year, and a big part of that is single-use plastic”. Moreover, because recycled paper fibers are cheaper than equivalent amounts of plastic, pulp molded trays are less expensive to produce. The average cost of pulp molded medical trays varies from $0.5 to $1. Two other benefits of pulp molded equipment trays are related to the field of their transportation. Being lightweight, they are cheaper to deliver. The ability to stack results in efficient warehousing.

Industrial Packaging

One of the most common applications of pulp molding is industrial packaging. This packaging is used extensively for shipping and handling such goods as electronics, machinery components, and other fragile items. In this case, a molded tray or other packaging piece is designed to form a protective shell around the product. This shell is molded to fit the contours of the particular goods, reducing the likelihood of damage on the way.

For example, when sending electronics, the industrial packaging can consist of pulp trays that will snugly hold each component of the electronics. The components will not slide, reducing the possibility of them hitting the sides of the tray, which could result in damaging impact or abrasive forces. In this application, pulp molding has a notable advantage over the commonly used materials such as expanded polystyrene foam. This advantage is in the possibility of molding the pulp into very complex shapes to fit the specific contours of the product without the need for costly custom molds.

From an environmental standpoint, the benefit of using pulp molded packaging is the fact that it is not synthetic foam, which can last millennia in a landfill. Being made from recycled paper-based materials, molded pulp is completely biodegradable, which means it is economically efficient to recycle it after use and return it to the circular economy. The molding process is also relatively low-cost, especially when compared to other molding processes.

Because it is a simple technology and the raw material – recycled paper – is abundantly available at very low prices, the production of molded pulp packaging pieces is affordable in high volumes. In addition, the cost of developing a new package is typically quite low, averaging between $1.00 and $2.50 per piece, depending on the volume of the order and the complexity of the piece. This makes pulp molding viable for low, medium and high volume businesses who seek reasonably low cost solutions with high levels of protection for their products.

It is also very light, which makes the transportation of goods in pulp molded packaging relatively inexpensive. The ability to stack and nest the packaging pieces together also results in good space utilization, further enhancing the effect. The benefits of using pulp molded packaging do not only lie in their effect and cost, however. Their use demonstrates to customers that the business is taking steps to be less wasteful of limited resources, and more and more consumers in the current day and age actively consider their personal impacts when shopping.

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Cup Carriers and Beverage Trays

Trays for holding several cups securely have been a popular molded pulp item – for instance, in fast food restaurants, cafes, and outdoor events. Pulp molded cup carriers feature multiple cups compartments and extendable hangers to survive shocks that may cause disposable cups to fall out. Molded pulp trays are hard and insulating by definition, which keeps hands protected from hot drinks. The convenience of pulp molded cup carriers is evident in the fact that they allow to hold and transport several containers at once.

For example, a four-cup carrier can be used by a single person to bring four hot coffees – it is especially important during busy morning hours as well as when large orders are delivered to an office. Up to 80% of spills are avoided when using a molded pulp breakfast tray or similar arrangement for fast drinks handling as opposed to not using a tray. In addition to customer satisfaction, it allows to cut on waste and cleaning costs. An important factor that is currently growing in relevance is the environmental friendliness of the carriers. Molded pulp cup carriers are made from recycled fibers and are 100% biodegradable and compostable – unlike plastic or Styrofoam, they do not contribute to waste build-up at landfills.

The manufacturing cost of such carriers is low, and the price for a single item, depending on the design and the volume, varies from 10 to 20 cents. Pulp molded carriers are sturdy and can hold the weight of a full disposable cup without deforming. In addition, they are light and easy to stock by producers; they match the space surrounding the machines for automatic molding, and they can be easily stacked up by carriers holding large volumes of them.

Seed Starters and Garden Pots

Pulp molded seed starters and garden pots are an eco-friendly solution for those gardeners and agricultural professionals who aim at sustainability. Such products are made of recycled paper and designed to be naturally degraded in soil. They create an optimal environment for seed starting generating conditions for the proper roots development and easy transplantation. Besides that, most of the garden lovers prefer biodegradable pots for planting starters because they can be put into the ground and there is no need for plastic pots, which are garbage-related. The direct planting method facilitates the gardening process and helps reduce the transplant shock because starters grown in pulp pots adapt better to the soil instead of those grown in plastic pots. Therefore, plants experience 15-20% growth in survival rates due to less root and soil disturbance.

In addition to the mentioned benefits of the use of such pots, the product also provides excellent growing conditions due to proper air circulation and water draining. The porosity of material is a salient factor because the pots ideally filter and drain out excessive water, preventing root rot and other diseases of the plant base.

Cost-wise, such eco-friendly solution is also quite a competitive product. On average, a pulp molded seed start set can cost from $0.05 to $0.15 a pot. Size and amounts obviously vary. There are also many certain discounts available. Therefore, it should be emphasized that such garden starters can be used for numerous purposes. Nor only private gardeners but also big agricultural production can afford such environmentally friendly product. Such pots are easily stored and transported due to their lightness and stackable features. Undoubtedly, such salient features not only promote the use of pulp molded pots by many growers, but also, in general, make such product easy and cost-effective.

Overall, pulp molded seed starters and garden pots are an excellent choice for environmentally-friendly garden lovers. Due to their various benefits and low price, they are in high demand and are used by private gardeners, farmers, and agricultural companies. Their production does not require any special cost-efficient technological processes, thus, this makes them not an expensive product.

Disposable Urinals and Bed Pans

Pulp molded disposable urinals and bed pans are highly important materials used in medical practice. It is especially relevant for the healthcare needs of bedridden or immobile patients who need both an individual and hospital approach. This product is convenient and hygiene for both patients and hospital staff. Pulp molded materials are chosen due to their soft and friendly-to-skin surface as well as an ability to hold the necessary liquid and solid components. After the use, such items are usually tossed away and do not require the attention of cleaning staff in terms of washing or either sterilization.

One of the main benefits of pulp molded disposable products is their very low level of cross-contamination. Regular tools used in clinical practice are supposed to be thoroughly washed and then sterilized after each use. Whereas such tools can already be a workload for cleaning staff, it also poses a contamination risk because there are no guarantees that the right measures have been taken. With disposable options, there is zero risk of contamination and it is highly convenient for practicing hospitals.

The cost of pulp molded healthcare products is low and a single piece of disposable bed-pans or urinals usually ranges from 50 cents to regular 1 dollar. From the environmental standpoint, pulp molded urinals and bed pans have a biodegradable nature because they are not made of plastic. Hence their use doesn’t influence the hospital waste percentage and their later disposal does little to no harm to the environment as they decompose notably faster in comparison to regular plastic.

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