Also known as: Moulded Fibre, Pulp Packaging, Egg-Box Packaging
Moulded pulp is packaging formed by pressing recycled paper slurry into a shaped mould and drying it. It produces rigid, contoured trays that cushion moderately and are fully recyclable and compostable, making it a common plastic-free alternative to foam fitments.
Recovered paper is pulped into a slurry, drawn onto a shaped screen mould under vacuum, then pressed and dried. The result is a rigid contoured shell that locates a product much like a foam tray.
Its main appeal is environmental. It is made from recycled fibre, is recyclable in the ordinary paper stream and is compostable, which makes it attractive to brands managing EPR obligations or plastic-reduction commitments.
The trade-off is cushioning performance. Moulded pulp is more rigid and less resilient than EPE or EVA, so it protects well against handling and light impact but does not match foam for repeated shock absorption on heavy or fragile goods.
It also requires a mould per shape, so tooling cost and lead time are significant, and it is best suited to reasonably high volumes with a stable product design.
Moulded Pulp at a glance
| Material | Recycled paper fibre slurry |
|---|---|
| Process | Vacuum-formed on mould, pressed and dried |
| End of life | Recyclable and compostable |
| Cushioning | Moderate — below EPE/EVA for repeated impact |
| Tooling | Mould required per shape |
Common questions
Can moulded pulp replace foam fitments?
For light to medium goods with a stable design and reasonable volume, often yes — and it helps with plastic-reduction goals. For heavy, high-value or highly fragile items needing repeated-impact protection, foam still performs better.
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