Skip to content
Why is moulded pulp packaging a good alternative to plastic packaging for perfume packaging? How is it made and what are the pros and cons of this type of packaging? Let’s explore the options for brand owners who want to develop more eco friendly perfume and cosmetics packaging…..
What is moulded pulp packaging?
First of all, what is Moulded Pulp Packaging?
Different fibres such as paper, bagasse (sugarcane pulp), newspaper or cardboard are mixed with water to form a type of slurry. We pour this mixture into special moulds and then allow the packaging items to dry. Vacuum technology together with heavy pressure removes the excess water from the pulp. Because of the way in which the pulp is pressed and formed, the top surface of the packaging is smoother than the underneath part. Sometimes a hot press machine is used which presses the packaging into the required shape and also dries it out quickly. See the hot press machine in action in the following video.
What is Moulded Pulp Packaging made from?
Moulded pulp packaging can be made from different materials:
- Bagasse is a by product of sugarcane processing and traditionally people would bury or burn the residue. But nowadays it can be used for something useful in moulded pulp packaging.
- Paper is also used for moulded pulp packaging. Sometimes the paper is recycled, sometimes it is virgin paper, though for eco friendliness recycled paper is preferable.
- Bamboo is also a good option for moulded pulp, though less easily available. Bamboo has the advantage that it is fast growing and extremely durable because its fibres are strong. However, more refining is required to remove the fibres in bamboo moulded pulp products.
- Wheat straw pulp is another good alternative for moulded pulp products. It is a byproduct of wheat harvesting, as the pulp is sourced from the stalks of the wheat plants. Wheat is naturally very stiff, so it is well suited to products which need a lot of strength. Wheat straw products have a smoother surface, though they are less flexible due to shorter fibre length. Often this type of pulp is used for unbleached tableware and seedling holders.
- Wood pulp offers the greatest strength out of all pulps It has a lower envirnonmental impact than paper pulp.
What is better - Bagasse or Paper moulded pulp packaging?
The answer to this question depends on what is your objective. Do you want to have a smooth, clean finish to your packaging which looks more refined? Or do you want more sustainability credentials and a more rustic look? Bagasse pulp is better when a smoother, more luxurious look is required. Bagasse contains shorter fibres and can achieve clean edges and a smoother surface. Paper moulded pulp is better if we need to convey the idea of sustainability in a more rustic way. The look of the paper pulp packaging is more natural and organic, though virgin paper is more white. Thermoforming (hot press) moulds can increase the smoothness of the products, but it is difficult for paper to match the smoothness of bagasse.
What are the limitations of moulded pulp packaging?
Moulded pulp packaging is not as water resistant as a PVC thermoformed tray. Coatings and laminations can be applied to moulded pulp, but this would affect its sustainability credentials. It would no longer be compostable or recyclable. Although we can put a locking mechanism on clamshell type packaging, it cannot be fully air tight. If a heavy load is required, moulded pulp is not suitable, as it can break more easily. Moulded pulp packaging is also more suited to single use applications.
How do I make moulded pulp packaging? And how much does it cost?
In a similar way to pvc thermoforming, a metal mould is required to manufacture moulded pulp packaging. However, at the time of writing, the cost of the moulds is considerably higher than the cost of a thermoform pvc tray mould. This is a big reason why smaller brands cannot afford to consider eco friendly options such as moulded pulp for their packaging. In China the cost of a new thermoform mould starts at a few hundred dollars, whereas a moulded pulp mould costs three to four thousand dollars. In the UK the cost is considerably higher, up to twenty thousand pounds per moulded pulp mould.
The unit cost of moulded pulp packaging is currently a bit more expensive than pvc. However, as the market demand for this type of packaging increases and more factories set up business, the price may fall.
How can I decorate my moulded pulp packaging?
There are two main options for decoration of moulded pulp packaging : Hot foil stamping and screen printing. Some suppliers can only offer a limited number of colours on the external surface.
Another way to decorate is through the art of texture. We can make very fine patterns and emboss or deboss effects on moulded pulp packaging.
A further way to differentiate your packaging is to put ink in the pulp to colour it. However, this requires a large minimum order quantity, as you have to colour the whole huge tank of pulp, you cannot do it in small batches.
Which perfume companies are already using moulded pulp packaging?
Chanel is leading the way in adopting moulded pulp packaging. They have experimented with this type of packaging for both its sauvage and Chanel No. 5 perfume ranges. Dries van Noten has been using moulded paper inserts inside its hard paper boxes. Penhaligons and Aqua Allegoria have also been experimenting with moulded pulp packaging.
In the next few years sustainability goals for packaging will be much stricter in Europe. This will mean that more brands will look at options like moulded pulp packaging to bring down their carbon footprint. Smaller brands will probably need more of a push from legislation to push them along this route, as the initial set up cost of moulds is quite high for a small brand.
We predict that this type of sustainable packaging will become more popular in the future. If you need help to meet your sustainability goals, do not hesitate to get in touch with our team of experts.
