Moulded fibre packaging — also known as moulded pulp — is experiencing a renaissance. What was once limited to egg cartons and basic transit protection has evolved into a sophisticated packaging technology capable of producing high-quality, aesthetically refined packaging for electronics, cosmetics, luxury goods, and fresh produce. The combination of plastic-free credentials, full recyclability through household waste paper collections, and compatibility with UK kerbside recycling infrastructure makes moulded fibre one of the most RAM-friendly packaging formats available.
How it’s made
Moulded fibre production begins with cellulose fibre — sourced from recycled paper and cardboard, virgin wood pulp (typically FSC certified), or agricultural residues such as wheat straw, bagasse (sugarcane fibre), and reed. The fibre is blended with water to create a slurry, which is then formed into shape using custom-made moulds. Two primary technologies are used:
- Wet moulding: The traditional process, where the slurry is deposited onto a mesh mould and then pressed and dried. Produces a slightly textured finish. Widely used for transit packaging, produce trays, and industrial applications.
- Dry moulding (thermoforming): A newer technology where pulp fibres are pressed under extremely high pressure without water, producing a dense, smooth substrate with a plastic-like finish. Offers superior barrier properties and aesthetic quality. Pioneered by Pulpac (Sweden) and licensed to UK manufacturer Fibre Revolution.
Both processes can incorporate barrier coatings — increasingly water-based and PFAS-free — to provide grease and moisture resistance for food-contact applications.
UK manufacturers leading the field
The UK has a strong base of moulded fibre manufacturers, several of which are listed in the FuturePack directory:
- James Cropper (Cumbria): Premium thermoformed moulded fibre under the Colourform brand. Specialises in luxury packaging for beauty, spirits, and premium consumer brands. On-site renewable energy from solar and hydro. Winner of over 25 packaging design awards.
- Cullen Packaging (Glasgow): Over a century of experience. Manufacturer of The Fibre Bottle and a wide range of moulded fibre and corrugated solutions. Recycles 8,000 tonnes of corrugated waste annually into moulded fibre feedstock.
- Omni-Pac Group (North Lincolnshire): Over 50 years of moulded fibre expertise. BRCGS certified. Specialises in custom solutions for food, electronics, and industrial sectors.
- Fibre Revolution: The UK’s first Pulpac licensee for dry moulded fibre technology. Produces trays, bowls, and cups with barrier capabilities for food packaging applications.
Why moulded fibre performs well under RAM
From a pEPR perspective, moulded fibre packaging scores well across all five RAM assessment stages. It is classified as paper/fibre (widely recycled), collected at kerbside by all UK local authorities, easily sorted by MRF equipment, reprocessed by established paper mills, and the resulting recycled fibre has strong end-market demand. Mono-material fibre packaging without plastic coatings or laminations is very likely to achieve a Green RAM rating, resulting in the lowest possible pEPR fees.