What is Dry Molded Fiber?

Dry Molded Fiber, or DMF, is a technology for manufacturing three-dimensional packaging from pulp fibers. The fibers are processed in a largely dry state, distributed within a mold, and compressed under pressure into rigid packaging structures. This process enables precise geometries, consistent wall thicknesses, and high-quality surface finishes.

How does the process differ from conventional wet molding?

In conventional wet molding, pulp fibers are processed with large amounts of water and then dried. In contrast, Dry Molded Fiber uses very little water during production. This significantly reduces drying requirements and forms the basis for an energy- and resource-efficient manufacturing process.

What types of packaging is the technology suitable for?

Dry Molded Fiber is particularly well suited for packaging applications that require dimensional stability, premium surface quality, and highly consistent dimensions. Typical applications include trays, bowls, cup lids, portion packs, and packaging for food, foodservice, and technical products. Whether a specific application is suitable depends on factors such as geometry, barrier requirements, production capacity, and target market.

Can it replace plastic packaging?

For suitable applications, Dry Molded Fiber can be an alternative to plastic packaging. However, product protection, structural integrity, barrier performance, production output, and cost must all meet the required specifications. As a result, each application should be evaluated individually to determine which fiber-based packaging technology offers the best technical and economic fit.

Is it the best solution for every fiber-based packaging application?

No. Dry Molded Fiber offers particular advantages for complex geometries, deep-drawn shapes, high precision, and premium surface finishes. For other applications, molded paper or paperboard solutions may be more appropriate. The selection of the right technology should therefore always be based on the specific product and production requirements. Optima supports customers in identifying the most suitable manufacturing process.

Precision, performance, and design

Industrial-Scale Dry Molded Fiber Packaging

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Dry Molded Fiber Technology

Built for high-performance packaging applications

Packaging today must do more than safe resources. Consumers expect a premium look and feel, brand owners need strong shelf differentiation, and manufacturers depend on economical, scalable production processes. This is exactly where Dry Molded Fiber excels.

The technology enables the industrial production of high-quality packaging made from dry cellulose fibers, combining the benefits of fiber-based materials with a level of precision and surface quality traditionally associated with plastic packaging. High design freedom, premium surface quality, and cost-efficient mass production create packaging solutions for demanding food, consumer goods, and foodservice applications.

Packaging solutions Machine portfolio

The Benefits at a Glance

Why Dry Molded Fiber?

Create complex packaging designs with ease Maximum shape agility for challenging geometries

Exceptional dimensional accuracy Tolerances up to ±0.1 mm

Enabled by inline recycling and integrated airlaid technology
Cost-efficient production at industrial scale

Performance comparable to plastic Outstanding stability and functionality for demanding packaging solutions

The Technology Behind Dry Molded Fiber

Material from the reel

Mill-to-Web

Tissue & Additives

Chip Cutting

Inline Recycling

Forming

Integrated Barrier Solutions

Material from the reel

Natural or bleached fiber materials are automatically fed from reels and prepared for further processing. The ability to process different material variants provides maximum flexibility for a wide range of packaging applications.

Mill-to-Web

Dry cellulose fibers are processed into a uniform airlaid web. The integrated mill-to-web process delivers consistent material quality, tight tolerances, and efficient production.

Tissue & Additives

Optional tissue layers and functional additives can be incorporated to optimize surface quality, printability, abrasion resistance, and other material properties for specific application requirements.

Chip Cutting

The material is converted into precisely cut chips that enable maximum design freedom and consistent product quality. Even complex packaging designs can be produced with exceptional accuracy.

Inline Recycling

Material trim generated during the cutting process is returned directly to production. This improves material efficiency and supports cost-effective, high-volume manufacturing.

Forming

Heat and pressure transform the fibers into their final shape. The result is highly accurate packaging with premium surface quality, excellent dimensional precision, and the ability to realize complex geometries.

Integrated Barrier Solutions

When required, functional barrier solutions are applied inline during production. This enables packaging designs tailored to demanding requirements for product protection, shelf life, and functionality.

Dry Molded Fiber Applications

Packaging solutions for high-performance applications

Dry Molded Fiber technology enables premium packaging solutions for a wide range of applications. The combination of precise forming, excellent surface quality, and industrial scalability opens new opportunities for brand owners and manufacturers.

Food & Beverage

Ready-Meals and fresh-food packaging
Dairy cups and trays
Bottles

Foodservice & On-the-Go

Foodservice solutions
Sip Lids
Takeaway packaging

Portion Packs

Coffee capsules
Sauce, dressing and jam portions
HoReCa applications

Cosmetics

Refill jars

Give us 90 seconds to convince you

Your one-stop-shop partner for market-ready fiber-based packaging

From the initial idea to stable series production: We support you in successfully bringing fiber-based packaging to the market. As a partner, we don’t think in terms of individual technologies, but in solutions that fit your products, your goals, and your production reality.

Together, we develop functional and scalable packaging concepts that stand out, while always keeping the bigger picture in mind: market requirements, production reliability, investment security, and your brand’s impact at the point of sale. Our goal is to reduce complexity and give you planning certainty for today and the flexibility to shape tomorrow.

Schedule a personal consultation

Rethinking product protection
High-barrier packaging without aluminum

Barrier technologies

OPTIMA FiberOne Family

Machine solutions for industrial fiber forming

The OPTIMA FiberOne family is designed to scale fiber-based packaging production from concept to high-volume manufacturing. Supporting both Dry Molded Fiber and Paper Thermoforming, the platform offers solutions tailored to different production volumes, packaging designs, and performance requirements.

With industry-leading precision, advanced shape capabilities, and broad material compatibility, the OPTIMA FiberOne enables manufacturers to produce high-quality packaging efficiently and reliably. From frequent product changeovers to large-scale production runs, the platform provides the flexibility needed to support future-ready packaging strategies.

OPTIMA FiberOne Alpha

Flexible entry into fiber-based packaging production

The OPTIMA FiberOne Alpha provides a flexible entry point into industrial fiber forming. Designed for paper-based packaging, it is particularly well suited for applications with smaller production volumes, frequent format changes, and a high degree of product diversity.
Its modular design supports a wide range of packaging concepts and can be enhanced with optional lamination technology to integrate additional material and barrier functionalities as product requirements evolve.

Product depths up to 60 mm
15 cycles per minute
Up to 300 pods per minute (depending on format and application)

OPTIMA FiberOne Core

Flexibility for complex packaging geometries

The OPTIMA FiberOne Core combines Dry Molded Fiber and Paper Forming capabilities in a highly flexible production platform. Featuring advanced chip technology and 3D airlaid capabilities, it enables the precise manufacturing of sophisticated shapes and complex packaging designs.

Designed for applications with high product variety, frequent changeovers, and demanding geometries, the OPTIMA FiberOne Core delivers the flexibility needed to bring innovative packaging concepts to market while maintaining consistent product quality.

Product depths up to 60 mm
15 cycles per minute
Up to 850 pods per minute (depending on format and application)

OPTIMA FiberOne Pro

High performance for industrial-scale production

The OPTIMA FiberOne Pro is the high-performance solution within the OPTIMA FiberOne family, designed for efficient, large-scale manufacturing. Combining maximum shape agility with industry-leading productivity, it enables the precise production of complex packaging geometries at industrial scale.

Optional inline lamination technologies further expand the platform's capabilities, allowing additional material and barrier functionalities to be integrated for demanding packaging applications. The result is a highly flexible production solution that supports both high output and advanced packaging designs.

Product depths up to 120 mm
Up to 20 cycles per minute
Up to 1,500 pods per minute (depending on format and application)

Why choose the OPTIMA FiberOne Family?

Built for high-volume production

Designed for complex packaging geometries

Compatible with a wide range of fiber materials

Scalable from pilot projects to mass production

Precision manufacturing with ±0.1 mm accuracy

Integrated Barrier Solutions for Added Functionality

What idea would you like to realize?

Request a feasibility assessment

Podcast
Home of fiber – the future of fiber-based packaging

Fiber-based packaging is currently transforming an entire industry.
But what’s behind it? Which technologies are ready for mass production, and where do the real challenges lie?

In the podcast Home of fiber – the future of fiber-based packaging, we dive deep into the world of fiber-based packaging. Our experts discuss technological breakthroughs, lessons learned from development and industrialization – and why the way we view packaging is fundamentally changing right now. Because suddenly, this statement rings true: Fiber is no more expensive than plastic.

A development that is changing a lot – and one that we explore from different perspectives in the podcast.

It’s worth a listen – for anyone who wants to know what Fiber is really capable of. And what’s coming next.

Listen now

Mockup Laptop und Smartphone showing podcast Home of fiber

Do you have any questions about fiber-based packaging or would you like to discuss your specific requirements with us?

Dominik Bröllochs

Director Fiber Solutions

+49 791 506-0 Write e-mail

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Dominik Bröllochs

Director Fiber Solutions

+49 791 506-0 Write e-mail

Insights and Articles on Fiber-Based Packaging

Frequently asked questions

What is Dry Molded Fiber?
Dry Molded Fiber, or DMF, is a technology for manufacturing three-dimensional packaging from pulp fibers. The fibers are processed in a largely dry state, distributed within a mold, and compressed under pressure into rigid packaging structures. This process enables precise geometries, consistent wall thicknesses, and high-quality surface finishes.
How does the process differ from conventional wet molding?
In conventional wet molding, pulp fibers are processed with large amounts of water and then dried. In contrast, Dry Molded Fiber uses very little water during production. This significantly reduces drying requirements and forms the basis for an energy- and resource-efficient manufacturing process.
What types of packaging is the technology suitable for?
Dry Molded Fiber is particularly well suited for packaging applications that require dimensional stability, premium surface quality, and highly consistent dimensions. Typical applications include trays, bowls, cup lids, portion packs, and packaging for food, foodservice, and technical products. Whether a specific application is suitable depends on factors such as geometry, barrier requirements, production capacity, and target market.
Can it replace plastic packaging?
For suitable applications, Dry Molded Fiber can be an alternative to plastic packaging. However, product protection, structural integrity, barrier performance, production output, and cost must all meet the required specifications. As a result, each application should be evaluated individually to determine which fiber-based packaging technology offers the best technical and economic fit.
Is it the best solution for every fiber-based packaging application?
No. Dry Molded Fiber offers particular advantages for complex geometries, deep-drawn shapes, high precision, and premium surface finishes. For other applications, molded paper or paperboard solutions may be more appropriate. The selection of the right technology should therefore always be based on the specific product and production requirements. Optima supports customers in identifying the most suitable manufacturing process.

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