Shape with precision. Protect with confidence.

Paper Thermoforming for high-performance packaging solutions

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Paper Thermoforming

Precision packaging solutions made from paper

Paper Thermoforming enables the production of precision-engineered packaging solutions made from formable paper for a wide range of consumer goods applications. The technology is particularly well suited for multi-cavity packaging designs, opening new possibilities for packaging concepts that have traditionally relied on plastic materials.

By combining heat, pressure, and advanced tooling technologies, stable packaging with outstanding dimensional accuracy and sophisticated geometries can be produced. At the same time, a wide range of barrier concepts can be integrated, from recyclable and compostable solutions to high oxygen and moisture barriers for sensitive products. Through seamless integration into existing filling lines, Paper Thermoforming enables efficient form-fill-seal processes and provides the foundation for scalable, cost-effective packaging production.

Packaging solutions Machine portfolio
Why Paper Thermoforming?

Key Benefits of Paper Thermoforming

Multi-Cavity Paper Packaging

Realize complex multi-cavity packaging designs with precision and cost efficiency.

Plastic-Like Performance

High levels of stability and functionality at output rates of up to 20 cycles per minute.

Precision Down to the Smallest Detail

Dimensional accuracy with tolerances of up to ±0.1 mm.

Premium Surface Quality

Enhanced by a variety of customization and decoration options.

The technology of Paper Thermoforming

The technology of Paper Thermoforming

FiberOne Pro Machine
Material Feeding from Reels
Integrating Tissue and Functional Additives
Precision Chip Cutting
Precision Forming
Integrated Product Protection
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FiberOne Pro Machine
Infeed
Dry Molded Process

Formable paper is fed directly from reels and prepared for further processing. Different paper grades can be used depending on the application requirements.

Coating

Optional tissue layers and functional additives can be incorporated to tailor surface quality, decoration, and barrier performance to the specific application.

Precision Chip Cutting

The material is converted into precisely cut blanks that provide the foundation for outstanding shape flexibility and the reliable production of sophisticated packaging designs.

Precision Forming

Heat and pressure transform the material into its final shape using specially engineered tooling. The result is highly accurate packaging with excellent stability and outstanding detail definition.

Integrated Product Protection

Optional barrier solutions can be applied inline during production, providing additional protection against moisture, oxygen, and other environmental influences.

Paper Thermoforming Applications

Versatile Packaging Concepts Made from Formable Paper

Paper Thermoforming enables the efficient and precise production of a wide variety of packaging solutions made from formable paper. The technology is particularly suitable for multi-cavity packaging and advanced packaging concepts that have traditionally been produced from plastic. Its exceptional design flexibility allows customized packaging concepts to be tailored to a wide range of product requirements.

Depending on product protection requirements, various barrier concepts can be integrated, ranging from recyclable and compostable solutions to high-performance oxygen and moisture barriers. Inline integration into filling lines enables efficient form-fill-seal production processes. Additional finishing options such as embossing, debossing, labels, printed tissue, or direct-to-shape printing create packaging solutions that combine functionality, product protection, and strong shelf appeal.

Thermoforming Product
Tailored to Every Product

Material and Barrier Flexibility for a Wide Range of Applications

By integrating different barrier technologies, packaging solutions can be precisely tailored to the specific requirements of each product. From recyclable and compostable concepts to high oxygen and moisture barriers, the technology supports a broad range of product protection solutions. Paper Thermoforming combines functional performance with circularity, helping brands develop packaging solutions for global markets and diverse end-of-life requirements.

Barrier technologies

Benefits at a Glance

Versatile Material Options

Process formable papers, paperboard, and cellulose-based materials in bleached and unbleached grades.

Tailored Product Protection

Flexible barrier solutions, including high oxygen and moisture barriers.

Premium Surface Quality on Demand

Optional tissue layers enhance appearance, tactile properties, and abrasion resistance.

PPWR-Ready and EPR-Optimized

Material and barrier concepts designed for current and future regulatory requirements.

Paper Thermoforming Machinery Portfolio
The Right System for Your Production Requirements

FiberOne Pro MachineFiberOne Pro Machine
OPTIMA FiberOne Family

Machine solutions für 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.

Starke Vorteile

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
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

Flexible entry into fiber-based packaging production

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)
FiberOne Pro Machine
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.

Stream now!
Mockup Laptop und Smartphone showing podcast Home of fiber
Dominik Bröllochs
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

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Dominik Bröllochs
Dominik Bröllochs
Director Fiber Solutions
+49 791 506-0 Write e-mail

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Dominik Bröllochs
Dominik Bröllochs
Dominik Bröllochs
Director Fiber Solutions
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