Fiber-based packaging as a cost-neutral alternative to plastic

Four technologies are shaping the future of fiber packaging

The following technologies are primarily used in the production of fiber-based packaging:

• Dry Molded Fiber
  In this process, loose cellulose fibers are compressed into sturdy packaging. Dry Molded Fiber technology delivers the highest quality at the lowest material and production costs. The process is considered particularly versatile: it offers design freedom, high dimensional stability, and is suitable for a wide range of packaging solutions.
• Paper Board Forming
  With this technology, the pre-printed material can be shaped into its final packaging form immediately before filling. This approach is particularly suitable for cup- or can-shaped packaging and provides high flexibility in production. Since the packaging does not need to be transported in a preformed state, storage and logistics costs can be significantly reduced.
• Paper Forming 
  Paper forming allows for the production of multi-cavity solutions at high output rates; even complex geometries and multi-cavity solutions are thus possible. This makes this technology a valuable complement to dry molded fiber.
• Barrier technologies
  The integration of barrier technologies plays a central role. Depending on the application, fiber-based packaging must provide protection against moisture, oil, grease, water vapor, or oxygen. Various approaches rely on modified materials, pre-spray processes, high-performance laminations, or targeted fiber treatments. This allows functional barriers to be integrated in a targeted manner without compromising the packaging’s recyclability or compostability.

The synergy of product, material, and process as a competitive advantage

The synergy between product understanding, material selection, and process design is crucial for future sales success. Fiber-based packaging must be tailored to the product. Barrier requirements, dimensional stability, and process parameters are all interrelated. When packaging design, the production process, and the supply chain are considered holistically, solutions emerge that are economically viable and scalable in the long term.

From concept to production: Packaging development as a key success factor

The packaging industry is at a turning point. Fiber-based solutions have evolved from being merely a sustainability option to a serious alternative to plastic that fully meets industrial requirements. Integrated development approaches are crucial for successful implementation, as innovative fiber-based packaging does not arise by chance but through structured development processes. These include simulations, material testing, prototyping, and the validation of new forms. Scalability is particularly important here, ensuring that product samples can quickly transition to stable and efficient industrial production for a short time-to-market.

Conclusion: Fiber-based packaging requires integrated approaches

Under the guiding principle “Home of fiber”, Optima embraces precisely this integrated approach. By combining packaging development, machine technology, and barrier integration across various fiber-based processes, solutions with high technological flexibility are created. For the first time, products can be realized using paper forming and dry molded fiber on a shared plant platform.

With in-depth product knowledge, flexible barrier concepts, and end-to-end system solutions, Optima supports companies in implementing fiber-based packaging in a technically reliable, economically viable, and resource-efficient manner.