What is Pulp Molding Process of Molded Pulp Packaging?

O pulp molding process is a manufacturing technique used to produce molded pulp packaging—a sustainable and eco-friendly alternative to traditional packaging materials like plastic or Styrofoam. This process involves converting fibrous raw materials into packaging products, such as sugarcane bagasse, recycled paper, cardboard, or natural fibers. These products are biodegradable, compostable, and recyclable, making them a popular choice for environmentally-conscious industries.

As a well-known Chinese molded pulp packaging manufacturer, Bioleader has focused on the pulp molding process for more than 10 years. This article introduces a complete production process for making disposable pulp tableware based on sugarcane bagasse pulp material.

Aquisição e preparação de matérias-primas

The quality of molded pulp packaging produced depends on the quality of sugarcane bagasse procured. The bagasse collected is transported to the manufacturing facility and stored there in a controlled environment to avoid deterioration.

Cartão de pasta de cana-de-açúcar

Para melhorar o brilho ou a brancura da pasta e de certos ingredientes contidos na mesma, pode ser utilizado um branqueamento controlado sem Dioxinas Secundárias (SDET). Uma vez feito isto, a pasta é peneirada para eliminar quaisquer contaminantes que possam estar presentes, para obter um produto final de boa qualidade. Neste caso, após o processamento das fibras húmidas da cana-de-açúcar, o produto apresentou-se como uma placa feita de pasta de cana-de-açúcar para facilitar o armazenamento e o transporte.

Processo de produção de pasta

O bagaço de cana-de-açúcar é triturado e cuidadosamente lavado para remover a sujidade e todos os outros materiais não fibrosos. Neste processo, são utilizadas máquinas sofisticadas que se limitam a decompor o bagaço em pasta bruta, que é desgastada de forma suave.

Incorporação de aditivos

Muitos aditivos são criteriosamente selecionados e incorporados na pasta para melhorar as caraterísticas específicas da loiça de mesa, tais como a resistência à água, a força e a flexibilidade. A inclusão destes aditivos é determinada pela sua consistência com a pasta, bem como pela sua capacidade de se degradar após a utilização para manter o carácter ecológico do produto. Para já, implementámos revestimentos de barreira ao flúor para água e óleo.

Moldagem, prensagem a quente e modelação

To make tableware such as plates, bowls, and food containers of different shapes and sizes, the machine compressed the blended pulp mass into a special column that contained sets of plates, wherein each plate had a recess containing desired shapes.

The main pulp molding processof this step: The molding procedure uses compression and heat to shape the pulp material according to the formed mold, which helps to achieve the required finish that is smooth and fine. The tableware is then exposed to a controlled drying operation whereby excess moisture critical for the structure of the product is removed by heating and dehydration built into the machine’s bulk.

Drying

The wet molded product is transferred to a drying station, where it is heated to remove moisture. Drying methods include oven drying, infrared drying, or natural air drying, depending on production scale and efficiency needs. (This step is usually connected to the previous step).

Corte de arestas

There are currently two main types of machines prevailing on the market. one is a fully automatic machine that doesn’t have any trimming operations – towards the end of the pulp molding process the required product shape is achieved by direct trimming of the edges on the molding machine Sullivan…. The mold is fitted around the still plastic products and a scraper is used to clean the edges of the molded articles to which various fine trims of little specifications are obtained for the molded pulp packaging products.

Tratamento de superfície e acabamento

To improve the usability and aesthetic of the tableware, other than food-grade water and oil-resistant coatings on the articles, additional surface treatments are also carried out. The finishing pulp molding process will also include giving soft surfaces, edge rounding out, surface polishing, and placing permissible foods and hygienically acceptable decorations.

Inspeção, garantia de qualidade e controlo

Bioleader’s strict quality control measures are also taken at all stages of production to guarantee that the tableware will be of international standards regarding safety, eco-friendly, and resilience. Each molded pulp packaging product undergoes both manual and machine inspection whereby all flaws, accurate shapes and measurements as well as adherence to the design are ensured.

Deteção de metais

Sometimes the screen wires might break and mix up with the product due to the use of a metal pulping screen in the product molding process. Hence, all the items made by Bioleader are metal tested to eliminate any metal parts leaking from the machine that could blend with the completed output.

Ensaios de resistência à água e ao óleo

Most of our products are for disposable tableware use and thus need to be resistant to water and oil. Since these are plastic products, we sample some pieces of each batch to test whether they leak and soak the samples in water and oil for 6 to 12 hours.

Embalagem e marca

There is a need for molding and packaging tableware for them to withstand the rigors of transportation and storage. The use of molded pulp packaging materials is of mind for the eco-friendly concept and the design is simple and easily disposable because of the nature of the product.

Armazenamento de produtos acabados

Existe uma ordem na organização dos produtos embalados no nosso armazém devido aos sistemas de armazenamento de produtos existentes que é necessário respeitar na espera dos contentores de exportação.

Export, Distribution, and Market Access

Containers are loaded and cargo ships set sails on directives issued by the buyers for exports. The finished molded pulp packaging tableware is kept in quality preservation conditions to avoid alteration in quality and then sold in the different explored markets. The perspective of the marketing communication is aimed at persuading households to accept the use of tableware made of sugarcane bagasse through advocacy on its ecological benefits.

Benefits of the Pulp Molding Process

·  Amigo do ambiente: Reduces reliance on plastic, minimizes waste, and uses recyclable and biodegradable materials.

·  Versatilidade: Can produce a wide range of products for different industries, including food, electronics, and healthcare.

·  Rentável: Utilizes inexpensive raw materials and is energy-efficient.

·  Customizable: Molds can be designed for specific product requirements, offering flexibility in shapes and sizes.

This process is an essential part of creating sustainable packaging solutions, aligning with global efforts to reduce environmental impact.