PulPac recruits PA Consulting and Seismic Solutions to pioneer Dry Molded Fiber in North America

17 Mar 2021 --- PulPac, PA Consulting (PA) and Seismic Solutions are partnering to deliver cost-effective, fiber-based alternatives to single-use plastics to global markets, including North America.

PulPac – inventor of the novel Dry Molded Fiber technology – is working with PA to develop a wide range of technical and commercial applications and scale up the manufacturing process.

Meanwhile, Seismic Solutions business development consultancy is introducing PulPac to its extensive network of brand owners and manufacturers in North America.

“While the US continues to lag Europe in packaging sustainability and recycling practices, many forward-looking CPGs are progressing on meaningful initiatives with targeted goal metrics tied to the year 2025,” Kent Dahlgren, general manager at Seismic Solutions, tells PackagingInsights.

“Consumer awareness and legislation are driving the reduction of single-use plastic and polystyrene packaging. Innovative processes and materials, along with a willingness to embrace change, will accelerate the journey to a more sustainable future.”

PulPac’s Dry Molded Fiber is a patented manufacturing technology for the circular economy, using renewable pulp and cellulose resources to produce affordable, high-performance, fiber-based packaging and single-use products.

Wide-ranging demand
Dry Molded Fiber boasts an 80-90 percent lower CO2 footprint than plastic at the same or lower cost, PulPac indicates. The technology enables high-speed manufacturing and can replace most packaging and single-use products presently made of plastics, including coffee cup lids, meat trays, deli carry-out containers, cosmetic packaging and bottles.

PA is running a development center, helping brands develop specific Dry Molded Fiber applications.“PulPac’s focus at this stage is high volume ‘market ready’ applications that need no or limited application R&D to start manufacturing, typically trays, bowls, blister-packaging, soda lids, spoons or fast-food containers,” Linus Larsson, PulPac CEO, shares with PackagingInsights.

Extended shelf life applications like bottled beverages or food packaging are entirely feasible but require additional R&D such as barrier development before they are market-ready.

PA is running an application development center, helping brands and manufacturers with their specific Dry Molded Fiber requirements.

“We are seeing great interest in fiber alternatives to currently available packaging in protein trays and single-use foodservice items like cup lids, cutlery, bowls, plates and sauce pods,” adds Dahlgren.

“The technology is extremely flexible, and we have also had inquiries for applications related to protective packaging for consumer electronics and clothes hangers.”

Collaboration is king
UK-based PA is an end-to-end innovator with a history of accelerating new product and packaging concepts toward market. Its multidisciplinary teams are recognized as instrumental to PulPac’s rapid growth.

“We strongly believe the partnership model – with good and stable relations and collaboration – is the way to reach our goal of replacing at least one million tons of plastic by 2025,” says Larsson.

“We have invented a fantastic technology and it has the potential to make an impact at scale. However, if we are to save the planet from plastic’s wastage, we need to act fast.”

“Working together with PA and Seismic means we can move at a much greater speed, and together, fast track the replacement of single-use plastics.”

Dry Molded Fiber technology is licensed to packaging manufacturers and brands setting up their own production.PulPac is also working with deSter to manufacture fiber-based airline and foodservice packaging.

Currently, the partnership has co-operation and licensing agreements with several large global brands operating in various industries, such as food and drink, beauty, toys, and healthcare.

To support the demand and growth ambitions, the partners have technology centers in Sweden and the UK and aim to set up one in the US.

“We believe this partnership has the potential to completely transform the packaging industry,” echoes Philip Fawcus, PA Consulting’s Sustainable Packaging Lead.

“I am confident that through PA’s breadth of capabilities and ingenious approach to tackling development, we can scale the technology required for brands to launch sustainable products into the market in 2021 and beyond.

Readying for launch
PulPac expects the first Dry Molded Fiber packaging to be launched this year. A selection of global brands and manufacturing leaders are presently implementing and adopting its technology.

“Among the ones we can mention at this stage is gategroup company, deSter, who is focusing on fiber-based single-use food packaging products for the airline and foodservice industries,” details Larsson.

“[Also,] AR packaging, focusing on trays and cutlery for the food, on-the-go and foodservice sectors.”

“Additional, currently ongoing, licensee and brand partnerships will be disclosed soon.”

By Joshua Poole