The Global Market for Molded Fiber Packaging 2024-2035

cover

Published: July 2024
Pages: 150
Tables: 36
Figures: 75
Series: Bio-Economy, Packaging, Plastics

As a green and sustainable packaging materials, molded fiber, also known as molded pulp, has increased in commercial use as a replacement for single-use plastics. Molded fiber packaging (MFP), traditionally used for packaging dunnage, egg boxes, and cartons, is finding increasing applications in primary and secondary packaging as a sustainable alternative to plastics. Continuous innovations in molded fiber are resulting in new types of packaging that companies say are more customizable and cost-competitive than plastic. Newer use cases and technologies, such as dry molded fiber, offer compostable alternatives to polystyrene foam that are being used in a range of industries.

Today, egg cartons and other food packaging remain common examples. Outside of the food industry, molded fiber is increasingly used as protective packaging for electronics and other household items. It can be made from a variety of materials — including wood, straw and bagasse — and custom tools can shape the pulp into the desired shape, size and thickness.

MFP is used for handling and packaging a wide range of products, including food containers, household items, industrial supplies, electronics, and single-use medical service items. It offers protection during shipment, customer convenience, and various economic and environmental benefits. Molded pulp products are a sustainable substitute for rigid single-use plastics, with applications spanning food containers and tableware, electronic product packaging, compostable containers for agricultural seedlings, medical and health products, building materials, and furniture. The development of innovative barrier solutions and the growing demand for fiber-based packaging have led to the adoption of MFP in other markets, such as FMCG.

The raw materials for MFPs are typically derived from biodegradable lignocellulosic fibers, which include recycled paper, newsprint, cardboard, and other natural planted fibers. MFP is recyclable, compostable, and eventually biodegradable, making it a viable alternative to oil-based packaging products like expanded polystyrene (EPS) or vacuum-formed polyethylene terephthalate (PET). The market for natural fiber packaging products has experienced consistent growth for over a decade, leading to a struggle among molded fiber producers to keep up with the increasing demand. As a result, production capacity expansions have become necessary to meet the growing market needs.

The Global Market for Molded Fiber Packaging 2025-2035 offers an in-depth analysis of the latest trends, innovations, and opportunities in this rapidly growing industry. The report provides a detailed market segmentation by application, including food service, retail food and drink, fast-moving consumer goods (FMCG), industrial packaging, single-use medical, and horticulture. Each segment is thoroughly examined, highlighting the unique challenges and opportunities within these sectors. The report also offers regional market insights and forecasts for North America, Europe, Asia-Pacific, and the Rest of the World, enabling stakeholders to identify high-growth markets and tailor their strategies accordingly.

One of the key focuses of the report is the technological advancements in materials, manufacturing processes, and barrier coatings. These innovations are enhancing the functionality and versatility of molded fiber packaging, making it a viable alternative to traditional plastic packaging across a wide range of applications. The report explores the latest breakthroughs in materials science, such as the use of agricultural waste and novel fibers, as well as cutting-edge manufacturing techniques like 3D printing and precision molding.

To provide a comprehensive understanding of the competitive landscape, the report includes detailed profiles of over 70 key players in the molded fiber packaging industry. These profiles range from established manufacturers with global reach to innovative startups. Companies profiled include Arctic Paper, EnviroPAK, HZ Green Pulp, Omni-Pac, PulPac, RyPax, Sabert Corporation, Tanbark Molded Fiber Products and TekniPlex.

The report also identifies the primary growth drivers, challenges, and opportunities within the molded fiber packaging market. It examines the impact of changing consumer preferences, regulatory pressures, and sustainability goals on the demand for eco-friendly packaging solutions. Additionally, the report explores the potential for molded fiber packaging to replace traditional materials in a wide range of industries, from food and beverage to electronics and automotive.

For packaging manufacturers, suppliers, investors, and end-users looking to capitalize on the expanding molded fiber packaging market while contributing to a more sustainable future, this report is an indispensable resource. With its comprehensive analysis, long-term outlook, and actionable insights, this report empowers stakeholders to make informed decisions, forge strategic partnerships, and stay ahead in this dynamic and rapidly growing industry.

As the world transitions towards a circular economy and seeks to reduce its environmental footprint, the molded fiber packaging market is poised for significant growth. This report is a vital tool for anyone looking to understand the complexities of this market, anticipate future trends, and seize the opportunities that lie ahead. By investing in molded fiber packaging, companies can not only meet the growing demand for sustainable packaging solutions but also contribute to a greener future for generations to come.

1 EXECUTIVE SUMMARY 14

1.1 Plastics packaging issues 14
1.2 Molded fiber market 15
- 1.2.1 Increased demand in recent years will continue 16
- 1.2.2 Meeting sustainability needs 16
- 1.2.3 New coatings technologies 18
- 1.2.4 In-house tooling 19
1.3 Advantages of molded fiber packaging 19
1.4 Packaging megatrends 20
1.5 Industry developments 2020-2024 21
1.6 Main market players 23
1.7 Global revenues for molded fiber/pulp packaging, 2018-2035 (millions USD) 23
1.8 Market segmentation for molded fiber/pulp packaging, 2018-2035 (millions USD) 26
1.9 Regional segmentation for molded fiber/pulp packaging, 2018-2035 (revenues, millions USD) 28
1.10 Market and technology challenges 30

2 TECHNOLOGY ANALYSIS 31

2.1 Cellulose fiber sources 31
- 2.1.1 Virgin fibers 31
  - 2.1.1.1 Bagasse 31
  - 2.1.1.2 Shredded bamboo 32
  - 2.1.1.3 Wheat straw 32
- 2.1.2 Recycled fibers 32
2.2 Manufacturing processes 33
- 2.2.1 Mechanical pulping and chemical pulping 34
- 2.2.2 Forming process 36
- 2.2.3 Drying process 36
- 2.2.4 3D printing 37
2.3 Types of molded pulp 39
- 2.3.1 Wet molding 39
  - 2.3.1.1 Thick-wall 40
  - 2.3.1.2 Transfer Molded 41
  - 2.3.1.3 Thermoformed Fiber 41
  - 2.3.1.4 Processed Pulp 43
- 2.3.2 Dry-molded/thermoformed fiber 44
2.4 Properties of molded products 45
- 2.4.1 Grades and prices 45
- 2.4.2 Additives 46

3 MARKETS AND APPLICATIONS 48

3.1 Food service 49
- 3.1.1 Products 49
- 3.1.2 Global Market 2018-2035 52
  - 3.1.2.1 Revenues 52
  - 3.1.2.2 Tonnes 54
3.2 Retail food and drink 55
- 3.2.1 Products 56
- 3.2.2 Global Market 2018-2035 59
  - 3.2.2.1 Revenues 59
  - 3.2.2.2 Tonnes 60
3.3 Fast-moving consumer goods (FMCG) including cosmetics 62
- 3.3.1 Products 63
- 3.3.2 Global Market 2018-2035 64
  - 3.3.2.1 Revenues 64
  - 3.3.2.2 Tonnes 65
3.4 Industrial or engineered packaging 67
- 3.4.1 Electronics packaging 69
- 3.4.2 Vehicle parts packaging 72
- 3.4.3 Global Market 2018-2035 72
  - 3.4.3.1 Revenues 72
  - 3.4.3.2 Tonnes 74
3.5 Single Use Medical 75
- 3.5.1 Products 75
- 3.5.2 Global Market 2018-2035 77
  - 3.5.2.1 Revenues 77
  - 3.5.2.2 Tonnes 78
3.6 Horticultural 80
- 3.6.1 Products 80
- 3.6.2 Global Market 2018-2035 81
  - 3.6.2.1 Revenues 81
  - 3.6.2.2 Tonnes 82

4 COMPANY PROFILES 84 (76 company profiles)

5 RESEARCH SCOPE AND METHODOLOGY 145

5.1 Report scope 145
5.2 Research methodology 145

6 REFERENCES 147

List of Tables

Table 1. Commonly used plastics in packaging. 15
Table 2. Advantages of Molded Fiber Packaging. 20
Table 3. Megatrends for molded fiber/pulp packaging. 20
Table 4. Molded fiber packaging Industry developments 2020-2024. 21
Table 5. Global revenues for molded fiber/pulp packaging, 2018-2035 (millions USD). 24
Table 6. Market segmentation for molded fiber/pulp packaging, 2018-2035 (millions USD). 26
Table 7. Regional segmentation for molded fiber/pulp packaging, 2018-2035 (revenues, millions USD). 28
Table 8. Market and technology challenges for molded fiber packaging. 30
Table 9. Comparison of Manufacturing Processes for Molded Fiber Products. 33
Table 10. Properties of forming-drying processes. 36
Table 11. Properties of types of molded pulp products. 39
Table 12. Types of procedure for moulding pulp materials. 43
Table 13. Grades and Prices for Molded Fiber Products. 45
Table 14. Additives Used in Molded Fiber Products. 46
Table 15. Markets and Applications for Molded Fiber Packaging Products. 48
Table 16. Examples of molded fiber products in food service. 50
Table 17. Global market revenues for molded fiber products in food service, 2018-2035 (millions USD). 52
Table 18. Global market volume for molded fiber products in food service, 2018-2035 (‘000 tonnes). 54
Table 19. Examples of molded fiber products in retail food and drink. 56
Table 20. Molded fiber packaging for wine bottles. 57
Table 21. Global market revenues for molded fiber products in retail food and drink, 2018-2035 (millions USD). 59
Table 22. Global market volume for molded fiber products in retail food and drink, 2018-2035 (‘000 tonnes). 61
Table 23. Example MF products in FMCG. 63
Table 24. Global market revenues for molded fiber products in Fast-moving consumer goods (FMCG) including cosmetics, 2018-2035 (millions USD). 64
Table 25. Global market volume for molded fiber products in Fast-moving consumer goods (FMCG) including cosmetics, 2018-2035 (‘000 tonnes). 65
Table 26. Applications of Molded Fiber Packaging in Industrial and Engineered Packaging. 67
Table 27. Comparison of Molded fiber and expanded polystyrene (EPS). 69
Table 28. Global market revenues for molded fiber products in industrial packaging, 2018-2035 (millions USD). 72
Table 29. Global market volume for molded fiber products in industrial packaging, 2018-2035 (‘000 tonnes). 74
Table 30. Applications of Molded Fiber Packaging in Single-Use Medical Applications. 76
Table 31. Global market revenues for molded fiber products in single use medical, 2018-2035 (millions USD). 77
Table 32. Global market volume for molded fiber products in single use medical, 2018-2035 (‘000 tonnes). 78
Table 33. Application of molded fiber/pulp packaging in horticulture. 80
Table 34. Applications of Molded Fiber Packaging in Horticulture. 81
Table 35. Global market revenues for molded fiber products in horticulture, 2018-2035 (millions USD). 81
Table 36. Global market volume for molded fiber products in horticulture, 2018-2035 (‘000 tonnes). 83

List of Figures

Figure 1. Example molded fiber packaging products. 16
Figure 2. Dry molded fiber Bailey’s bottle 17
Figure 3. Paper Water Bottle. 18
Figure 4. Global revenues for molded fiber/pulp packaging, 2018-2035 (billion USD) 25
Figure 5. Market segmentation for molded fiber packaging, 2018-2035 (millions USD). 27
Figure 6. Regional segmentation for molded fiber packaging, 2018-2035 (revenues, billions USD). 29
Figure 7. Bagasse molded fiber coffee capsules. 32
Figure 8. Manufacturing process for molded fiber products. 35
Figure 9. Process chain of the plain moulding process. 37
Figure 10. HP molded fiber 3D printing. 39
Figure 11. Thick-walled molded fiber packaging. 41
Figure 12. Transfer molded pacakging. 41
Figure 13. Manufacturing stages in the production of Thermoformed pulp products. 42
Figure 14. Thermoformed molded fiber packaging. 42
Figure 15. Processed molded fiber. 43
Figure 16. Dry-molded fiber (DMF) beverage containers. 44
Figure 17. Main application areas for molded fiber products. 48
Figure 18. Takeaway food clamshell packs. 50
Figure 19. Pactiv disposable bowl. 50
Figure 20. Molded fiber drink carrier. 51
Figure 21. Molded fiber food serving tray. 51
Figure 22. Molded fiber plates and platters. 51
Figure 23. Kraft Heinz Mac & Cheese microwavable fiber cup. 52
Figure 24. Chinet® molded fiber tableware. 52
Figure 25. Global market revenues for molded fiber products in food service, 2018-2035 (millions USD). 53
Figure 26. Global market volume for molded fiber products in food service, 2018-2035 (‘000 tonnes). 55
Figure 27. Transfer molded egg box. 56
Figure 28. Molded fiber punnets. 56
Figure 29. Molded fiber produce tray. 56
Figure 30. James Cropper COLOURFORM™ wine bottle wraparounds 57
Figure 31. Mycelium-based packaging for wine bottles. 57
Figure 32. Diageo paper Johnnie Walker bottle. 58
Figure 33. Molded fiber can rings. 58
Figure 34. Frugalpac paper wine bottles. 59
Figure 35. Global market revenues for molded fiber products in retail food and drink, 2018-2035 (millions USD). 60
Figure 36. Global market volume for molded fiber products in retail food and drink, 2018-2035 (‘000 tonnes). 61
Figure 37. Be Green Packaging molded fiber packs. 63
Figure 38. Mycelium-based packaging for cosmetics and toiletries. 63
Figure 39. L'Oréal molded fiber pump bottle. 63
Figure 40. Lush clamshell cosmetic packages. 64
Figure 41. Global market revenues for molded fiber products in Fast-moving consumer goods (FMCG) including cosmetics, 2018-2035 (millions USD). 65
Figure 42. Global market volume for molded fiber products in Fast-moving consumer goods (FMCG) including cosmetics, 2018-2035 (‘000 tonnes). 66
Figure 43. Molded fiber industrial parts packaging. 67
Figure 44. PaperFoam® packaging. 70
Figure 45. Molded fiber electronics packaging. 71
Figure 46. FiberCel automotive parts packaging. 72
Figure 47. Global market revenues for molded fiber products in industrial packaging , 2018-2035 (millions USD). 73
Figure 48. Global market volume for molded fiber products in industrial packaging, 2018-2035 (‘000 tonnes). 74
Figure 49. Typical applications of molded fiber/pulp packaging in single use medical. 75
Figure 50. Global market revenues for molded fiber products in single use medical , 2018-2035 (millions USD). 78
Figure 51. Global market volume for molded fiber products in single use medical, 2018-2035 (‘000 tonnes). 79
Figure 52. Global market revenues for molded fiber products in horticulture, 2018-2035 (millions USD). 82
Figure 53. Global market volume for molded fiber products in horticulture, 2018-2035 (‘000 tonnes). 83
Figure 54. Be Green Packaging molded fiber products. 86
Figure 55. Beyond Meat Molded Fiber Sausage Tray. 87
Figure 56. Fiber-based screw cap. 89
Figure 57. Molded fiber trays for contact lenses. 91
Figure 58. Cullen Eco-Friendly Packaging beerGUARD molded fiber trays. 95
Figure 59. Molded fiber plastic rings. 96
Figure 60. Mushroom leather. 99
Figure 61. Genera molded fiber meat trays. 104
Figure 62. Unilever Carte D’Or ice cream packaging. 108
Figure 63. Kiefel fiber transfer of pre-pressed products in the hot-press station for final pressing and drying (transfer process). 111
Figure 64. Matrix Pack molded-fiber beverage cup lid. 113
Figure 65. Molded fiber Labeling applied to products. 114
Figure 66. Coca-cola paper bottle prototype. 120
Figure 67. PulPac dry molded fiber packaging for cosmetics. 125
Figure 68. Molded fiber tray. 127
Figure 69. Molded pulp bottles. 131
Figure 70. Molded fiber laundry detergent bottle. 133
Figure 71. Tanbark’s clamshell product. 134
Figure 72. Varden coffee pod. 140
Figure 73. UFP Technologies, Inc. product examples. 141
Figure 74. npulp packaging. 143
Figure 75. Western Pulp Products corner protectors. 144

The Global Market for Molded Fiber Packaging 2025-2035

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1 EXECUTIVE SUMMARY 14

2 TECHNOLOGY ANALYSIS 31

3 MARKETS AND APPLICATIONS 48

4 COMPANY PROFILES 84 (76 company profiles)

5 RESEARCH SCOPE AND METHODOLOGY 145

6 REFERENCES 147

List of Figures

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