Wet and Dry Process Pulp Molding Technology from AGICO

As the environmental protection wave join modern industry development, pulp molding technology as a green tech, is gradually replacing traditional foam plastic packaging and becoming an innovative force in industrial packaging. Dry process pulp molding technology has become one of the most widely used technologies. AGICO also supplies wet process pulp molding production line with high flexibility, strong adaptability, and excellent environmental performance. Here AGICO will introduce the dry process method from the perspective of process introduction, production processes, and industry prospects.

Pulp Molding Dry Process Introduction

The pulp molding dry pressing process uses recycled resources such as waste newspapers, carton scraps, straw pulp, etc. as raw materials, and uses fiber reorganization technology to create paper products with specific shapes and functions. The core is to use the fluidity of pulp and the adsorption force of the mold to reweave the scattered fibers into a dense 3-dimensional structure. Compared with the “in-mold drying” of the wet pressing process, the dry pressing process adopts a unique process of “out-mold drying + hot pressing shaping”, which can not only achieve rapid molding of complex structures, but also retain the natural toughness of the fibers.

4 Steps of Dry Process Pulp Molding Process

1. Pulping: Pulp Fiber Regeneration

A hydraulic pulper decomposes waste paper into fiber slurry. By precisely controlling the slurry concentration (usually 1%-3%) and fiber length, a plastic substrate is formed. Waterproofing agents, oil-proofing agents, or pigments are added as needed to give the product a functional or colorful appearance. The circulating water system ensures efficient use of water resources, and the wastewater reuse rate can reach more than 90%.

2. Wet Blank Molding: Vacuum Adsorption Technology

The specially made aluminum alloy mold uses vacuum adsorption technology to evenly deposit the slurry on the surface of the die to form a wet blank. This process is particularly suitable for small batches and customized orders, and the molding accuracy can reach ±0.5mm. The flexibility of the manual mold connection link provides advantages that traditional injection molding processes cannot achieve for the production of special-shaped parts.

3. Drying Process Methods

The moisture content of wet pulp molded trays is as high as 65%-75%, and 3 types of drying methods are adopted:

• Natural drying: zero energy consumption sunlight drying, suitable for small workshops
• Hanging basket drying: medium temperature (80-120℃ ) circulating hot air, balanced energy saving
• Drying in drying oven: 220℃ high temperature rapid dehydration, can be completed in 15-30 minutes

4. Shaping by Hot pressing Machine: Forging Better Mechanical Properties

Hot pressing machine shaping of paper tray production is processed at a high temperature of 180-250 ℃. A hydraulic press applies a pressure of 5-15MPa to heat cure and crosslink the fibers. This process can improve the surface finish of the paper tray and increase the compressive strength by 200%- 300%, and the shockproof performance is comparable to EPE foam. After hot pressing, precision edge-cutting technology ensures that the product size tolerance is controlled within 0.2mm.

 Pulp Molded Product Application Field: From Lining To Outer Packaging

At present, the application of pulp-molded dry-pressed products has broken through the traditional boundaries, pulp moded trays are used in following fields:

• Precision protection: Lining of electronic products such as mobile phones and chips, 5G anti-static is achieved through structural design
• Heavy-duty load: The three-dimensional packaging of automotive parts can withstand dynamic loads of more than 50kg.
• Food-grade packaging: Sugarcane pulp molded lunch boxes are FDA certified and heat-resistant up to 120 °C
• Green logistics: Express buffer boxes can be recycled 5-8 times, reducing carbon footprint by 70%

Join Pulp Molding Industry Business: Green Opportunities in a Hundred-Billion-Dollar Market

According to the Global Environmental Packaging Alliance, the pulp molding market will exceed US$30 billion in 2025. The dry pressing process has become the main development due to the following advantages:

• Cost advantage: Compared with wet pressing process, equipment investment is reduced by 40% and energy consumption is reduced by 35%.
• Material revolution: Straw/bamboo fiber composite pulp reduces costs by another 20%
• Policy-driven: EU SUP ban and China’s “plastic restriction order” accelerate the replacement process

The rise of dry pressing technology in pulp molding plants signifies a significant advancement in the packaging industry and realizes a better commitment to sustainable development. With the supply of semi-dry pressing and auto pulp molding equipment from AGICO,  this green technology, which has its roots in ancient papermaking, is paving the way for environmental protection in modern industrial practices. As each express package is transformed into “growing packaging,” our city move one step closer to the vision of a “zero waste earth”.