Faller Packaging: Sustainable fibre form trays as an alternative to plastic

Sustainability and functionality are not mutually exclusive when it comes to pharmaceutical packaging. A new solution made of moulded fibre shows how both can work together: Harvest Packaging manufactures moulded fibre trays that can replace plastic – and as a partner of the manufacturer, Faller Packaging is bringing this innovation to the European market.

With the new regulation (EU) 2025/40 – also known as PPWR (Packaging and Packaging Waste Regulation) as part of the EU Green Deal – the demands for circularity and recyclability are rising. For pharmaceutical manufacturers this means higher licensing fees and additional charges for plastic packaging – so companies must review their materials and switch to sustainable solutions.

Faller Packaging has accepted this challenge and is now relying on a fibre-based system from Irish manufacturer Harvest Packaging. The company’s moulded fibre trays are made from FSC® C104125-certified fibres, are PFAS-free and meet PPWR requirements. The trays are stable, dimensionally accurate and fully recyclable. The use of monomaterials also improves sortability in the recyclingprocess.

Handling sensitive products

The focus during the development of the new trays is on material efficiency and product protection. This also allows vials, pens and prefilled syringes to be packaged safely. For applications with sensitive active ingredients or electronic components, Faller Packaging offers structured inserts and combined solutions.

Many companies are currently looking for alternatives to plastic that can be easily integrated into existing packaging lines. The moulded fibre trays meet these requirements and enable the reliable and precise handling of sensitive products.
Niklas Mößner, Product Manager at Faller Packaging

Precision and process reliability in detail

Harvest Packaging drew on its experience in the food industry to design the trays, which are produced in Ireland. In contrast to the classic dry-moulded process, the fibre form is created using the Wet Moulded Fibre process. A watery fibre pulp is first formed in appropriate tools, then compressed under pressure and heat. This results in particularly smooth surfaces, precise contours and a high material density.

The trays are designed for automated production lines. Auto-stacking and de-nesting with a very low stack height facilitate integration into existing processes without any major conversion being necessary. Negative demoulding angles, locking mechanisms and click effects secure the products during transport and storage.

For companies with ambitious sustainability goals, switching to fibre forms can reduce Scope 3 emissions and eliminate plastic taxes and EPR fees at the same time, making the fibre-moulded trays a real alternative to plastic solutions.

Sustainability as a competitive advantage

For pharmaceutical and MedTech companies, switching to sustainable materials is more than a regulatory obligation. It is increasingly influencing procurement strategies along the supply chain. Harvest Packaging’s trays can be manufactured in large volumes, but they are also suitable for early development phases with single-cavity prototypes. The trays’ high dimensional accuracy and stability enable them to be used even with complex geometries and combination kits.

Faller Packaging offers the new moulded fibre trays in cooperation with Harvest Packaging and supports companies as a partner if they want to align their packaging systems with PPWR requirements.