Fenix Industries: Molded pulp packaging – the ultimate guide (2025 edition)

Everything brands, packaging buyers, and sustainability managers need to know.

What is molded pulp packaging?

Summary: Molded pulp packaging is eco-friendly, highly customizable, and ideal for protective or retail packaging.

Molded pulp (AKA molded fiber OR paper pulp) is a sustainable, cost-effective alternative to plastic. It can be made from natural fibers, cardboard, or recycled papers and is then formed into custom shapes—like trays, clamshells, protective insert, and even boxes—using heat and pressure. Molded pulp is biodegradable, compostable, and often recyclable, making it a top choice for eco-conscious brands.

For an overview of our molded pulp capabilities, please visit our Molded Pulp Packaging page.

Key benefits of molded pulp packaging

• Eco-Friendly: Biodegradable and compostable, reducing landfill waste and keeping our oceans clean!
• Protective: Excellent shock absorption for shipping and storage, think egg cartons but prettier!
• Sustainable: Can use post-consumer recycled content!
• Custom-Tailored: Can be formed into all sorts of shapes!

How molded pulp packaging is made (in a nutshell)

Molded pulp packaging is produced using one of two main methods: wet-press or dry-press. While the cycle time and forming process may vary, both methods follow a similar core process that includes forming, pressing, trimming/finishing. Each step of this three-part process requires a separate mold (tooling) to complete.

Types of Molded Packaging

There are different ways to classify the types of molded pulp packaging, depending on manufacturing method or industry use. For example, the International Molded Fiber Association (IMFA) outlines molded pulp types such as thick wall, transfer molded, thermoformed, and processed pulp. At Fenix Industries, we simplify this by grouping molded pulp into two main manufacturing categories as previously discussed: wet press and dry press. Wet press molded pulp produces a smooth, premium finish ideal for retail packaging, while dry press is more industrial, faster to produce, and suited for items like trays and protective inserts where function is more important than form. Understanding these types helps brands choose the right molded pulp solution for their product and sustainability goals.

Why More Brands are Switching to Molded Pulp in 2025

Brands are switching to molded pulp packaging because it’s sustainable, protective, and now highly customizable. As manufacturing technology advances, molded pulp can deliver retail-quality finishes while meeting the rising demand for plastic-free solutions. With global leaders like Apple and Sony adopting it, molded pulp is becoming the new standard for eco-friendly, high-performance packaging. Fenix Industries helps brands make this shift with in-house design, engineering support, and full-scale production facilities across the Asia-Pacific region.

• Sustainability Mandates: Governments and retailers demanding plastic reduction
• ESG Reporting: Brands need packaging that aligns with carbon reduction goals
• Consumer Demand: Shoppers prefer brands with visible sustainability efforts
• Improved Technology: Manufacturing processes for molded pulp have matured significantly, allowing for more precise, scalable, and aesthetically pleasing results than ever before
• Adoption by Global Brands: Industry leaders like Sony, Dior, and Chanel are making the switch to molded pulp, setting a precedent for the rest of the market

Did You Know? Major companies like Apple, L’Oréal, and Nestlé are actively replacing plastic with molded pulp in their supply chains.

Start Your Sustainable Packaging Journey with Fenix Industries

At Fenix Industries, we specialize in high-performance, eco-conscious molded pulp packaging. Whether you’re launching a new product or transitioning away from plastic, we help you design and deliver custom packaging solutions that stand out on shelves—and support your sustainability goals. Our team of packaging industry veterans are ready to help you take your brand to the next level in sustainability!

Let’s work together. Contact us today to get started with a custom molded pulp solution.

This article was originally published by Fenix Industries.