Moulded Fibre Manufacturing Process

Recovered paper and cardboard provide important raw materials for OMNI‑PAC’s moulded fibre manufacturing processes. The selected fibre materials are prepared and processed before being combined with water to create a consistent pulp suitable for forming.

By returning recovered fibre to productive use, we help preserve the value of existing materials and reduce reliance on conventional plastic and foam packaging in suitable applications. Material composition is selected according to the required strength, surface quality, hygiene, barrier and end-of-life characteristics of each product.

Across the Group, OMNI‑PAC processes more than 100,000 tonnes of recovered paper and cardboard annually, transforming fibre resources into useful packaging products.

Tooling defines the shape, dimensions, surface details and functional features of a moulded fibre product. OMNI‑PAC’s in-house capabilities allow our teams to design and manufacture bespoke tools around the approved packaging concept and intended production process.

Close collaboration between designers, toolmakers and production specialists helps ensure that each tool supports efficient fibre distribution, reliable product release and consistent manufacture. Keeping tooling expertise within the Group also allows designs to be assessed and refined with production requirements in mind.

From protective inserts and trays to specialist medical and horticultural products, our tooling is developed around the precise demands of each application.

OMNI‑PAC develops custom moulded fibre packaging around the shape, size, weight and vulnerability of each product. Solutions can be engineered for electronics, consumer goods, medical applications, fresh produce, horticulture and industrial components.

A product-specific design can help control movement, protect vulnerable areas and improve stability throughout packing, storage and transportation. The packaging can also be developed for efficient nesting and integration with existing packing processes.

Our support can cover concept development, design, bespoke tooling, prototype evaluation, refinement and controlled full-scale manufacture. This provides customers with a coordinated route from initial packaging brief to production-ready solution.

Once production and quality checks are complete, finished moulded fibre products are counted, weighed, packed and labelled for dispatch. Automated systems support accurate product quantities and traceability, while experienced team members monitor the process and address any issues.

Product formats and pallet configurations are developed to support efficient storage, transport and customer handling. Nestable designs can help reduce the space required for finished products throughout the supply chain.

Where required, dried moulded fibre products undergo an additional pressing stage using matched, heated tools. After-pressing can refine the product’s shape, compress the fibre structure and improve dimensional consistency, rigidity and surface quality.

This process is particularly valuable for applications requiring closer tolerances, improved nesting, enhanced presentation or more precise interaction with the packaged product. The appropriate finish and pressing requirements are determined by the intended application