As the global push to reduce plastic waste intensifies, industries are seeking packaging solutions that are not only sustainable but also efficient and cost-effective. Dry Moulded Fibre (DMF), pioneered by PulPac, emerges as a revolutionary alternative, offering a compelling lifecycle advantage over traditional plastic packaging.
What is Dry Moulded Fibre?
Dry Moulded Fibre is an innovative manufacturing technology that transforms renewable pulp into rigid, three-dimensional packaging products. The process involves mechanically milling pulp fibres, air-laying them into a web, and then moulding them into shape using heat and pressure. a short video clip of the DMF process
Lifecycle Assessment (LCA): DMF vs. Plastic
A comprehensive LCA conducted by the Research Institute of Sweden (RISE)* in 2022 conducted a recyclability report and climate impact study for Dry Moulded Fibre spoons. The report revealed a climate impact of approximately 0.66 kg CO₂-equivalent per kilogram of product. In stark contrast, in an LCA by Takou et al. with focus on single use plastic products similar polypropylene (PP) cutlery displayed a climate impact of about 4.2 kg CO₂-equivalent per kilogram. This indicates that DMF cutlery has roughly 85% lower carbon emissions than its plastic counterpart. Source: PA Paper Advance
Notably, the DMF production process itself accounts for only 7% of the total climate impact, with the majority stemming from the production of input materials like fluff pulp and tissue. This underscores the efficiency of the DMF process in minimising environmental impact.
Environmental Benefits of Dry Moulded Fibre
- Water Conservation: The dry process virtually eliminates the need for water in molding, preserving valuable water resources and reducing wastewater generation.
- Energy Efficiency: DMF’s streamlined process consumes significantly less energy compared to traditional moulding methods, contributing to lower greenhouse gas emissions.
- Material Efficiency: With in-line recycling, DMF achieves up to 99% material utilisation, minimising waste and promoting circularity.
- Speed and Scalability: DMF boasts rapid cycle times enabling high-volume production to rival plastic manufacturing speeds.
End-of-Life Advantages of Dry Moulded Fibre
DMF products are designed with sustainability in mind throughout their lifecycle.
- Recyclability: DMF products can be recycled within existing paper-recycling streams, facilitating easy integration into current waste management systems.
- Biodegradability: DMF products are bio-based, they are made from naturally occurring carbon and will biodegrade over a short time span if disposed of, significantly reducing environmental pollution.
Globally paper pulp is much more widely recycled than plastic. The rates of recycling paper are over 65%. Countries that either have a robust recycling system (European) or have a fibre shortage (Middle and Far East) are averaging over 80%.The rates of recycling plastic (apart from PET bottles) are less than 8% globally. According to the Ellen MacArthur Foundation, only 5% of the plastic material value is retained during recycling, the rest (most of it) is down-cycled into lower-value products.
One of the major reasons the above numbers are skewed in favour of paper pulp are that paper is much easier to recycle. One can process mixed paper into new fibre with ease; something that is not possible with plastic. Newsprint or corrugated medium can contain fibre that came from many sources such as office waste, newpapers, pulp packaging, cardboard boxes etc… Something that is not possible with a cross section of plastic waste.
Industrial Adoption and Future Outlook of Dry Moulded Fibre
DMF technology is gaining traction among global brands and manufacturers. As industries continue to prioritise sustainability, DMF stands out as a transformative solution that combines environmental responsibility with operational efficiency.
Conclusion
Dry Moulded Fibre represents a significant advancement in sustainable packaging, offering a low-carbon, resource-efficient alternative to single-use plastics. With its impressive lifecycle performance and growing industrial adoption, DMF is poised to play a pivotal role in the transition towards a more sustainable future.
