Katie PyzykSenior Reporter
Speakers at an International Molded Fiber Association event detailed advancements in the energy efficiency of manufacturing equipment, dry molded fiber and R&D to expand into new end use markets. 

While market growth emerged as an underlying theme at the International Molded Fiber Association’s annual conference from Sept. 11-13, innovation became the frequently repeated strategy for accelerating that trend.

Innovating by upgrading existing molded fiber products as well as entering new territory, such as coffee pods, is a key strategy for market expansion, said John Sherwin, co-director of custom research at The Freedonia Group. And exploring viable new barriers as alternatives to PFAS will further boost growth for food-safe molded fiber disposables, he said.

Jan Ridderman, sales manager at Inmaco Solutions, said he’d seen the industry change during his last two decades making machinery. As more customers to turn molded fiber solutions to meet sustainability goals, Ridderman said the manufacturing equipment also is changing to keep up with the industry’s innovations.

Automation advancements

Nick Palumbo, North American technical sales manager for the fiber division at equipment supplier Kiefel Technologies, offered an overview of recent technical advancements in molded fiber automation.

For one, he described changes in trimming during the manufacturing process that reduce tooling costs and offer higher precision.

“We’ve seen that multi-stage trimming can really help increase output. It will allow you to do multiple cuts on the same article,” he said. “Then we’re looking also into laser trimming as well — currently being developed.”

Examining how best to configure machines for process optimization also presents opportunities, he said.

“We’ve done a few different, newer things, where we’re actually feeding multiple thermoformers, or molded fiber machines, into one set of automation tools,” Palumbo said. “You can increase your automation usage so you’re not having your automation sit unutilized. It’ll lower your labor costs and reduce the footprint of having automation on individual machines — you have them in a cell.”

In addition, digitizing via a human-machine interface, which operates similarly to a standard tablet, helps by giving live feedback about operations data. This HMI boosts precision and allows operators to get ahead of potential issues, Palumbo said.

Ring of fiber

Molded fiber’s push into new end markets is a key theme that The Freedonia Group flagged as a driver for growth earlier in the conference. Multipack beverage carriers are a top category that fits under that umbrella, according to the research firm. 

Francisco García, co-founder and chief operating officer at E6PR, detailed how his company was a trailblazer in developing molded fiber rings to replace plastic rings on beverage multipacks.

“I want to share with you the potential of molded fiber parts going into new markets,” García said. “There are still new markets we see every day.”

E6PR worked with Florida-based SaltWater Brewery for a couple years to design the molded fiber carriers. Numerous rounds of testing during R&D prompted the company to tweak the design to be more moisture resistant and durable under the rigors that ring carriers face.

Going to market after years of work “was a big milestone for the market and the industry,” García said. “The concept was good and the customer was willing to pay more.”

But the product price has come down to nearly reach parity with plastic rings as E6PR has scaled. That’s expected to draw in even more customers.

https://www.packagingdive.com/news/international-molded-fiber-association-conference-innovation-technology-advancement/727047/