Abstract

As an essential segment of electronics and industrial packaging, display packaging is undergoing a transformation from traditional materials to eco-friendly molded pulp packaging. This article compares conventional display packaging materials—such as EPS foam, EPE foam, and corrugated board—with emerging plastic-free molded pulp packaging, focusing on sustainability, transport efficiency, and protective performance. Drawing on multiple authoritative reports and data sources , this study finds that while foam materials offer excellent cushioning and lightweight advantages, they pose environmental challenges due to low recyclability and poor biodegradability . Corrugated paper is recyclable but often requires foam inserts to achieve sufficient cushioning. Molded pulp packaging, made from renewable fibers, is biodegradable, recyclable, and carries a much lower carbon footprint than plastic-based packaging . Its optimized structural design reduces shipping volume and enhances transport packaging efficiency , meeting both protection and sustainability needs for display packaging. Industry data indicate that the global molded pulp market is expanding rapidly and will maintain strong growth over the next decade. In summary, display packaging is evolving toward a greener and more efficient direction, with molded pulp packaging emerging as a viable alternative to traditional foam—balancing transport protection with sustainability goals.

 

Chapter 1. Introduction

1.1 Industry Background and Current Status

As a representative of electronic product packaging, display packaging has long relied on a combination of foam inserts and corrugated cartons. These packaging systems must meet the industrial packaging requirements of shock absorption, stacking strength, and protection during long-distance transport. Historically, manufacturers used EPS (expanded polystyrene) and EPE (expanded polyethylene) foam as interior cushioning for displays and similar fragile products . Although these materials deliver strong protection and light weight, they have serious environmental drawbacks—being non-biodegradable and difficult to recycle (global EPS recycling rate <30%) . Packaging waste accounts for roughly 40% of total global plastic waste, making plastic reduction in packaging a key focus for display manufacturers and electronics brands.

In response, global brands have begun committing to plastic-free packaging targets . For example, some leading technology companies achieved over 99% plastic-free packaging by 2024, cutting total packaging weight and volume by over 50% . Such transitions not only improve sustainability but also enhance transport and storage efficiency. Regulatory bodies are reinforcing this momentum—most notably the EU Single-Use Plastics Directive (EU 2019/904), which restricts non-recyclable materials and promotes fiber-based alternatives . Under this dual pressure of policy and market demand, display packaging is shifting decisively toward sustainable materials.

1.2 Research Objectives and Methodology

This study targets display manufacturers and electronics packaging buyers, examining the evolution of packaging materials and comparing traditional vs. molded pulp options. Using data-driven analysis and references from Packaging Strategies, Statista, and iResearch, we aim to:

• Evaluate traditional display packaging materials (EPS, EPE, corrugated board);

• Investigate molded pulp’s characteristics, applications, and advantages;

• Compare both categories across sustainability, logistics efficiency, and protective performance;

• Conclude key trends in the evolution of display packaging and provide insights for sustainable transitions.

 

Chapter 2. Traditional Display Packaging Materials

2.1 EPS and EPE Foam

EPS (Expanded Polystyrene) and EPE (Expanded Polyethylene) are long-established cushioning materials in display packaging and electronics packaging. They feature low density (~0.03 g/cm³), lightweight construction, and excellent shock absorption . Foam cells deform elastically upon impact, extending deceleration time and minimizing G-force transmission during drops or vibration. Variants with anti-static or moisture-resistant additives further enhance their suitability for sensitive electronics .

However, the environmental cost is substantial: EPS/EPE are petroleum-based, non-biodegradable, and persist for decades in the environment . Less than one-third of foam packaging is successfully recycled, and most ends up in landfills or incineration . Increasingly stringent global plastic waste regulations have placed these materials under compliance and taxation pressure, prompting the industry to seek greener cushioning alternatives.

2.2 Corrugated Board and Paper-Based Packaging

Corrugated fiberboard, widely used for outer cartons and inner supports, offers advantages such as renewable sourcing, recyclability, and low cost. It provides rigidity for stacking and compression while offering limited cushioning capacity. Paperboard packaging is easy to recycle with a mature global recovery system . However, its shock absorption is inferior to foam, and it loses strength in humid conditions. As a result, traditional display packaging combines foam (for cushioning) and corrugated paper (for external protection).

2.3 Limitations of Conventional Packaging

• Low sustainability: Plastic foam relies on fossil-based feedstocks and exhibits poor recyclability.
• Regulatory pressure: Many regions now restrict EPS/EPE use or impose eco-taxes .
• Logistics inefficiency: Bulky foam increases transport volume and warehousing costs .
• Poor user experience: Foam residues create cleanup issues and negatively affect brand image.

These challenges are driving the adoption of eco-friendly molded pulp packaging in the display industry.

 

Chapter 3. Molded Pulp Packaging: The Emerging Solution

3.1 Overview

Molded pulp packaging—made from recycled paper fibers through pulping, molding, and drying—has evolved from egg trays to industrial-grade electronics packaging. Key features include:

• Renewable raw materials: Recycled paper fibers reduce virgin pulp demand .
• Biodegradability: Fully decomposes in natural environments .
• Formability: Custom molds allow precision-fitting trays, supports, and inserts.
• Plastic-free and low-emission: No harmful additives, anti-static by nature.

Modern manufacturing techniques (e.g., dry pressing, surface coating, high-precision molds) have significantly enhanced strength, smoothness, and moisture resistance —making molded pulp suitable even for fragile electronics.

3.2 Sustainability Advantages

• Lower carbon footprint: Life-cycle studies show molded pulp emits up to 92% less CO₂ than equivalent plastic packaging .
• Biodegradable waste: Fully decomposes within months .
• Circular economy: Easily recycled as paper waste, enabling true closed-loop recovery .
• Regulatory compliance & brand image: Aligns with plastic reduction policies and enhances sustainable branding .

3.3 Industrial Applications and Growth Trends

• Market growth: Global molded pulp market valued at USD 4.8B (2021), projected to exceed USD 9.1B by 2030at a 7% CAGR .
• Adoption rate: Penetration across packaging sectors reached ~30% and rising. 
• Policy-driven demand: Plastic bans in the EU and corporate sustainability pledges accelerate adoption .
• Technological innovation: Dry-pressing cuts energy use by 30%; bio-based coatings enhance water resistance .

 

Chapter 4. Comparative Analysis of Packaging Materials

4.1 Sustainability Comparison

4.2 Logistics and Transport Efficiency

• Volume reduction: Pulp inserts reduce packaging height by ~17%, boosting container utilization .
• Stackability: Molded pulp trays nest compactly, saving ~40% in warehouse space .
• Ease of handling: One-piece pulp trays simplify packing, improve workflow, and enhance end-user unboxing experience .

4.3 Protective Performance

• Shock absorption: While foam remains superior in multi-impact resilience , properly designed pulp trays achieve comparable drop protection (damage rate ≈0.5%) .
• Product fixation: Custom-molded pulp provides tight geometric locking, preventing internal movement during transit .
• Moisture and ESD control: Bio-based coatings and conductive additives can achieve required moisture and static resistance levels.

 

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Conclusion

The evolution of display packaging demonstrates a clear transition from function-first to eco-first design philosophy. Comparing foam-based and molded pulp systems reveals:

• Molded pulp dramatically improves sustainability while maintaining adequate protection.
• Optimized designs offer superior logistics efficiency and cost savings.
• Technological advancements close the performance gap with foam, especially for robust electronics like displays.

Adopting molded pulp packaging enables manufacturers to meet tightening regulations, reduce carbon emissions, and enhance brand sustainability. As plastic-free industrial packaging becomes the new norm, early adopters will lead the market shift toward a low-carbon, recyclable future for display and electronic product packaging.

 

References

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