How sustainable, plastic free molded pulp packaging improves protection, cost and customer experience in shipping packaging.

Abstract

Shipping packaging is no longer just a cardboard box around a product. It is a complete system of outer cartons, inner trays, dunnage and void fill that must protect goods in transit while supporting eco friendly, sustainable packaging goals. This article explains core principles of shipping packaging design and shows how molded pulp trays and pulp-based dunnage can replace traditional foams and plastic void fill. By combining smart packaging design with molded fiber packaging, brands can reduce damage rates, cut logistics costs and move toward plastic free, recyclable and biodegradable packaging solutions.

Keywords: shipping packaging, eco friendly packaging, sustainable packaging, biodegradable packaging, industrial packaging, packaging solutions, heavy duty packaging, plastic free packaging, molded pulp packaging, molded fiber trays, pulp products, dunnage, void fill, B2B packaging

1. Introduction

1.1 Shipping packaging in a world of plastic waste

Global plastic production has exploded to more than 450 million tonnes per year, and a large share of that plastic quickly becomes waste. Across major economies, packaging alone accounts for roughly 37–45% of all plastic waste, making it the single largest application of plastics.

Governments are responding. The EU’s new packaging rules and the forthcoming Packaging and Packaging Waste Regulation (PPWR) aim to make all packaging reusable or recyclable by 2030 and to reduce per-capita packaging waste by at least 15% by 2040. At the same time, global negotiations on a plastics treaty seek to curb plastic production and pollution worldwide.

For brands shipping products across continents, shipping packaging sits right at the intersection of these pressures: it must protect products, control logistics costs and meet rising expectations for eco friendly, sustainable packaging.

1.2 Why shipping packaging design matters

Good shipping packaging design is a business issue, not just a sustainability slogan. Packaging that is properly engineered for shipping can:

1. reduce product damage and returns;
2. optimize dimensional weight and pallet efficiency, cutting transport costs;
3. improve the unboxing experience and brand perception;
4. demonstrate a tangible move toward eco friendly packaging.

This guide focuses on how molded pulp trays, molded fiber packaging and pulp-based dunnage can be built into shipping packaging design to deliver both performance and sustainability.

2. Key principles of shipping packaging design

2.1 Understand your product and shipping journey

The first step in designing shipping packaging is to map out the product and its journey:

1. Product characteristics – weight, geometry, centre of gravity, fragile zones, surface sensitivity. A flat-screen monitor, a round heater, and a bag of pet food each load packaging in very different ways.
2. Shipping route – parcel courier, palletised freight, LCL or FCL ocean shipping, air freight, regional fulfilment networks. Each adds different risks in terms of drops, stacking and vibration.
3. Handling environment – automated sortation, manual cross-docking, temperature and humidity swings.

Understanding the worst-case handling scenarios helps define what the shipping packaging really needs to withstand.

2.2 Define protection goals and test standards

Best practice is to translate the above risks into clear performance targets:

1. Drop tests to simulate falls during parcel handling.
2. Vibration tests for long-distance road or rail transport.
3. Compression tests to ensure boxes survive stacking in warehouses and containers.

Several ISTA and ASTM standards provide test protocols for consumer electronics, appliances and industrial products. While this article does not dive into specific test numbers, the key idea is that shipping packaging performance can and should be measured, not guessed.

2.3 Balance protection, cost and sustainability

Over-packaging with thick foam and oversized boxes drives up:

1. Material cost,
2. Dimensional weight and freight charges,
3. Environmental impact via excess plastic packaging.

Under-packaging, on the other hand, leads to parcel damage, returns and warranty costs.

The aim of shipping packaging design is to find the sweet spot where protection, cost and sustainability are optimized together. This is where molded pulp trays and pulp dunnage can play a powerful role.

3. Molded pulp trays in shipping packaging

3.1 What are molded pulp trays and molded fiber packaging?

Molded pulp packaging (or molded fiber packaging) are three-dimensional parts formed from water-suspended plant fibers—typically recycled paper, corrugated board, or agro-waste fibers such as bagasse and bamboo.

Unlike flat corrugated sheets, molded pulp pieces can closely follow product geometries, creating protective pockets, ribs and walls that act as custom-fitted industrial packaging. They are widely used in egg cartons and fruit trays, and increasingly in electronics packaging and shipping packaging for monitors, small appliances and consumer goods.

Because they are fibre-based, these trays are generally recyclable in paper streams and biodegradable under appropriate conditions, supporting eco friendly and plastic free packaging goals.

3.2 Design types and applications

Shipping packaging commonly uses several types of molded pulp trays:

1. End-cap and corner protectors – shaped blocks that absorb impact at the corners of a TV or monitor carton.
2. Full inner trays – top and bottom trays cradling a product, used for electronics, small appliances, smart home devices and pet products.
3. Multi-cavity inserts – trays with many pockets, ideal for sets of bottles, jars, mechanical parts or medical devices.
4. Heavy-duty trays – thick-wall molded pulp parts designed for industrial components or metal hardware.

By tailoring cavity shape, wall thickness and rib patterns, designers can channel loads away from critical areas and create stable, stackable shipping packaging systems.

3.3 Environmental perspective: molded pulp vs foams

Several life-cycle assessments (LCAs) have compared protective packaging materials such as EPS foam, honeycomb board and molded pulp. A recent industry LCA for 1 cubic foot of packaging, for example, found that molded pulp had lower packaging-stage greenhouse gas emissions than EPS, while overall climate impact depended on disposal pathways and material weights.

Academic work comparing EPS and molded pulp for consumer goods also reported that fibre-based solutions can reduce fossil energy demand and CO₂ emissions, though trade-offs exist in areas like water use and solid waste.

The takeaway is not that molded pulp is “perfect”, but that well-designed molded fiber packaging offers a credible route to lower fossil-based plastic use, and in many scenarios can achieve favourable life-cycle performance when combined with recycling or composting systems.

4. Dunnage and void fill with pulp products

4.1 What are dunnage and void fill?

In shipping packaging, dunnage refers to the materials used to secure and protect goods during transport—inside cartons, on pallets or in containers. It prevents items from shifting, colliding or being crushed.

Void fill is a specific type of dunnage whose main job is to fill empty space inside a box so that products cannot move around. It absorbs shocks and keeps outer cartons from collapsing.

Traditionally, dunnage and void fill rely on materials such as air pillows, plastic bubble wrap, loose fill peanuts and foam blocks—effective, but heavily dependent on plastics.

4.2 Pulp-based dunnage options

Pulp-based options allow brands to design eco friendly shipping packaging without sacrificing protection:

1. Molded pulp blocks and bumpers – positioned at high-stress points to absorb impacts.
2. Pulp corner posts and edge protectors – used inside or outside cartons for stacking strength.
3. Pulp cradles and saddles – shaped pieces holding cylindrical or round objects such as heaters, speakers or bottles.
4. Layer pads and trays – flat or slightly formed sheets separating product layers, often made from recycled corrugated pulp.

Because these parts are often nestable and stackable, they can reduce warehouse space and inbound freight compared with bulky foam pieces.

4.3 Design tips for molded pulp dunnage

When integrating molded pulp dunnage into shipping packaging:

1. Start from the product – define contact points where the product is strongest (ribs, housings) and areas to avoid (screens, buttons, glass).
2. Combine trays and dunnage – for example, bottom tray + top compression pad + side blocks. This distributes loads and controls movement in all directions.
3. Check dimensions early – pulp parts typically shrink slightly during drying; allowing for these tolerances avoids fit issues with outer cartons.
4. Consider moisture and climate – for high-humidity or long ocean voyages, fibre recipes and coatings can be adjusted to maintain performance.

Good packaging design uses dunnage not as an afterthought, but as an integral part of the shipping packaging solution.

5. Shipping packaging design workflow with molded pulp

For brands working with a molded pulp partner such as KPNECO, a typical shipping packaging design workflow looks like this:

5.1 From 3D drawing to concept

1. The customer shares 3D CAD files or physical samples of the product and any existing packaging.
2. Packaging engineers analyse the product, shipping route and test requirements, then propose a layout for molded pulp trays, dunnage and outer cartons.

5.2 Prototyping and testing

1. Prototype molds (often rapid tooling) are built to produce sample trays and blocks.
2. These are packed into trial cartons and subjected to drop, vibration and compression tests according to relevant standards.
3. Design tweaks adjust wall thickness, ribs or cavity geometry to eliminate damage and improve packing efficiency.

5.3 Scaling up to mass production

1. Once validated, production tooling is built and material recipes are finalised—often using recycled corrugated pulp, bagasse or bamboo fibres.
2. Carton suppliers are aligned to ensure everything fits as a coherent shipping packaging system.
3. For global B2B packaging projects, supply planning ensures consistent quality and capacity across forecast volumes.

This process turns “eco friendly packaging ideas” into robust, test-proven shipping packaging ready for real-world logistics.

6. Mini case studies: molded pulp in real shipping packaging

6.1 Monitor shipping packaging – from EPS foam to molded pulp trays

A monitor brand wanted to replace traditional EPS end caps in its electronics shipping packaging. The foam design worked but created problems:

1. Unstackable foam dunnage filled warehouse aisles.
2. The outer carton had to be larger than necessary, increasing freight and handling cost.
3. EPS was difficult for end users to recycle and clashed with the brand’s sustainable packaging commitments.

Working with KPNECO, the brand adopted a set of custom molded pulp trays:

1. The new trays are nestable, reducing inbound packaging volume.
2. A slightly slimmer overall profile allowed a smaller shipping carton, improving pallet utilisation.
3. Because the packaging is 100% fibre-based and FSC-certified, it can be recycled with paper streams and supports plastic free, biodegradable packaging messaging.

Transport tests confirmed that the molded pulp design matched the original EPS in drop and vibration performance, while significantly improving sustainability and logistics efficiency.

6.2 Blanket heater packaging – Round product protection

A home-comfort brand needed shipping packaging for a compact heated blanket / heater set with a round central unit. The initial plastic and foam inserts were functional but inconsistent with the company’s eco friendly positioning and created mixed-material waste for customers.

KPNECO developed top and bottom round molded pulp trays:

1. The trays hold the product securely from top and bottom, acting as both dunnage and display packaging inserts.
2. They are stackable for efficient storage and quick packing in the factory.
3. The entire inner system becomes plastic free shipping packaging that consumers can flatten and recycle with paper.

The brand reported lower damage rates in parcel shipping, faster packing on the line, and positive feedback from customers about the sustainable packaging.

7. Conclusion

Shipping packaging design is one of the most powerful levers brands have to reduce waste, lower costs and keep products safe. As regulations tighten and customers demand more eco friendly packaging, companies can no longer rely on oversized cartons and generic plastic foam.

By understanding the product journey, setting clear protection targets and collaborating with a molded pulp packaging manufacturer, brands can design shipping packaging solutions that:

1. Protect goods using custom molded pulp trays and pulp dunnage,
2. Cut dimensional weight and warehouse volume through smarter geometry,
3. Move decisively toward sustainable, plastic free, biodegradable packaging.

Molded fiber packaging is not a silver bullet, but as part of a well-engineered system it offers a credible path away from single-use plastics and toward a circular, fibre-based future for shipping packaging.

References

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