High-capacity molded fiber production

Valmet 3D Fiber technology enables the pulp to be directly pressed into three-dimensional forms, such as plates, trays, and cups used in food or takeout packaging. New technology innovations and high-quality end products offer our customers wider market opportunities than traditional wet molded fiber packaging (MFP) technology.

The manufacturing process can be easily tailored to different purposes and products, thanks to the modular concept of the production line and Valmet MFP tooling (molds). Unique fiber layering technology with foam injection forming enables the production of lightweight and rigid end products and tailoring properties by layer e.g., supporting optimal use of barrier chemistry for food contact side. Outstanding surface smoothness and capability for appealing packaging designs offer value add for brand owners and retailers but also offer the basis for different barrier coatings.

The 3D Fiber production converts cellulose fiber directly into ready packaging products without several converting steps. The process is engineered for efficient use of raw materials, energy, and water. Unique fiber layering technology enables the production of lightweight and resource-efficient products using high-yield pulps like CTMP. The technology also enables the circulation of off-quality and trimming broke back into the process, unlike in many other competing solutions. Efficient water circulation minimizes freshwater usage and chemical consumption.

Maximize throughput and profitability with Valmet 3D Fiber that is designed to take the speed and competitiveness of wet molded fiber packaging production to a completely new level. The technology is aimed at producing packaging solutions for high-volume markets, such as food packaging.

Key features include:

• Capacity and speed: The production line operates even 5-8 times faster than competing technologies.
• High OEE (Overall Equipment Effectiveness): Highly efficient and productive production line.
• Forming area: The forming area is 1,200 x 800 mm.
• Cycle time: The cycle time is less than 10 seconds.

Operate smarter, with fewer manual steps utilizing Valmet 3D Fiber lines that are operated with Valmet DNA, a future-proof Distributed Control System (DCS). It is used for process controls, machine controls, drive controls, quality controls, information management and condition monitoring from stock preparation to the end of the 3D Fiber production lines. Furthermore, online quality control system with camera-based defect detection and moisture control systems secure the high automation level for the plant and therefore, low operational personnel requirement.

Our goal is to help you deliver packaging that stands out on the shelf — smooth, strong, and sustainable. The 3D Fiber technology produces molded fiber products that are unique including their deep shapes, smooth surfaces, and high quality. The innovative fiber layer structure further enhances the product's strength and surface smoothness.

Since 2020, Valmet has partnered with Metsä Group's innovation company Metsä Spring to develop 3D fiber-based packaging with new technology aimed at achieving excellent end product properties. A demo plant was inaugurated in 2022 at Metsä Group’s bioproduct mill in Äänekoski, Finland, where Muoto products are produced.