Fiber-Based Caps Aim to Replace Plastic Closures
PulPac introduces next-generation fiber caps at interpack 2026, targeting plastic replacement in packaging closures.
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PulPac is developing a new generation of fiber-based caps designed to replicate the functionality and user experience of plastic closures, marking a step forward in sustainable packaging solutions.
Context: Closures as a key packaging challenge
Caps and closures are among the most widely used plastic components in packaging, presenting a significant opportunity for material substitution. While fiber-based packaging has advanced in areas such as containers and trays, closures remain technically demanding due to requirements for sealing, durability, and user interaction.
Technology: Dry Molded Fiber for complex components
The new caps are based on PulPac’s Dry Molded Fiber technology, enabling the production of structured fiber components with precision and consistency.
The development focuses on achieving performance characteristics typically associated with plastic closures, including thread engagement, sealing integrity, and repeated opening and closing functionality.
Performance: Toward plastic-like functionality
Early testing indicates that the fiber caps can deliver key functional properties such as reliable sealing and mechanical performance. In addition, the caps are designed to provide a tactile experience similar to plastic, addressing consumer expectations.
The design also allows differentiation between internal and external surfaces, enabling both functional optimisation and branding opportunities.
Collaboration: Industry-wide development
The project is being developed in collaboration with PA Consulting and machine partner Optima, as well as through the Bottle Collective initiative involving multiple industry stakeholders.
This collaborative approach supports the development of integrated fiber-based packaging systems, including both containers and closures.
Applications: Broad packaging potential
Fiber-based caps are being evaluated across various packaging formats and industries. Early prototypes have been tested in real-world conditions, demonstrating feasibility for integration into existing packaging systems.
The development reflects growing interest in reducing plastic use and improving material circularity across the packaging value chain.
Exhibition: First public showcase
The caps will be presented for the first time at interpack 2026, where visitors can explore both current Dry Molded Fiber solutions and future developments in fiber-based packaging.
Conclusion: Advancing material substitution in packaging
PulPac’s fiber-based caps highlight ongoing efforts to replace plastic components with renewable materials. By addressing functional and consumer requirements, the development supports the transition toward more sustainable and circular packaging systems.
Edited by an industrial journalist, Lekshman Ramdas, with AI assistance.
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