How to compare fibre based packaging production methods and airlaid technology

Choosing between fiber based packaging production methods affects quality, cost, utility demand and scale-up risk. Brands often move from plastic to fibre to meet policy targets and customer needs. The right route depends on geometry, barrier performance, surface quality and throughput.

Wet moulded fibre, paperboard conversion and airlaid dry forming all serve different needs. CAMPEN supports customers that need a reliable airlaid route for fibre-based material production. Airlaid technology forms fibres in a dry process, before later converting or shaping.

How to compare fiber based packaging production methods

Most fibre packaging is made through three main production routes. Each route has clear strengths and limits. Your choice should match the target product, raw materials and total operating cost.

Wet moulded fibre process

Wet moulded fibre disperses pulp in water. The slurry is vacuum-formed on tools, then dried and pressed. This route supports deep 3D shapes, formed rims and defined edges.

Water handling and drying energy are key cost factors. Tool design also affects wall thickness, detail and repeatability.

It can suit trays, cups and clamshells with strong 3D geometry.
It supports detailed surface definition and formed edges.
It requires slurry handling, vacuum forming, drying and pressing.

Paperboard conversion

Paperboard conversion uses rollstock that is printed, cut and folded. It is efficient for simple 2D-to-3D packaging shapes. Board grades and coatings provide many key functions.

It can suit cartons, sleeves and simple trays with crease lines.
It supports high print quality and high line speed.
It is less suitable for deep shapes without extra forming steps.

Airlaid dry forming

Airlaid dry forming disperses fibres in air and lays them into a web. The web is bonded thermally or chemically, then converted or formed downstream. This separates material production from final part forming.

It can suit absorbent layers, cushioning layers and multi-layer structures.
It supports control of basis weight, thickness, porosity and bulk.
It can reduce water use compared with wet fibre routes.

Where airlaid technology fits in packaging

Airlaid technology is relevant when fiber based packaging production methods require a controlled fibre web. The web can be converted into packaging parts or combined with other substrates.

The process is strong in thickness control, porosity control and stable fibre distribution. This supports consistent quality in later converting and forming steps.

Layer design can combine cellulose, binders or biopolymers for targeted performance.
Low-moisture processing helps reduce drying energy and utility demand.
Accurate basis weight control helps improve consistency and reduce waste.
Embossing or pre-densifying can improve stacking, cushioning and sealing.

Typical applications include protective inlays, absorbent pads, interleaves and lids with seal layers. Semi-rigid parts can also be produced after downstream forming.

CAMPEN airlaid production technology

CAMPEN supplies complete airlaid lines and modules for fibre-based material production. Our systems turn pulp and fibres into a stable web for further converting.

We have worked with nonwovens since the 1970s. We bring process knowledge from hygiene, wipes and technical materials into packaging applications.

Core modules for stable production

Fibre preparation and forming heads help deliver even fibre distribution.
Multi-layer capability places functional layers where they add value.
Thermal and latex bonding options balance strength and end-of-life targets.
Calendering, embossing and lamination add stiffness, texture or surface function.

Process control and quality management

Closed-loop basis weight control helps reduce variation and material waste.
Web inspection supports quality control, documentation and traceability.
Data logging helps document process stability over time.
Dust management and safety systems help keep the line clean and compliant.
An easy-to-operate HMI helps shorten training and changeover time.
Recipe control supports repeatable settings across products and shifts.

Sustainability and cost outcomes

Dry forming can limit water use compared with wet laid fibre routes.
Lower drying demand can help reduce energy use and operating costs.
Robust mechanics support high uptime and predictable maintenance.
Flexible fibre input helps manage raw material cost and availability.

From concept to stable production

CAMPEN focuses on your product targets and process requirements first. Our engineers can model the line, run trials and support scale-up.

We design reliable, robust and easy-to-operate equipment. We also support commissioning, ramp-up, service and later upgrades.

Pilot and demo support helps validate material properties and conversion steps.
Line layouts can integrate dosing, bonding, calendering and winding.
Systems can interface with downstream forming or external moulding partners.
Lifecycle service and spare parts help keep performance stable.

CAMPEN supplies the airlaid route to fibre-based material production. Wet moulding tools and final part forming normally require other equipment. We collaborate with partners to support a smooth process handover.

Considering in-house airlaid production? Talk to CAMPEN about airlaid technology, pilot testing and line configuration before you invest. Learn more about CAMPEN’s airlaid solutions or explore our airlaid test center.