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Moulded Fibre

General Process

Moulded fibre is the raw material used in the production of DFM PACKAGING.
The raw material is from renewable wood fibres. Moulded Fibre Products are a matrix of fibres.

Pre-Process

Step 0

The fibre source in DFM’s process is a combination of Waste Paper and Paper Mill Waste:

  • Newspaper
  • Office Waste
  • Boxes
  • Waste destined for the landfill

Raw Material

Step 1

The raw material is pulped in a “giant liquidiser” to single fibres. A fibre resembles a human hair between 1mm and 5mm in length.

Moulding

Step 2

The Fibre is diluted to make a mixture of water (99%) and fibre (1%) and pumped into a vat. The liquid pulp is drawn onto the plenum (moulds) by vacuum and the water is simultaneously extracted, leaving a very soggy, even layer of pulp on the mould.

Drying

Step 3

The wet product is transferred onto a “canier belt” that transports it through a drier (oven) at extreme heat to dry the product to “touch-dry”. This extreme heat causes the product to undergo considerable shrinkage.

    Afterpress

    Step 4

    The product is then ironed into the perfect shape by an afterpress, using a combination of heat and extremely high pressure.

      Finished product

      Step 5

      The product is then either fed into a printer for customised logo’s, trademarks and product description or packed for despatch.

        Pre-Process

        Step 0

        The fibre source in DFM’s process is a combination of Waste Paper and Paper Mill Waste:

        • Newspaper
        • Office Waste
        • Boxes
        • Waste destined for the landfill

        Raw Material

        Step 1

        The raw material is pulped in a “giant liquidiser” to single fibres. A fibre resembles a human hair between 1mm and 5mm in length.

        Moulding

        Step 2

        The Fibre is diluted to make a mixture of water (99%) and fibre (1%) and pumped into a vat. A plenum, with product moulds mounted on it, passes through this mixture. The liquid pulp is drawn onto the moulds by vacuum and the water is simultaneously extracted, leaving a very soggy, even layer of pulp on the fine stainless steel mesh covering the mould.

        Drying

        Step 3

        The wet product is transferred onto a “canier belt” that transports it through a drier (oven) at extreme heat to dry the product to “touch-dry”. This extreme heat causes the product to undergo considerable shrinkage.

        Afterpress

        Step 4

        The product is then ironed into the perfect shaped by an afterpress, using a combination of heat and extremely high pressure.

        Finished product

        Step 5

        The product is then either fed into a printer for customised logo’s, trademarks and product description or packed for despatch.

        Free Form

        This is the most basic type. The process uses vacuum forming and take-off or transfer moulds, where the mould is an extremely fine wire mesh in the shape of the upper/exposed surface. 

        Prior to the moulding process, the mesh is mated with a vacuum chamber that draws air and moisture through the mesh into the chamber, with the mesh mould suspended above a liquid return pool. The fibrous slurry is sprayed from below onto the mould, and the vacuum draws the slurry tightly against the mesh, filling all gaps and spaces. When airflow through the mesh has been sufficiently blocked, the excess slurry falls into the return pool for recycling, and the mould advances onward to the drying process where it passes though an oven where it is dried out to form the packaging unit. 

        The surfaces are rough on one side and moderately smooth on the opposite side. Product definition is moderate due to the use of relatively inexpensive single-pass moulds and the use of mixed recovered paper and kraft paper slurries.

         

        Form Dried

        This is designed to retain dimensional stability and its shape. The form is deposited from the mould into a female mould which then proceeds through the drying oven.

        The fibrous slurry is pumped into a vat. A plenum, with product moulds mounted on it, passes through this mixture. The liquid pulp is drawn onto the moulds by vacuum and the water is simultaneously extracted, leaving a very soggy, even layer of pulp on the fine stainless steel mesh covering the mould.

        The wet product is transferred onto a “carrier belt” that transports it through a drier (oven) at extreme heat to dry the product to “touch-dry”. This extreme heat causes the product to undergo considerable shrinkage.

        The product is then ironed into the perfect shape by an afterpress, using a combination of heat and extremely high pressure.

        The product is then either fed into a printer for customised logo’s, trademarks and product description or packed for despatch.

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