PRODUCTION PROCESS

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PRODUCTION

Molded pulp packaging, also referred to as viyol production, is a process of shaping paper pulp using molds specifically designed for each product. The dimensions of many products are more complex than a simple cube. Molded pulp packaging is a material that allows for deep cavities to be created to protect the most fragile corners and protrusions of your product while providing exceptional flexibility.

Product design, mold manufacturing, and the production process are all specialized and require know-how. Various plant pulps such as recycled paper, reed pulp, and sugarcane pulp can be used in molded paper packaging production. Viyol packaging has the capability to process 100% recycled paper as well as virgin paper pulp.

Molded paper packaging production is suitable for medium to high-volume production. Molded paper packaging products are typically gray as a standard but can be produced in different colors when required.

Advantages of Viyol Products

Cost: Due to its structural and design characteristics, molded pulp packaging products have lower unit costs as a natural result of using less material. While the prices of petroleum-based plastic raw materials continue to rise, molded pulp packaging products are made from recycled or virgin paper pulp, which results in relatively stable raw material costs. These products can significantly reduce overall costs by up to 70% when compared to cut cardboard materials, EPS, and similar materials. Additionally, the anti-static properties of paper pulp eliminate the need for electrostatic bags, reducing assembly time and costs. In short, from a cost perspective, molded pulp packaging products are cost-effective and high-performance packaging materials.

Design: Molded pulp packaging products can be processed into different shapes to meet customer requirements. They are ideal for cushioning applications, offering superior protection and performance against damaging factors like vibration and shock in shipping tests. Molded pulp packaging products are durable and flexible. They can be processed to improve surface quality for presentation and come in various colors. When processed with special chemicals, molded paper pulp packaging products are resistant to acid, alkali, water, oil, and leakage. They are also non-toxic. Molded pulp packaging products can absorb excess moisture and are resistant to humidity. They are resistant to repeated shocks and can be thermoformed for a high-quality appearance.

Customization: Molded paper pulp packaging products can be printed with text and embossing. They provide cushioning as well as blocking and bracing. They are used for easily breakable items as well as heavy components. Molded paper packaging products are suitable for automatic packaging processes and are not affected by extreme temperatures.

Storage: It frees up storage space, saving approximately 70% of floor space compared to EPS. When compared to traditional packaging materials like EPS, EPE, and EPP, molded pulp packaging products require minimal storage space as they can be nested and compressed. Reductions in storage volume directly translate into cost savings for storage. Stacking 35 nested molded paper packaging products results in a total height of 119.3 cm, while stacking 35 EPS products results in a total height of 398.7 cm.

Assembly: Molded pulp packaging products have an integrated structure. They are ready to use and easy to handle. Designed as a single piece, they provide convenience both during assembly and when opening the package.

Customer: Molded pulp packaging enhances the direct presentation of items to customers. Because they can be easily disposed of after use, they are well-received by end-users.

APPLICATION AREAS

APLICATION AREAS

The application areas of molded paper pulp (viyol) include the following:

  • Buffer packaging of electrical and electronic appliances
  • Food packaging
  • Flower and fertilizer pots and containers
  • Corner protection for furniture
  • Packaging for bottled materials
  • Single-use containers used in hospitals
  • Various other applications
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Electronic Products

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Bottled Products

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Different Industries

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Plant Pots

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Corner-Edge Protection

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Shoe Industry

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Food Packaging

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Different Aplications

ENVIRONMENTALLY FRIENDLY

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ENVIRONMENT

Molded pulp packaging is environmentally friendly. It complies with ISO 14000 and European Green Dot standards. These are 100% recyclable products. Packaging products made from molded paper pulp do not have a self-flammable structure and are not toxic even after combustion (non-toxic). They are entirely safe.

After disposal of the material or finished product, it can be biologically decomposed by 100% (in line with environmental protection requirements). The recycling costs of molded paper products (Viyol) are very low.

Recycling costs: In Europe, Asia, Latin America, and South America, $0.50 is paid for recycling 1 pound (0.45 kg) of plastic, while $0.05 is paid for recycling 1 pound (0.45 kg) of paper. Plastic users pay 10 times more.

Recycling: Paper and cardboard are recycled at a rate 4 times that of plastic. The biological decomposition of paper takes approximately 2 to 5 months, whereas plastic can take over 500 years to decompose.

Processing 1 ton of waste paper prevents:

  • Cutting down 17 mature pine trees,
  • Wasting 4100 kwh of electricity,
  • Emitting 267 kg of polluting gases into the atmosphere,
  • Wasting 1750 liters of fuel oil,
  • Destroying 85 square meters of forested area,
  • Wasting 26.3 tons of water.

    • Molded paper pulp (Viyol) packaging products are the choice of companies with environmentally conscious.

COMPARISONS and TESTS

COMPARISON OF MOLDED PAPER PACKAGING PRODUCTS WITH EPS IN TERMS OF GENERAL FEATURES

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COMPARISON OF MOLDED PAPER PACKAGING PRODUCTS WITH EPS IN TERMS OF GENERAL FEATURES (Continue...)

TEST RESULTS FOR 14” TV

IT'S CUSHIONING FEATURE IS BETTER THAN EPS.

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DROP TEST RESULTS OF THE TV USING MOLDED PULP PACKAGING PRODUCT



TEN POUND DROP TEST RESULT

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VIVRATION TEST RESULTS



SINE SWEEP VIBRATION TEST RESULTS

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