PulPac has revealed a new generation of ‘plastic-like’ Dry Molded Fiber caps, developed alongside PA Consulting and Optima to replace conventional plastic caps and unlock new branding opportunities.
Considering caps to be one of the most widely used plastic components in everyday packaging, PulPac hopes that designing a fibre-based alternative will unlock a ‘significant opportunity within packaging’.
The new caps are intended to match the functional requirements and consumer expectations of conventional plastics. According to early testing, they perform well across parameters like thread engagement, opening and closing functionality, sealing architectures, and overall tactile experience.
Developed in collaboration with PA Consulting and machine partner Optima, the caps are set to align with increasing interest from across the value chain to experiment with fibre-based alternatives, including closures, in pursuit of improved material alignment and circularity.
Additionally, the caps are set to offer design flexibility. This includes differentiating between the outside and the inside of the cap, which is expected to offer brands a new surface area for branding.
Early versions of the caps are currently undergoing bottle and packaging evaluations and have already been tested in real-life environments, PulPac says. The caps will also be on display at PulPac’s and Optima’s booths at interpack 2026.
“At PulPac, we focus on creating value both in what can be realized today and what comes next in packaging,” says Charlotte Walldal, chief technology officer at PulPac. “Advancing fibre-based caps is a natural step in that journey.
“When we show the cap to customers, the reaction says a lot. The first response is often disbelief that they’re made from fibre.
“The look, the sound when you tap it against a tabletop, and especially the tactile feel challenge expectations of what fibre can be. It’s unexpected and something you need to experience firsthand to fully understand.”
PulPac also emphasizes its ongoing work within the Bottle Collective initiative, in which complete fibre-based bottle systems – including closures – are explored and evaluated as integrated solutions.
In similar news, Blue Ocean Closures took home the top prize under the Recyclable Packaging category at last year’s Sustainability Awards. Reportedly, the closure is certified recyclable as paper, supports recycling performance, and is currently on the market for neutraceutical products.
Additionally, PulPac recently partnered with SIG to establish a development programme and manufacture Dry Molded Fiber closures for SIG’s aseptic cartons.
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