FALKO

The shape variety of conventional paper-based packaging is limited by the constraints of traditional forming methods such as winding, folding, and bending. An innovative alternative is Dry Molding, in which a thick fiber fleece is thermo-mechanically pressed into a mold. The achievable forming depth depends strongly on the fleece’s thickness and internal network properties. In contrast, compression drawing of paperboard materials enables high forming degrees with relatively low material consumption. However, due to the material’s limited flow capacity, excess material tends to accumulate as characteristic wrinkling, which complicates downstream processes such as printing or coating.

The combination of fiber fleece materials with compression drawing technology offers significant advantages: high forming degrees, improved surface quality, and moderate material usage. The porous structure of formable fleece allows local fiber-to-fiber displacement, accommodating deformation without immediate wrinkling. Although this reduces material strength, it delays the appearance of visible wrinkles to higher forming levels.

This research project investigates the interactions between fleece structure, pore volume, material conditioning, and process parameters. Based on these findings, we will develop a robust, wrinkle-free forming process for fiber fleece from renewable raw materials, offering clear benefits for industrial use:

1. High forming degrees and shape variety
2. Excellent surface quality, compatible with printing and coating
3. Efficient use of natural materials
4. Economic advantages, especially for SMEs in the packaging and food industries