Valmet has launched Valmet 3D Fiber, a new technology designed to help packaging producers manufacture lightweight three-dimensional food packaging from cellulose fibres. Developed in collaboration with Metsä Spring, the process is positioned as a high-capacity alternative for producing fibre-based trays, plates and other food packaging formats as demand grows for renewable materials and plastic reduction.

The launch comes at a time when foodservice, fresh food and ready-meal packaging are under increasing pressure to move away from fossil-based plastics and difficult-to-recycle formats. Moulded fibre has become one of the most closely watched areas of packaging innovation because it can offer rigidity, tactile appeal and compatibility with fibre-based recycling systems, while using renewable raw materials.

Valmet 3D Fiber is described as a fast and efficient process that enables the circulation of side streams and trim waste back into production. This is important because resource efficiency is now a central measure of packaging performance. A material may be renewable, but the production process must also minimise waste, energy use and unnecessary fibre losses to deliver meaningful environmental benefits.

The next generation of fibre packaging will be judged not only by material origin, but by production speed, waste recovery, functional performance and scalability.

The technology combines fibre layering, automation and production capacity to create demanding three-dimensional structures. According to Valmet, this allows customers to develop food packaging solutions that are lightweight but still suitable for practical use. For applications such as trays and plates, the pack must maintain shape, protect the product, handle moisture or grease exposure where required, and run efficiently through converting and packing operations.

Compared with some wet moulded fibre alternatives, Valmet expects the 3D Fiber platform to offer wider market opportunities. This suggests a focus not only on sustainability, but also on industrial productivity and design flexibility. Packaging producers need technologies that can compete commercially with established plastic and paperboard formats, especially in high-volume food packaging categories.

Juho Pyrrö, head of Valmet 3D Fiber, said the strength of the technology lies in combining unique fibre layering, production capacity and automation. He noted that the platform enables customers to develop demanding three-dimensional packaging while maintaining high productivity and resource efficiency.

The collaboration with Metsä Spring also reflects the importance of partnerships in fibre-based packaging development. Bringing new materials and forming technologies to market requires expertise in fibre science, paper process engineering, automation, converting and end-use performance. No single part of the value chain can solve the transition alone.

• Renewable materials: cellulose fibres provide a lower-plastic route for food packaging applications.
• Process efficiency: side streams and trim waste can be circulated within production.
• Scalability: high-capacity technology supports commercial adoption beyond niche applications.

For packaging producers, the commercial opportunity is significant. Retailers, foodservice operators and brand owners are looking for alternatives to plastic trays, plates and single-use food containers. Fibre-based formats that combine functionality with strong sustainability credentials can help companies respond to regulation, consumer expectations and corporate packaging targets.

Valmet’s broader packaging strategy is also visible in the launch. The company has long experience in paper, board and process technologies, and is increasingly applying that knowledge to packaging innovation. By adding automation and end-to-end process capability, Valmet aims to help customers strengthen market position while accelerating the shift toward fibre-based packaging.

The launch follows other Valmet developments, including its IQ Virtual Sensor software for paper and board mills, designed to support consistent quality, lower fibre and starch costs, reduce energy consumption and improve production efficiency. Together, these technologies show how digital control and fibre innovation are becoming increasingly connected in modern packaging manufacturing.

The moulded fibre market is also becoming more diverse. Other companies are exploring lignocellulosic feedstocks such as agricultural residues, bamboo, hemp hurds and fallen leaves to create packaging with functional and premium tactile qualities. Valmet’s cellulose-based platform enters this growing field with an emphasis on industrial scale, automation and process reliability.

Valmet 3D Fiber therefore represents more than a new forming technology. It reflects a wider shift toward fibre packaging systems that must be renewable, efficient, scalable and suitable for demanding food applications. As brands seek practical alternatives to plastic, technologies that can combine performance with high-volume production will be essential to the next phase of sustainable packaging growth.

Image concept: a modern fibre-based packaging production line showing cellulose fibres being formed into lightweight three-dimensional trays and plates, with automated handling, recycled trim waste loops and finished food packaging samples.