Sustainable, Environmentally Friendly Protective Packaging

Made from 100% residual agriculture product such as sugarcane (as known as bagasse) and recycled paper, molded fiber/molded pulp is a cost effective and environmentally friendly packaging solution that reduces packing labor and require less storage space while providing superior protection at every stage of the supply chain.

The inherent flexibility of molded fiber offers substantial cushioning qualities and the “geometry” that we incorporate into each design lends strength to each part. Sydney Bio Packaging can deliver innovative, environmentally-friendly, sustainable, protective packaging solutions for consumer goods, electronics, and industrial products to customers across Australia.


Sydney Bio Packaging takes pride in helping your company fulfill its vision. Initially our business was focused on supplying food packaging, due to customer demand we have expand our fiber based packaging offering to the following markets:


For our customers in the electronics industry Sydney Bio Packaging provides highly engineered molded fiber protective packaging for computers, cell phones, and other electronic devices.


Sydney Bio Packaging specialises in designing and manufacturing molded fiber packaging for beverages including fragile items such as wine and glass bottles.


We specialise in creating shelf and retail ready molded fiber packaging solutions for consumer products with fine, smooth finishes as well as color options and embossing to help you differentiate your products in a competitive retail setting.


Sydney Bio Packaging’s candle packs, made from 100% recyclable molded fiber material are ideal for protecting jarred candles in shipping.


Stackable and nestable molded fiber trays are ideal for lightweight industrial products, such as plumbing fixtures, as they reduce shipping costs and protect delicate surfaces.

Medical & Scientific

Sydney Bio Packaging’s 100% recycled molded pulp packaging has proven to be an excellent protective packaging medium for the medical & scientific market. We have the ability to make gray, white, and pressed products with the manufacturing and design capabilities to meet the stringent needs of the medical & scientific industry.


Thermoformed (Thin-Walled) Molded Packaging

Thermoformed (Wet molded) packaging is quite smooth on one side and gives appearance of plastic and the second side also smoother with or without grid texture.  Usually has the wall thickness of between 0.8mm – 1.2mm.

It is usually designed mainly for making insert & inner tray packaging. The products not only with very smooth surface and finish that enhance your brand values, but superior packaging performance, protection, cushioning, nesting and stacking capabilities, saving space, assemble and transports cost.As these products are designed for direct contact with food, the input material is always virgin pulp made of residual agricultural products such sugarcane fiber (as known as bagasse), bamboo fiber, wood pulp, recycled paper pulp and other natural plant fiber.

Transfer Molded Packaging

Transfer or Semi Wet molded packaging is smooth on one side and other side will be less smooth compared to thermoformed molded packaging. The second side is relatively rough in nature.  Usually has the wall  thickness between 0.8mm – 2.0mm.

It is usually designed mainly for manufacturing trays in complex shapes or if a higher emphasis is placed on the surface quality. During the production process the wet trays are hot pressed to smooth the surface. Such trays are mainly used for premium electronics, the cosmetics or car industry or components in complex shapes or those that are small.

The input material is mainly pure pulp made of residual agricultural products such sugarcane fiber (as known as bagasse), bamboo fiber,
wood pulp, recycled paper pulp and other natural plant fiber.

Thick-Walled Molded Packaging

Thick or  Dry walled molded packaging is relatively smooth on one side while the other is rougher. Usually has the wall thickness between 2.0mm -7.0mm.

It is usually designed to protect industrial packages such as packaging for furniture, steel components, machine parts, engine parts, electronics, agriculture, etc.

The primary input material is made from 100% bio-degradable & compostable materials such as recycled cardboard, newspapers, tissues or combinations of these. It is also possible to use pulp made of residual agricultural products such sugarcane fiber (as known as bagasse), bamboo fiber, wood pulp, recycled paper pulp and other natural plant fiber




After all input data have been defined, a simple sketch of a tray is drawn. This serves to the initial price calculation and shows the basic packaging principle.

3D design

The second preparatory step is the set-up of a full-size 3D model. For the set-up of the 3D model we need that the customer would provide us with real samples or models of the product to be packaged.

Final product

The final step of the preparatory process is the manufacture of a sample mold and subsequent manufacture of a real sample. Samples are used for the verification of real shapes and for the drop tests. Material used for the manufacture of the samples is of the quality identical with that for the standard production.

Features and Benefits of Molded Fiber Packaging 

Molded fiber is cost competitiveHelps reduce packaging costs
Material is strong, yet flexibleProvides excellent product protection
Molded fiber packaging nests and stacks easilyEfficient use of shipping and storage space
Molded fiber comes ready to use with no assembly neededReduces labor required for packaging end product
Made from recycled material and is recyclableAn environmentally friendly protective package
Tools are precision machined from aluminum or plasticBetter precision in manufacturing, tools last longer
Experienced designersGood designs can improve performance and cut costs
Most capacity in the industryEconomies of scale can help reduce overall costs

 Packaging Material Comparison

FeatureMolded FiberCorrugated FiberboardThermoformed
Polystyrene (EPS)
Shipping & storage efficiencyNests wellStores flatNests wellNo nesting
Project development time4-6 weeks2-3 weeks4-6 weeks4-6 weeks
Assembly & handlingNo assembly requiredAssembly requiredNo assembly requiredNo assembly required
EnvironmentalRecycled and recyclableSome recycled contentSome recycled contentClaims to be but not practical

When Molded Fiber Is Not A Fit

There are several other criteria that would tend to challenge the use of molded fiber as a packaging medium, including:

  • If the product cannot be exposed to fiber particles
  • Electrostatic discharge (ESD): Molded fiber cannot be used in an environment that is susceptible to ESD.