Moulded pulp fibers for disposable food packaging: A state-of-the-art review

The paper provides a comprehensive review of moulded pulp production, properties and advantages over single-use plastics and bioplastics for food packaging. Bagasse, wheat and bamboo are replacing wood as the fiber sources due to their cost effectiveness, wide availability and rapid renewability. Non-wood pulping and thermoforming processes have also advanced greatly which lead to improved fiber recovery, production efficiency and product quality. Challenges include lengthy production cycles, high chemical and energy uses, competition from bioplastics, and presence of toxic per-and poly-fluoroalkyl substances (PFAS). The industry is evolving rapidly to overcome these challenges including new laminated dry thermoforming processes, natural additives, customized fiber mixes, and PFAS-free products. Life-cycle assessments and provision of clear, viable green waste and recycling pathways relative to plastic alternatives are still needed to establish and maintain the competitiveness of cellulosic bioproducts with plastics. Critical research areas are proposed.