PulPac develops next‑gen fibre caps

PulPac is pushing fibre innovation into one of packaging’s most technically demanding territories with the development of a new generation of plastic‑like fibre caps.

The move signals a major step forward for brands seeking material‑aligned, circular alternatives to conventional closures.

PulPac’s new fibre‑based versions — created using its dry moulded fibre technology — are designed to match the functional and consumer expectations of plastic, including thread engagement, opening and closing performance, sealing behaviour and tactile feel. Early tests show “promising” results across all key parameters.

The caps will be publicly unveiled at interpack 2026, marking the first time fibre has been demonstrated at scale in such a complex packaging component.

PulPac says the new caps offer high design flexibility, including the ability to differentiate the inside and outside surfaces — opening new opportunities for both functional engineering and brand identity. This level of design control is typically associated with plastics, making the development a significant milestone for fibre‑based packaging.

Early versions have already been produced and tested in real‑life bottle and packaging applications as part of ongoing evaluations with brand owners and packaging partners.

The project is being delivered in collaboration with PA Consulting and Optima, PulPac’s designated machine partner for the segment. It also builds on the company’s work within the Bottle Collective, where complete fibre‑based bottle systems — including closures — are being explored as integrated solutions.

Charlotte Walldal, chief technology officer at PulPac, said the new caps challenge long‑held assumptions about fibre’s capabilities:

“At PulPac, we focus on creating value both in what can be realised today and what comes next in packaging. 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.”

With brand owners under pressure to reduce plastic use and improve material alignment, PulPac’s fibre‑based caps represent a significant new opportunity for packaging portfolios. The development suggests fibre could soon move beyond trays, lids and containers into more complex, high‑precision components — potentially reshaping the future of rigid packaging.