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Molded fiber has emerged as a promising solution in the world of sustainable packaging. This versatile material, produced from cellulose fibers, offers an eco-friendly alternative to plastics and other petroleum-derived materials.
Sweden and Finland have been at the forefront of using molded fiber for disposable utensils and food packaging, leveraging their extensive forest resources. In the United States and Western Europe, it’s widely used for egg and fruit packaging, while in Japan, it’s common in electronic product packaging.
In late 2024, The Navigator Company took a groundbreaking step in innovation and sustainability. The Semapa Group subsidiary opened a molded fiber packaging production unit in Aveiro, Portugal, becoming the world’s first to produce such packaging in a vertically integrated facility using eucalyptus fiber. This innovation was the result of collaboration between Raiz, Navigator’s R&D center, and three Portuguese universities.
With an annual production capacity of about 100 million packages, the unit is currently Europe’s largest. This initiative not only showcases Portuguese industry’s innovative potential but also underscores Navigator’s commitment to sustainability and the circular economy.
Luis Rodiles, director of the new molded fiber division for rigid packaging, shared insights about the unit’s operations. “By the first quarter of 2025, we’ll be running continuously and will have doubled our industrial workforce to 32 employees,” he explained.
The initial production focuses on three food sector product lines: tableware, take-away containers, and packaging for fresh food and ready meals. These fully recyclable and/or compostable solutions offer a viable alternative to single-use plastics.
A standout feature of Navigator’s packaging is its use of eucalyptus fiber (Eucalyptus globulus), a global first. Traditionally, long-fiber species were thought to be more suitable for molded products. However, extensive testing revealed that eucalyptus pulp provides the necessary flexibility and strength, while offering a smoother finish and softer touch.
Luis Rodiles highlighted an important aspect of their packaging: “For products like raw protein (meat or fish) and ready meals, we apply a plastic film lamination. This crucial step creates an oxygen barrier, ensuring food preservation in industrial packaging environments.”
Navigator is initially targeting nearby European markets, a strategy that reduces transport-related greenhouse gas emissions and ensures stricter quality control and compliance with EU regulations. The new molded fiber packaging can withstand temperatures up to 90 degrees Celsius (194°F) and resists moisture, making it a truly sustainable alternative to traditional plastics. While not designed for washing, these packages can briefly contact water without deteriorating, opening possibilities for a wider range of future applications.
Navigator’s initiative marks a significant milestone in the transition to more sustainable packaging. By leveraging local resources and developing cutting-edge technologies, the company is driving transformation in the packaging sector.
This innovation not only positions Portugal as a leader in sustainable packaging production but also demonstrates the circular bioeconomy’s potential to create solutions that meet both market needs and environmental demands. As global focus intensifies on reducing single-use plastics, Navigator’s molded fiber packaging offers a promising outlook for a more sustainable future in the packaging industry.