customshapeable paper packaging adds a tactile distinctiveness to food and nonfood products. now commercialized, freeformpack enables brand owners to create distinctive rigid paper packages with a custom shape or texture in a costeffective formfillseal process.freeformpack is the result of a partnership between swedish paper maker billerudkorsnas and italian machinery manufacturer curti. freeformpacks are produced on the curti pambom formfillseal system using fsccertified fibreform paper from billerudkorsnas.curti&rsquos pambom paper moldingboard molding system runs at speeds from 50 to 100 packages per minute and can macroform or microform the fibreform paper into 3d patterns and designs, even in register to printed graphics. changeovers&mdashtypically done within two hours&mdashcan include different package heights, graphics, diameters, forming and embossing.this is an energyefficient cold forming process no heat is needed. according to gary robinson, director of business development, formable packaging, north & south america, at billerudkorsnas, the fibreform material will 3d form when you apply a force to it and it then keeps that shape. all that&rsquos needed is a malefemale tool and nip point to provide the pressure. robinson describes the machine as &ldquoabout the size of an suv. very compact.&rdquorobinson also says that they have engaged with several brands and clients on freeformpack projects, but cannot identify any specific customers or product lines yet.watch the youtube video introducing freeformpack here.for freeformpack applications, billerudkorsnas starts with a base fibreform material and then builds various polylaminates to create the required barrier properties and sealing features for a brand&rsquos needs. approved for food contact, fibreform is suitable for food markets granulates, powders, tablets and pieces, as well as all nonfood markets. and, although freeformpack is leakfree, the company has chosen not to pursue the liquid beverages market.fibreform is made from 100 virign fiberbiodegradable and recyclable, fibreform is made from 100 virgin fiber. robinson explains why &ldquowe cannot use recycled fiber with freeformpack or fibreform because this is a highly advanced and sophisticated paper that we have developed to deliver these 3dformed shapes. the mechanical attributes that this paper is undergoing are&hellipextreme. that&rsquos where a lot of our patents lie. the ability for us to deliver those characteristics comes from an exceptionally highquality primaryfiber, virgin paper. it has to do with the length of fiber and the fiber characteristics, which you are not ever going to achieve with a recycled fiber because it is too inconsistent and too short.&rdquotalking about mechanical stresses&hellipfibreform is able to withstand &ldquosuper deep microforming,&rdquo robinson says, up to ten times deeper than traditional paper.as with other formfillseal packaging processes, freeformpack generates substantial supply chain savings and benefits. the rollstock takes up less space for shipping and storage, and minimizes material waste on the production line. robinson points out another sustainable advantage freeformpack offers approximately a 70 reduction in carbon footprint versus a comparable preform pet bottle.according to robinson, the company is exploring two options for global implementation 1 having brand owners invest in a pambom forming machine themselves and 2 working with contract packagers that could create freeformpack packages as a service for product manufacturers.&ldquoin different market regions, we&rsquoll see both applications play out. however, we think the best economics come when the brand purchases it direct because you have the savings associated with not shipping all that air and empty bottles. that&rsquos the beauty of freeformpack. it&rsquos formfillseal and you can make it right on your production floor.&rdquo
