PaperFoam Packaging

What Is PaperFoam Packaging?

PaperFoam is an innovative biobased, injection-molded packaging material made from industrial starch, cellulose fibers, water, and a proprietary premix. It’s lightweight, protective, home-compostable, and designed to replace plastic inserts, trays, and clamshells in retail packaging.

Despite its name, it’s not actually foam or paper, it’s a natural material with the soft texture of an egg carton and the strength of molded fiber, offering premium product protection without environmental guilt.

How Is It Made?

PaperFoam is created by mixing starch, fibers, and water, which are then injected into custom molds. The packaging is baked at low temperatures until it solidifies into shape. This process uses minimal energy and generates almost zero waste, making it one of the most sustainable molded packaging options available.

The material can be colored naturally and shaped precisely to fit products, just like plastic, but it’s made entirely from renewable, compostable ingredients.

Why Does It Matter?

Traditional plastic inserts are a major contributor to packaging waste. PaperFoam offers the same level of protection with a fraction of the environmental impact, and it breaks down in home compost within weeks. It’s also lighter than molded pulp or plastic, reducing shipping emissions.

For brands looking to elevate their unboxing experience while staying fully aligned with sustainability goals, PaperFoam delivers form, function, and a zero-waste future.

Best Use Case:
Protective trays, custom inserts, and retail clamshells, perfect for electronics, cosmetics, supplements, and eco-conscious premium goods.

Eco-Benefits:

• Made from 100% biobased, renewable ingredients

• Compostable at home and industrially (breaks down in weeks)

• Ultra-low carbon footprint during production

• Lightweight—reduces shipping impact

Printing Capabilities:
Very good. PaperFoam supports debossing, embossing, and screen printing with biodegradable or soy-based inks, allowing for high-end, custom-branded packaging with a low-impact finish.