Custom Moulded Pulp Boxes Shaped Around Your Product

What is a moulded pulp box?

A moulded pulp box starts as paper fibre mixed with water. The wet pulp is drawn onto a shaped mould, pressed, then dried until it is firm. What comes out is a single piece with the shape of the mould pressed into it.

Because the shape is formed rather than folded, it can follow curves and steps that board cannot. A pocket can match a phone, a bottle or a coffee capsule almost exactly.

Our photos show a hinged clamshell holding coffee capsules and a ribbed lidded box in a printed paper sleeve. A third shows a group of smooth white pulp trays and lids. They sit in our packing supplies and protective inserts range.

Which moulded pulp style do I need?

The style depends on whether the pulp is the whole pack or the inside of a larger box.

How do I give you the product size?

Pulp is shaped closely around the product, so accurate sizes matter more here than with a folding box. Measure length, width and height at the widest points, and note any curves, buttons or caps.

Photos help a great deal. Take one from the top, one from the side and one from the end, each with a ruler in view. Our designers use them to plan where pockets, ribs and finger holes go.

If several products share one tray, tell us how you want them arranged. A drawing on paper is fine. Our box measuring guide with diagrams shows the basics.

Natural or white pulp?

Natural pulp is a soft beige or light grey with a gently rough feel. It reads as plain and earthy, which suits coffee, plants and craft goods.

White pulp has a cleaner, smoother look. The white trays and lids in our photos show how close it can come to ceramic or plastic at a glance. It suits skincare, tech and premium gifts where a quiet, neat finish matters.

If you are unsure, think about the sleeve. A kraft or earthy sleeve sits well on natural pulp. A bright, clean sleeve usually looks better over white.

How do I brand a pulp box?

Pulp itself is not a good surface for detailed ink. The usual route is a printed paper sleeve or a band that wraps around the box, as in our ribbed box photo.

We print sleeves and labels in one colour, two colour or full colour CMYK. Matte or gloss lamination, spot UV, foil stamping and embossing are all available on the sleeve. A simple logo can also be pressed into the pulp lid itself. That gives a quiet, raised mark with no ink at all.

Our designers set up the sleeve artwork free and send you a digital proof before anything is made.

What goes wrong with pulp packaging?

The biggest risk is a change to the product after the shape is agreed. Pulp pockets are formed to a set size, and a new bottle or case may not fit. Settle the final product first.

Next, damp. Pulp is paper, so it softens if it stays wet. Keep stock in a dry room, off the floor.

Finally, some buyers expect bright print straight on the pulp. The texture makes fine detail soft, so plan for a sleeve or label instead.

It also helps to tell us where your current packaging fails. If bottles crack at the neck or gadgets scuff at one corner, say so. Our designers can then add a deeper pocket or an extra rib at that point.

Can moulded pulp boxes be posted on their own?

A clamshell or lidded pulp box is sturdy, but its outer surface is textured and marks easily in a sorting centre. For posting, most brands place it inside a plain or printed corrugated outer.

The pulp holds the product, and the outer box takes the knocks and carries the address label. A close fit is best, such as one of our custom mailer boxes made to size. We can size the mailer to the pulp pack so the two arrive together.

Pulp tray or corrugated insert: which is better?

Both hold products in place, but they suit different jobs. A corrugated insert is cut and folded from flat board. It handles straight sides and simple holes well, and it prints sharply.

Moulded pulp follows curves. A round bottle, a phone with a camera bump or a tapered jar sits more snugly in pulp. The fibre also gives a little under impact, which helps with glass.

If your products are boxy and the insert will be printed, a die cut corrugated insert is often simpler. If the shape is curved or fragile, pulp tends to win. Send us photos and we will suggest the better fit.

How do I order moulded pulp boxes?

Prices start from £0.25 per unit, and the written quote confirms the figure for your shape. Send your product sizes, photos, the style you want and the quantity. Use the quote form for moulded pulp, or email info@ordercardboardboxes.co.uk. WhatsApp works too.

We send a free digital proof first. Production runs 4 to 6 business days after approval. The tracked parcel then takes 2 to 3 business days, with free delivery to all UK addresses. Any damage or misprint reported with photos within 10 days is reprinted or refunded.