In a significant stride towards sustainable packaging solutions, Campen Machinery has announced that its revolutionary process for creating biodegradable airlaid trays is now patent pending at the PCT level. The breakthrough comes as an answer to the industry’s urgent call for eco-friendly packaging alternatives.

Airlaid technology is a method employed to produce nonwoven materials, traditionally used for hygiene products, napkins, wet wipes and the like. Distinct from the traditional wetlaid process, which is commonly used to manufacture cardboard and paper, the airlaid process disperses fibers, predominantly wood pulp, into an airstream to form a structured web. This web is then bonded, often without the use of water, to generate a highly absorbent material. One of the paramount advantages of airlaid over wetlaid is its capability to produce materials with superior bulk, softness, and absorbency. Furthermore, the dry nature of the airlaid process reduces water consumption, making it an environmentally conscious alternative. This innovative technique paves the way for the creation of diverse, sustainable products, such as Campen’s revolutionary biodegradable trays.

At the heart of this innovation is the company’s state-of-the-art Airlaid Test Center, where not only new machinery but also pioneering processes are brought to life. At the test center, prototypes of the airlaid trays can be made together with the customer, so they can evaluate if the trays align with their expectations.

At the test center, the airlaid material is made according to customer requirements and desired product qualities and subsequently dry moulded in an automatic process. The airlaid material is then transformed into biodegradable trays made from 100% natural fibers, pure cellulose or a balanced blend of cellulose and natural fibers or upcycling fibers, such as straw or waste fibers from e.g. internal cardboard production.

Entirely devoid of plastic, these trays are 100% home compostable, ideal for fruit and vegetable packaging.

“Our aim was always broader than just machinery. Starting 25 years ago, we envisioned a greener, more sustainable future for packaging, and with this airlaid process, we believe we’re taking a giant leap in that direction,” says Jens Erik Thordahl, airlaid specialist at Campen Machinery.

Campen’s approach goes beyond mere innovation. The company is inviting collaborators and businesses to test this unique dry molding process at their Airlaid Test Center. In a display of collaboration over competition, participants are encouraged to bring their own tools and moulding forms.

Thordahl emphasizes: “At Campen, we believe in strengthening the industry through collaboration. Our doors are always open for innovators who share our vision for a sustainable future. We also want to highlight, that we are offering the process and machinery to produce airlaid – the dry moulding can be made with any tools available at our customers. They may also bring their own tools to our test center.”

Apart from offering machinery and processes, Campen also offers their knowledge and experience to their clients as a technical partner.

“For us, it is of importance, that our customers can count on us to not just provide them with machinery, but also with knowledge of airlaid processes,” Thordahl explains. “So, even if customers are new to the world of airlaid technology and drylaid processes, they can trust being in safe hands with us. Additionally, we always work with our clients in complete confidentially and with a signed mutual NDA.”