Project Overview

We received a consultation from a precision equipment manufacturer for a cushioning tray that combined visual beauty with functionality. Rather than the conventional craft color, they wanted a high-definition pulp mold finished in white.

Packtoss proposed a tray using a wet pulp molding process to achieve a smooth surface, combining the clean, premium feel unique to white. The recesses that hold the product were given rounded shapes to reduce stress on the components.

The Customer’s Challenge

• Wanted an environmentally friendly material that also placed importance on visual beauty
• Wanted a smooth finish that resists scratching or marking the product
• Wanted packaging that conveys a premium feel when opened

Packtoss’s Proposal

We adopted a wet pulp molding process that finishes the surface smoothly, achieving a uniform texture even in white. The rounded recess shapes gently support the components while absorbing vibration and impact.

This design led to the following results.

• Packaging that combines environmental responsibility with a premium feel
• Improved product protection performance through a smooth surface
• Design quality that enhances the unboxing experience

Key Points of This Case

A Smooth Finish Through Wet Pulp Molding

A process that finishes the surface uniformly achieves a premium texture even in white.

Rounded Protective Shapes

The smooth, corner-free recess shape prevents scratches and marks on the components.

Applicable to Precision Equipment and Premium Products in General

This can be applied not only to electronic components but also to cushioning packaging for premium products in general where visual beauty is required.

Differences in Finish by Manufacturing Method

Even with the same white pulp mold, the texture of the front and back surfaces changes significantly depending on the drying method used during molding. Here we introduce the differences between four representative methods: “wet press,” “semi-wet,” “semi-dry,” and “dry press.”

Wet Press: The Smoothest, Most Premium Finish

Wet press, which is molded by high-pressure pressing while still wet, results in a moist, smooth texture with finely compacted fibers on both the front and back surfaces. Embossed logos can also be reproduced sharply, making it ideal for brands that place importance on a premium feel when opening. Because drying requires extra effort, it is the most expensive of the four methods.

Semi-Wet: A Near-Wet Texture at a Lower Cost

Semi-wet is a method positioned between wet press and semi-dry. It uses virgin pulp to achieve a smooth surface close to that of wet press, while simplifying the drying process to keep costs down. It is widely adopted by customers who want a premium feel but cannot afford the budget of wet press.

Semi-Dry: A Decent Finish Using Virgin Pulp

The front surface of semi-dry has a finish nearly equivalent to semi-wet. The photo shows the back surface: it does not have the coarse fiber texture or mesh marks seen in dry press using recycled waste paper, and instead achieves a relatively uniform texture unique to virgin pulp. This method suits customers who want to avoid the rugged texture characteristic of recycled waste paper while still keeping costs down.

Back Surface

Dry Press: A Natural Texture from Recycled Waste Paper

Dry press is made primarily from recycled waste paper, resulting in a natural, rugged texture with fiber unevenness remaining on the surface. The back surface is also characterized by mesh (wire mesh) marks left from the molding process. This method is recommended when cost is the top priority, or when you want to deliberately embrace the material’s natural texture for an eco-friendly package.

Method Comparison Table

Method	Main Raw Material	Surface Texture	Cost Guide	Recommended For
Wet Press	Virgin Pulp	Very smooth (embossing possible)	High	Those seeking the utmost premium feel
Semi-Wet	Virgin Pulp	A smoothness close to wet	Medium to High	Those who value a balance of premium feel and cost
Semi-Dry	Virgin Pulp	White, reasonably smooth	Medium	Those who want to avoid a rugged texture while also keeping costs down
Dry Press	Recycled Waste Paper	A rugged, natural texture	Low	Those who want to prioritize cost and eco-appeal above all

For customers who say “I want to avoid the rugged texture of recycled waste paper, but wet press is difficult on the budget,” we recommend semi-wet or semi-dry, which offer the best of both worlds. We propose the optimal method according to your budget and application, so please feel free to consult us.

← Back to All Case Studies