1. Discovery & Technical Brief
Every project begins with a detailed technical discussion. We assess product dimensions, weight, protection requirements, shelf-life considerations, line speed, automation constraints and regulatory targets. This early-stage collaboration ensures fibre geometry, wall thickness and material formulation are aligned with the real application; not retrofitted later.
2. Budget alignment & feasibility
Once a technical brief is agreed upon we work on feasibility and budget alignment. Tooling investment, unit cost targets, expected volumes and production assumptions are reviewed in detail. This stage ensures all parties have clarity on commercial expectations before further development proceeds.
3. Draft concepts & early design
After budget alignment is agreed, our team produces initial draft concepts and design proposals. These early designs explore geometry, stacking behaviour, nesting depth and material distribution, allowing performance trade-offs to be evaluated before committing to tooling. At this stage, concepts remain flexible, enabling rapid iteration.
4. Technical drawing & CAD development
Following agreement on concepts, detailed technical drawings and CAD models are created. These drawings define precise dimensions, tolerances, draft angles, radii and stack heights—critical factors in thermoformed moulded fibre performance. Designs are engineered specifically for repeatability, consistency and manufacturability at scale.
5. Custom sample creation
Custom samples can then be produced to validate form, fit and function. These samples allow physical evaluation of strength, surface quality, stacking behaviour and compatibility with downstream processes such as top-sealing or lidding. Feedback at this stage is used to refine designs prior to tooling manufacture.
6. Production tooling manufacturing
Once designs are finalised and approved, production tooling is manufactured. PulpVision manages the tooling process to ensure accuracy, durability and performance consistency. Tooling is engineered for long production runs, tight tolerances and stable output, essential for replacing plastic formats reliably.
7. Scale-up & ongoing optimisation
Following tooling validation, products move into full production. We continue to support customers through scale-up, monitoring performance and identifying opportunities for optimisation in material usage, cycle times and packaging efficiency.
