This article provides a concise insight into the thermoforming of airlaid CTMP pulp. First, the airlaid process was studied, showing that fiber fractionation and the retention of fines occurred in the forming head. Then, the effect of temperature and pressure during thermoforming was investigated. Harsher conditions, i.e. higher temperature and pressure, yielded greater densification of the substrate and higher tensile strength. The maximum strength was found at the highest settings tested, that is, 100 MPa and 200°C. The screening of thermoforming conditions was also compared to previously published results on wetforming. Next, the effect of softwood CTMP pulp was delineated, which on average showed the best mechanical properties at elevated freeness and high degrees of bleaching. At last, a comparison between dry forming and wetforming was made for one selected pulp quality. Here, the dryformed substrates were stiffer at low elongation, yet the wetformed substrates yielded a greater extensibility and higher tensile strength. In conclusion, dryformed pulp mostly relies on temperature and pressure for bond formation during thermoforming, which produces materials that are distinctly different from wetformed molded pulp.
The research in this article was conducted as part of the project “TEFFI – Termoformede fiberprodukter for funksjonell og bærekraftig emballering av ferske matvarer”, grant number 309727. BEWI Norplast AS is acknowledged for supporting the project and MM FollaCell AS for providing the different pulps. The authors gratefully acknowledge the funding from the Research Council of Norway