IN Brief:
- Z1RO's bamboo, hemp and fallen-leaf materials were processed on Kiefel's NATUREFORMER KFT Lab in Freilassing, Germany.
- The trials produced moulded trays and coffee lids, demonstrating compatibility with the equipment under the conditions tested.
- Z1RO is seeking €500,000 for industrial scale-up, while food-contact suitability and commercial production performance remain unverified.
Z1RO and German machinery manufacturer Kiefel have completed equipment trials using bamboo, hemp and fallen leaves to produce moulded fibre packaging. The materials were processed on a NATUREFORMER KFT Lab system at Kiefel’s Customer Innovation Center in Freilassing, where the companies formed trays and coffee lids to investigate compatibility with established wet fibre moulding technology.
The trials tested whether different non-wood feedstocks could be converted into finished shapes on existing equipment. Z1RO develops packaging materials from alternative plant fibres and underused biomass, while Kiefel supplies forming machinery for fibre-based packaging. The completed samples provide evidence of processing feasibility, although the companies have not disclosed commercial production rates, rejection levels or comparative mechanical performance.
Each of the three feedstocks produced parts with different visual and tactile characteristics. These differences reflect the materials’ composition and their behaviour during forming, as well as the characteristics sought by Z1RO for its packaging products. The companies have not established that any one feedstock offers superior barrier performance, durability or food-contact suitability.
Wet moulded fibre production begins with the preparation of a water-based suspension containing the fibres to be formed. The material is drawn onto a shaped tool using vacuum, which causes fibres to accumulate against its filtering surface while water passes through. The resulting wet structure must then be consolidated and dried sufficiently to retain the intended geometry.
Kiefel’s NATUREFORMER process uses forming and pressing operations to develop the shape and remove water from the material. A cold prepressing stage reduces moisture before further processing, while subsequent heating and pressing contribute to the finished part’s dimensional accuracy and surface characteristics. The arrangement differs from simply pressing dry plant material into shape, because fibre distribution takes place while the feedstock is suspended in water.
The behaviour of individual fibres influences the process. Fibre length, flexibility, surface chemistry and the presence of non-fibrous material can affect the formation of a consistent layer on the tool. The amount of water retained after initial forming also influences subsequent pressing and drying requirements. Feedstocks with differing characteristics may therefore require adjustments to the suspension, forming conditions or tool configuration.
Fallen leaves, bamboo and hemp are not interchangeable industrial raw materials. Their composition varies, as can the extent of cleaning and preparation required before they enter a fibre-forming process. Consistent manufacturing would require control over those differences, including variation between sources and batches. The October trials establish that samples could be formed, but do not demonstrate that every available grade of the materials can be processed under identical conditions.
The NATUREFORMER KFT Lab is designed for research, product development and sample production. According to Kiefel’s published specifications, it has a maximum forming area of 300 × 200 mm, can accommodate parts up to 130 mm high and provides a pressing force of 26 kN. Its tooling can be configured with one or more cavities, depending on the product being developed.
These specifications describe the laboratory system rather than the operating conditions achieved during the Z1RO trials. The companies have not disclosed how many samples were formed per cycle, the material concentration in the suspension or the temperature and pressure settings used for the three feedstocks. Consequently, the trial results cannot be converted into a verified production throughput.
Kiefel also offers machinery intended for series production. Its larger NATUREFORMER KFT 90.1 has a maximum forming area of 900 × 700 mm and a pressing force of 450 kN, according to the manufacturer’s specifications. The larger equipment provides a possible route for industrial development, but the companies have not reported that the three Z1RO feedstocks have already been qualified for commercial operation on that machine.
Scaling the process will require further assessment of material preparation, water handling, forming consistency and energy requirements. Equipment operating continuously must maintain reliable part dimensions and material distribution over repeated cycles, while the supply of prepared fibre must be sufficient and consistent. The behaviour observed during laboratory sample production does not automatically establish performance at the larger forming area or operating duty of a production system.
Z1RO currently identifies protective and presentation trays for cosmetics, consumer electronics and premium products among its target applications. The formed coffee lids create a possible route into foodservice packaging, although the successful production of a lid-shaped component does not establish its suitability for contact with hot beverages.
Foodservice qualification would need to address the intended contact conditions and the performance of the finished material. A coffee lid must retain its shape when fitted to a cup and handled during use, while its composition must be suitable for the relevant food-contact application. Exposure to heat, moisture and liquid can also change the properties of moulded fibre, depending on its formulation and any additional treatment.
Similar considerations apply to trays intended for food packaging. Dry products may require different protection from moist or greasy foods, while particular applications could need functional barriers or additional processing. The October report does not identify completed migration testing, moisture resistance measurements or food-contact certification for the new Z1RO and Kiefel samples.
Material recovery presents a separate technical requirement. Non-wood fibres may be suitable for recycling or biological treatment under particular conditions, but those outcomes depend on the complete packaging composition and the collection and treatment infrastructure available. Neither the renewable origin of the fibres nor their successful conversion into formed parts is sufficient evidence of a particular end-of-life outcome.
Z1RO founder Alexander Sobolenko has described the company’s objective as developing packaging from locally available biomass, while Kiefel product manager Michael Seeboeck has identified the importance of testing new fibres on established forming equipment. Their collaboration concentrates on the relationship between the material formulation and the machinery required to process it.
The company is seeking €500,000 to support industrial scale-up and further commercial packaging projects. The funding is a stated fundraising objective, not investment already secured. Z1RO has invited packaging manufacturers and brands to investigate additional development opportunities, but has not identified a confirmed food manufacturer purchasing the products at commercial scale.
The Freilassing trials demonstrate that three alternative plant fibre sources can be converted into moulded samples using Kiefel’s laboratory equipment. Further trials will need to establish continuous production performance, material consistency and the properties of finished parts under intended use conditions. Coffee lids offer a potential foodservice application, but food-contact qualification and commercial manufacturing performance remain outstanding.
