Faller Packaging and Harvest Packaging: Practical trays for the pharmaceutical industry
Fibre-based trays can replace plastic products in a wide range of applications. This is clearly demonstrated by Faller Packaging and Harvest Packaging with their solution for the pharmaceutical and MedTech industries.
With the new requirements of the Packaging and Packaging Waste Regulation (EU) 2025/40 (PPWR), which is part of the EU Green Deal, the standards for recyclability and material efficiency are set to rise significantly. For pharmaceutical companies, this means that plastic packaging is coming under increasing regulatory and economic pressure. Market expectations are also changing. Nowadays, products must combine environmental benefits with practical, everyday usability.
“Packaging should be sustainable, process-reliable and scalable,” says Niklas Mößner, Head of Business Development & B2B Marketing at Faller Packaging. “This is the foundation for our collaboration with Harvest. We wanted to offer a solution that will prove itself in industrial use, not just on paper.”
A partnership with a clear practical focus
The joint approach is deliberately application-oriented. Each partner contributes their respective strengths and together, they further develop the product continuously. Harvest contributes the technological expertise in the production of the moulded fibre, while Faller Packaging has the necessary know-how for the pharmaceutical packaging.
A key element of the partnership is close communication with customers. At events or during joint projects, feedback is immediately documented and incorporated into the further development of the trays. This results in solutions that prove their worth, not only at the prototype stage, but also in the actual packaging process. “It’s not just about an alternative material, but about packaging that can be integrated into existing processes,” adds Mößner. “That’s why we support our customers along the way, from the initial feasibility study right through to implementation on the production line.”
Precision for demanding applications
The trays are made from responsibly sourced materials. What’s more, they are PFAS-free and fully recyclable. The use of monomaterials further improves sortability in the recycling process. The trays are manufactured using the wet-moulded fibre process. Fibres are processed in moulds and compacted under pressure and heat. In-mould curing ensures dimensional stability and a smooth surface. As a result, the trays deliver a performance that’s comparable to that of plastic solutions. They are suitable for applications in healthcare, such as auto-injectors, pens and diagnostic solutions.
“Our goal was to overcome the typical limitations of traditional moulded fibre,” explains Neil Reilly, founder of Harvest Packaging. “The trays offer the precision, stability and surface quality required for pharmaceutical applications – even with complex geometries.”
Integration into processes
A key challenge with new materials is meeting regulatory requirements and integrating them into existing packaging processes. This is precisely where the joint approach comes in. The trays are specifically designed to be integrated into existing packaging lines with only minimal modification. Features such as reliable de-nesting, low stacking heights and stable geometries facilitate processing on automated production lines. Pilot projects have clearly shown that integration into existing systems is possible. Both Faller Packaging and Harvest Packaging see particular potential in new developments that coordinate the product, packaging and machinery from the outset.
For companies with ambitious sustainability goals, switching to fibre-based trays can help reduce Scope 3 emissions and lower plastic-related levies and EPR charges. “We’re seeing a significant increase in demand for solutions that combine sustainability with industrial scalability,” says Neil Reilly.
For further information about the moulded-fibre trays click here
