The work aims to systematically review the technical pathways and industrial value of replacing traditional EPS foam with molded pulp materials for the development of inner cushioning pads in dairy product packaging, in response to the ongoing global plastic restriction directives and increasing consumer environmental awareness, and provide a theoretical basis for upgrading dairy packaging towards greener and higher-end solutions. Focusing on the category of transport cushioning packaging in ordinary industrial packaging, by synthesizing studies on the microstructural characteristics of plant fibers and process parameters of molding, the formation mechanisms of the mechanical properties of molded pulp materials were analyzed. Structural design concepts, including nested inner-outer structures, optimized rib layouts, and cup-shaped cavity cushioning mechanisms, were summarized to propose a series of cushioning pad configurations that met the positioning and protection requirements of dairy products. A comprehensive evaluation was conducted regarding material properties, structural efficiency, and cost-effectiveness. Existing literature indicated that molded pulp exhibited outstanding lightweight properties (density 0.3-0.8 g/cm³), foldability (saving >40% in storage space), and cushioning performance (energy absorption coefficient 0.65-0.75). Compared with EPS foam, molded pulp offered irreplaceable advantages in positioning complex-shaped products, enhancing brand value, and improving consumer experience. Additionally, it could reduce procurement costs by 15%-25% and held potential for establishing intellectual property barriers. The comprehensive analysis concludes that molded pulp cushioning pads can effectively replace EPS foam to meet environmental compliance requirements, while creating comprehensive competitive advantages for enterprises in terms of storage efficiency, cost control, and brand differentiation. Thus, they can drive the green and high-end transformation and upgrading of the dairy packaging industry.
Key words
dairy packaging /
molded pulp /
cushioning pad /
EPS substitution /
structural design /
sustainable packaging
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