At Zenpack, one of our favorite challenges is examining a plastic-based product to determine if it is possible to design a paper-based counterpart. While plastic is an incredibly effective and reliable material, we can no longer sacrifice human health and the environment for petroleum-based products. Together with Scilutions Labware, we tapped into our packaging expertise to create PulpFixin, a line of paper-based labware designed to seamlessly replace their polypropylene and polycarbonate counterparts. Laboratories worldwide rely heavily on single-use plastic components, many of which have extremely short lifecycles and are discarded almost immediately after use. It’s estimated that biological, medical, and agricultural research alone produces approximately 5.5 million tons of plastic waste annually. This widespread use contributes significantly to global plastic pollution and the growing microplastic crisis. PulpFixin was created as a practical, scalable response to this challenge. By replacing single-use plastic with responsibly sourced paper-based materials, PulpFixin aims to cut down on microplastic pollution while offering products that are recyclable and compostable. PulpFixin’s core product line includes tube racks, pipette tip trays, and cryogenic storage boxes. These components directly replace conventional plastic labware but are constructed entirely from layered paper-based materials. Laboratory technicians require precise instruments for their research. These include tube racks, small boxes with circular inserts specially designed to hold specimen tubes filled with blood, saliva, and other liquids. The racks rotate between automated liquid handling systems, cappers, de-cappers, and refrigerated storage containers. Researchers handle thousands of tubes per day, so the racks need to be durable and able to withstand extreme temperatures. The industry tells us that plastic is the perfect material for the task. But history and our experience tell us that paper is the better option. We knew that the right combination of paper materials could perform to industry standards—we needed time and space to experiment. Zenpack structural engineers studied dozens of plastic racks and then designed and produced prototypes for testing. We sent the prototypes to Scilutions, who would test them on their in-house lab equipment. They sent feedback, we made minor adjustments, and this cycle continued for months resulting in the first fully functional 24-tube AutoRack. We scaled the design up to 48-tube and 96-tube, along with capper and de-capper adapters, pipette tip trays, and cryogenic storage boxes. The packaging is made using precision die-cutting and laser cutting techniques for accuracy and minimal waste. Laser cutting allows for detailed, clean cuts—particularly useful for complex geometries—while die-cutting supports high-speed production of standardized parts. After cutting, each component enters a carefully controlled alignment and assembly process, where parts are positioned and joined with exacting precision. This step is critical for ensuring that products meet tight tolerances and remain fully compatible with automated lab systems. The labware is made from paperboard, corrugated board, greyboard, and kraft paper—each chosen for its strength, structural integrity, and moisture resistance. These products directly replace conventional plastic labware but are constructed entirely from layered paper-based materials. The labware does use a small amount of glue; however, tab-locking and structural folding mechanisms eliminate the need for additional bonding agents. This approach not only enhances strength and integrity but also streamlines recyclability. Despite the material shift, the packaging products match the precision, temperature stability, and structural performance of traditional lab plastics to meet or exceed the critical standards of research and clinical environments. All PulpFixin designs are now ANSI SLAS 1-2004 compatible with automated liquid handling systems, cappers, de-cappers, and 2D barcode scanners. Industry leaders in the testing, pharmaceutical, and clinical space now use PulpFixin. They report that PulpFixin labware performs seamlessly alongside plastic labware, without the environmental cost. Now that the proof is in the paper, PulpFixin will continue creating sustainable solutions for the scientific community. Once used, the labware is considered “regulated medical waste” because sample tubes held by PulpFixin AutoRacks contain blood and other bio-contaminated materials that can spill onto the racks. For the health and safety of users and the general public, regulated medical waste is treated using two primary methods: autoclaving and incineration. In autoclaving, the waste is treated to a high-pressure, high-temperature steaming process to neutralize infectious agents so that the waste can enter the landfill or recycling center. Regulated medical waste containing highly dangerous agents is incinerated. In both processes, PulpFixin labware significantly reduces the amount of plastic waste that can leach into soil, waterways, or the atmosphere. For example, if a PulpFixin AutoRack is autoclaved, it is then sent to either a landfill, where it will decompose at the same rate of similar paper-based packaging, or a recycling center to be recycled with other paper-based packaging. If the AutoRack is incinerated, it releases a minuscule amount of harmful chemicals compared to its plastic-based counterpart. A full line of PulpFixin labware is now available to the scientific community, and Scilutions has plans to expand the line with additional paper-based options. Leading research labs are now working with Scilutions to create custom AutoRacks. In May of 2025, the company was honored with the New Product Award at the Society for Laboratory Automation and Screening (SLAS) conference. A few months later, Pentawards recognized the packaging in their 2025 Shortlist in the Sustainable Design category.
PulpFixin Labware
The world’s first paper-based labware
The Problem
The Outcome
Challenges
Solution
Result
