Compression moulding tool and method for manufacturing a fibrous pulp tray using the tool

A method for manufacturing a fibrous pulp tray comprising:

• depositing a fibrous pulp suspension in a first female mould element having a floor and sidewalls, the female mould comprising a plurality of first recessed portions, each first recessed portion having a first volume, and a water permeable filter configured to retain pulp fibers arranged in in the first female mould element and configured to follow the surface of the first female mould element;
• pressing a male mould element against the first female mould element to dewater the fibrous pulp suspension such that a fibrous pulp product is formed therebetween and such that fibrous pulp fills the plurality of first recessions, the male mould element having a surface profile free from macroscopic features at locations corresponding to the first recessed portions of the female mould;
• moving the fibrous pulp product from the first female mould element to a second female mould element, the second female mould element having a floor and sidewalls corresponding to the first female mould element, the second female mould comprising a plurality of second recessed portions at locations corresponding to the first recessed portions of the first female mould element, each second recessed portion having a second volume smaller than the first volume;
• pressing the male mould element against the second female mould element such that a fibrous pulp product is formed therebetween and such that the fibrous pulp product fills the plurality of second recessions, thereby forming a fibrous pulp product having a floor, sidewalls and protrusions corresponding to the second recessed portions of the second female mould element.