<p>Polyfluoroalkyl substances (PFAS) have been widely used in food packaging due to their thermal and liquid resistance; however, health and environmental concerns have driven efforts to develop safer alternatives. This study investigates the production of PFAS-free molded pulp trays using a pilot-scale fiber molding system scalable for industrial applications. The process involves vacuum-assisted fiber deposition, membrane prepress dewatering, and hot pressing. Process parameters were first optimized using a formulation of bleached hardwood kraft pulp, bio-based wax, alkyl ketene dimer, and retention aids. This commercial formulation significantly reduced water and oil absorption of the trays as compared with those without bio-wax addition. Subsequently, the effects of pulp type, refining level, and cellulose nanofibril (CNF) addition on tray properties were evaluated under the optimal set of processing parameters, including pre-pressing (10 kN, 18 s) and hot-pressing (17 kN, 220 °C, 16 s), whereas suction time was optimized based on pulp freeness to achieve the targeted weight of trays. Softwood pulps outperformed hardwoods in mechanical and barrier properties, requiring less refining and offering a more energy-efficient path to performative molded fiber. Unbleached softwood pulp demonstrated superior performance under the tested conditions. Unrefined hardwood pulp showed the lowest performance in mechanical and barrier properties, making it the most suitable candidate for refining or reinforcement by CNFs. Preliminary energy analysis showed direct refining was more efficient than CNF reinforcement. Findings provide design and material insights for scalable, PFAS-free production of molded fiber trays.</p>