A wood substitute packaging material was prepared through the breaking, molding and drying of the wood processing residues of fast-growing poplar with its physical and mechanical properties analyzed. Samples of different wood substitute packaging materials were produced via the orthogonal design method, and the influences of different process parameters on wood substitute material’s physical and mechanical properties were analyzed by the range analysis method. The results of the tests indicated the optimal properties of wood substitute packaging material as the hot-processing temperature being 120～125 ℃, the hot-processing time being 10 min, the hot-processing pressure being 10 MPa and sizing amount being 10%. Under this condition, the MOR, inner bonding strength, thickness swelling rate of water absorption and density of the prepared material were 17.7 MPa, 1.61 MPa, 6.1% and 0.73 g/cm3 respectively. The prepared wood residue packaging products satisfied the requirements of national standard (GB/T4897—1992) and met the standards of green packaging materials.