From pulp to Roll
We start in the cellulose hall. This is where the cellulose is placed on the conveyor belt, together with other ingredients and additives. We import the cellulose (wood, cotton, maize, bamboo, to name a few) mainly from Scandinavia, Portugal and Canada. We use only cellulose from areas where new trees are planted after logging. Cellulose is the basic ingredient for paper. Other additives that occur in the paper recipe are broke (discarded paper from our own mill), chalk, clay and glue (mostly potato starch).
In the pulper, we first add water to obtain a good stock, and then colouring agents. The colour is checked to ensure that it’s exactly the same as the recipe. The pulp is then sprayed in liquid form onto the wire of one of the five paper machines, to form a mat.
98% Water: the very beginning
At the ‘wet end’ of the machine, the mat still consists of 98% water and 2% fibres. Gravity and heat ensure that the percentage of water is reduced. Immediately after the dandy roll (which applies any watermarks and laid lines) you can see the paper clearly change colour. This is where the drying stage begins. In this phase of the process, the mat is approximately 70% dry. Further drying is caused by a combination of the pressure and speed of the dry cillinders and heat.
These three aspects are increased the further you proceed in the process. It’s a process that requires very careful adjustment because if it goes slightly too quickly or too harshly, the paper mat will break. So it’s a question of craftsmanship. The paper mat then runs through the size press. Here a layer of glue is applied to the paper to make it better to write and print on. At the end of the machine, the paper is rolled onto a mother reel.
Embossed, cut and calendere
After this, the paper may undergo a number of surface treatments, such as calendaring to make the paper smoother, for example. Or it may be embossed to produce one of many surface textures such as linen, leather, ostrich, stream, picot or hammered. Following this, the rolls are cut to the desired width. We can also cut paper to smaller sizes. Finally, the paper is packed.
Research & Development
Our central Research and Development department works with Marketing and Sales to develop new papers on the basis of market demand, trends, developments in the industry or to solve (technical) problems faced by the client. In their laboratory, papers are tested, samples are made and analysed, and technical possibilities are researched.
Process Quality Management
The mill has a Process Quality Management department that is responsible for the recipes for each type and colour of paper. This department constantly monitor the quality of our products and processes. They also deal with any complaints.
On its way to you
The Logistics department co-ordinates the entire production process both inside and outside the mill. Together with the Dispatch department, they ensure that the ready-to-use product is delivered to you correctly. And, it’s now up to you to do something beautiful with the paper.