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.
In the pulper, we first add water and then coloring agents. The color is closely monitored to ensure matches with the recipes and/or samples. The pulp is then sprayed in liquid form controlled onto the wire of one of the three paper machines, to form a mat.
98% WATER: THE VERY BEGINNING
At the ‘wet end’ of the paper machine, the mat still consists of 98% water and only 2% fibers. Gravity and heat ensure that the percentage of water is reduced. Immediately after the first roll (which can also apply watermarks and laid lines) the mat clearly changes in color. 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 drying cylinders in combination with heat.
These three aspects are increased the further you proceed in the process. The process requires careful adjustment and tweaking, if decisions made slightly too quickly or too harshly, the paper mat will break. In general paper production is a matter of craftsmanship. The paper mat then runs through the size press. Here a layer of glue can be applied to give the product several properties such as write- and print abilities. At the end of the paper machine, the paper is rolled onto a mother reel.
PAPER FINISHING: EMBOSSING, CUTTING AND CALENDARING
The paper can follow 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. A complete range of embossing patterns are available. Following this, the rolls are cut to the desired dimensions. We can also cut paper to smaller sizes. The paper can leave our premises in several shapes and packaging.
RESEARCH & DEVELOPMENT
Our Research and Development department works with Marketing and Sales to develop new papers on the basis of market demand, trends, and developments in the industry or to improve our current product portfolio’s.
In the laboratory, after sample production papers are tested and analyzed, and technical possibilities are researched.
PROCESS QUALITY MANAGEMENT
The mill has a Process Quality Management system that ensures the high level of quality of the paper. In-line measuring, off-line sample control, recipe improvements, color tuning are just a number of the key tasks. Besides the regular quality control of the products also quality assurances and improvements are critical for the Quality department.
ON IT'S WAY TO YOU
The Logistics department coordinates the entire production process both inside and outside the mill. Together with the Logistical department, they ensure that the ready-to-use product is delivered to the customer correctly. One of the key drivers is a complete service level for the customer. It’s now up to the customer to do something beautiful with the paper.