Paper production at Crown Van Gelder takes place in one straight line, from reception of raw materials to storage of packed reels. The length of this line is 280 meters: 100 meters are covered by our 2 paper machines, the beating heart of our factory.
The lining up of bales of pulp (cellulose fibers) in front of each machine starts the process. Bales are conveyed into a pulper, where they are broken down in water, resulting in a slurry. The fibers undergo different treatments to bring them to the right size and shape. Cellulose is mixed with other ingredients such as starch, whiteners and the other ingredients to determine paper characteristics.
Containing only 1% of solids, the slurry is cleaned of impurities and sprayed onto a wire mesh. Gravity and a vacuum under the mesh extract the first part of moisture. With a humidity content of 80%, the paper enters the pressing area. Rolling cylinders apply pressure, further reducing moisture to 55%.
The drying unit is the largest part of the machine. Via movement over steam-heated cylinders, the moisture is reduced to the desired level. The paper then receives a selection of applications that determine surface characteristics, for example a starch-based coating.
Determination of thickness and smoothness is the final step in making paper. A set of drums uses pressure and temperature to create final specifications . Smoothness can be made differently for both sides of the paper.
Large rolls of paper of several meters wide and weighing up to 25 tonnes are delivered to the automatic cutter. Here, these master rolls are transformed into customer products. Next to cutting, the rolls also receive the core that customer require. Finally the rolls are carefully packed by robots and stored in our conditioned warehouse.
During the whole process, the paper is scanned and monitored in-line, ensuring a consistent high quality. A sample from each master roll is always immediately tested in the in-house test lab.