Paper Making Process

 OCC (Old Corrugated Cartons) is purchased from Local and Foreign Suppliers. The OCC purchased locally is shredded and baled to facilitate easy handling and weighing; the imported OCC is stored for processing.

 At the beginning of the process the OCC is added to the Pulper; this machine uses mechanical action and water to convert the OCC to slurry (pulp). Plastics, adhesive tapes, ink, metals and other particles are separated from the fibers at this stage.The pulp is processed through a series of cleaners and screens, each removing contaminants such as pitch, adhesive tapes, staples and Styrofoam. After each cleaner there is a storage chest (tank) that holds the pulp for transfer to the next stage of the process.The Stock Preparation section consists of Thickeners and Disc Refiners; these units condition the fiber for the final stage of the paper making process. The Disc Refiners consists of 2 sets of rotating discs that cut and "brush" the fiber to improve bonding and strength characteristics.The Machine Line consists of two final screening processes to remove sand and stickies (adhesive and pitch) and the pulp is then fed onto a continuous porous forming fabric. At this stage the pulp is 99% water and 1% fiber, the water is removed by gravitational action and by a series of 5 high pressure vacuum boxes below the forming fabric; this is known as the forming table.

 The web then leaves the forming table and enters two high impression presses, these presses compact the fiber into a sheet form and further removes water from the web. The sheet then enters a series of 18 dryer cans. These dryer cans are heated by steam and the temperature of each can is regulated to ensure the gradual heating and cooling of the sheet as it moves through the dryers.

 As the sheet exits the dryer section it passes through a press consisting of two finely ground metal rolls, this press further compacts the sheet and enhances surface finish. The sheet is then wound on a master roll called the Pope Reel. At the end of the recycling process, the master roll is then tightly re-wound and cut to the desired width on the rewinder machine.

Packaging Making Process

 The finished rolls are transported and stored in the Box Plant for use at the Corrugator Plant.

 The Corrugator Plant makes the corrugated boards by combining three layers of paper together by the use of heat and adhesive (mainly corn starch). The layers are as follows: Inside Liner – the inside of a carton Corrugated Medium (also called fluting) – the middle corrugated part of a carton Outside Liner – the outside of a carton that carries the print.

 After the layers are combined and the corrugated board is formed, the knife section of the Corrugator cuts the board to a specified dimension, for the box making process.

 The corrugated boards are then processed through the Flexo/Folder/Gluer called the Flexographic Machine, where it is printed (as required by the customer), slotted, folded and glued to form presentable corrugated carton.The cartons are bundled in a "knock-down" form and palletized for delivery to the customer.