Waste Paper Collection & Sorting
The foundation of our sustainable Kraft paper manufacturing lies in our meticulous waste paper collection and sorting process. At Sezon Papers, we rely on skilled workers who manually sort waste paper, ensuring each piece is evaluated for quality and purity. Unlike automated systems, this hands-on approach allows for greater precision in identifying reusable materials, particularly when dealing with complex waste streams.
Our sorting process begins as waste paper is unloaded into a spacious, well-ventilated room. Workers spread the paper and visually inspect each piece, manually separating recyclable materials—such as Old Corrugated Containers (OCC), mixed paper, and kraft cuttings—from contaminants like plastics, metals, and food residues. This labor-intensive process ensures that only clean and usable paper enters the next stage of production, ultimately contributing to higher recovery rates and cleaner feedstock.
Hydra Pulping Technology
After sorting, waste paper enters our state-of-the-art Hydrapulper system, where it is transformed into pulp using water and mechanical agitation. This high-speed rotating machine efficiently separates fibers while removing impurities such as plastics and staples. Our Hydrapulpers operate at an impressive capacity of 16m³, optimizing both temperature and chemical ratios for superior fiber separation and brightness. The hydra pulping process significantly reduces energy consumption compared to traditional methods, providing us with high-yield pulp that meets industry standards while minimizing environmental impact.
A. Screening Technology
Our screening equipment, featuring precision-engineered turbo screens with openings as small as 2.5mm, removes up to 80% of impurities, ensuring the purity of our pulp. The centrifugal cleaners operate at an impressive 1.5-2.5kg G-force, effectively eliminating fine particles and other contaminants. Additionally, our proprietary Cascade Clean system recycles 30-40% of process water, significantly reducing water consumption while maintaining optimal pulp consistency.
B. Refiner Technology
To improve the quality of the pulp, we utilize advanced Refiner Machines. These machines refine and fibrillate the pulp, enhancing fiber bonding, strength, and smoothness, which is critical for high-quality Kraft paper production. Additionally, we employ a three-stage screening system coupled with centrifugal cleaning technology to remove any remaining contaminants.
Fourdrinier Machine
Once the pulp is refined, we move to the paper formation stage, where we employ an advanced Fourdrinier Machine. Capable of producing paper sheets ranging from 80 to 350 GSM, the Fourdrinier machine ensures efficient, continuous production at speeds up to 140-350 m/min. Its hybrid forming table, which combines vacuum foils with dandy rolls, ensures uniform sheets with excellent dimensional stability. This design enables precise control over the paper’s weight tolerance, maintaining an impressive ± 5% variation across the sheet width.
The Fourdrinier machine is ideal for producing lightweight packaging materials, contributing to the efficiency and sustainability of our paper production process.
Calendaring Machine
After the paper sheets are formed, they pass through our state-of-the-art Calendaring Machine, which enhances the smoothness, gloss, and uniformity of the paper. This machine utilizes multiple rolls in a super-soft arrangement to ensure even pressure distribution, achieving consistent surface characteristics. The calendaring process ensures that the final product maintains a moisture content of 7.0 ± 7.5% while preserving bulk density around 7-7.5 g/cm³, resulting in paper with superior smoothness and improved printability. This final step ensures that our Kraft paper is not only functional but also aesthetically refined.
Once the paper has passed through the calendaring stage, it is ready for cutting and rewinding. Our advanced rewinding and cutting machines ensure that large rolls of paper are converted into smaller, customer-specified sizes with smooth edges and precise dimensions. We use automatic slitting, rewinding, and trimming functions to guarantee the highest quality in every roll.
Our integrated vision systems inspect each roll for defects such as uneven edges or surface imperfections, ensuring that only defect-free products are packaged and shipped. We offer customizable roll sizes tailored to specific client requirements, with a 99.95% defect-free shipment rate. This rigorous quality control process ensures that our Kraft paper meets or exceeds industry standards.
