1. Raw Material Source: Collection of Waste Paper
First Step: Beginning of the Recycling Process:
The foundation of recycled kraft paper production is the correct collection of used paper. Waste such as paper, cardboard, corrugated board, old newspapers, and office paper are collected from industrial facilities, retail chains, recycling centers, and municipalities in both Europe and Arab countries.
Collection Types:
Collected waste is classified as “mixed” or “source-separated.” Source-separated waste allows for the production of higher-quality pulp, which is particularly important for demanding markets like Germany, France, and Saudi Arabia.
2. Sorting and Pre-Processing Stage
Removal of Foreign Substances:
Collected papers are sorted using magnetic, mechanical, and pneumatic systems. Plastics, metal staples, paper clips, glass fragments, and textile fibers are removed to eliminate elements that could hinder the recycling process.
Color Separation and Quality Grading:
Colored papers are generally not preferred in kraft paper production. Therefore, unbleached, fiber-rich brown or gray-toned papers are prioritized, ensuring strong and durable end products for international markets.
Soaking: Papers are softened with water and chemical solutions.
Homogenization: The fiber structure is blended in refiners to ensure uniform pulp quality.
3. Pulp Preparation and Cellulose Separation
Recovery of Cellulose Fibers:
The waste paper is mixed with water in large tanks called hydropulpers, where it is separated into fibers. The resulting mixture is called “paper pulp.” Contaminants such as plastics, ink, and other residues are removed by the following methods:
Flotation: Small air bubbles lift light substances to the surface.
Screening: Thick fibers and heavy particles settle at the bottom.
Chemical Cleaning:
Some facilities use lime, enzymes, or soap-based cleaners to further purify the pulp, a step critical for markets with strict environmental regulations like the Netherlands and the UAE.
Pulp Quality Adjustment:
The cellulose obtained from the pulp is diluted according to the desired grammage. For kraft papers, the length and density of the fibers determine the final product’s strength, elasticity, and smoothness—factors tailored to customer needs in both Europe and the Middle East.
4. Paper Production Line: Forming and Drying
Paper Formation (Wire Section):
The prepared pulp is poured onto a continuously running wide mesh belt. Here, fibers align, excess water is drained, and the initial paper layer begins to form—a crucial step for achieving uniformity expected in European and Arab export markets.
Pressing and Drying:
The formed paper is pressed between rollers to remove up to 50% of the moisture. It is then fully dried in large cylinders at 100–120°C. This process results in paper ready to be wound into rolls, ensuring dimensional stability during transport to clients in Germany, Egypt, Qatar, and beyond.
Final finishing steps ensure that the paper is suitable for printing and further industrial processing.
5. Finishing and Quality Control
Surface Smoothing and Hardness Adjustment:
The dried paper is passed through calender rollers to achieve a smooth surface. This step both enhances print quality and gives the paper the targeted hardness value required for automated packaging and bag lines.
Cutting and Rewinding:
The paper is cut to width and length as per customer specifications. It is then wound into rolls or cut into sheets and stretch-wrapped onto pallets for safe shipment to Europe, the Middle East, and North Africa.
Quality Control Procedures:
Each production batch is tested for grammage, moisture content, color consistency, and tear resistance. Results are evaluated according to ISO standards and customer specifications—guaranteeing reliable, certified quality for buyers in both the European Union and Arab countries.
