How paper is made – step by step

The cycle begins with the collection of waste paper. Every year we process Perlen Papier over 500,000 tons of it. The waste paper is reduced in size, cleaned, boiled, bleached, sorted and processed into a pulp in so-called pulpers – a crucial basis for new paper products.

The pulp, consisting of waste paper, groundwood pulp and cellulose, is enriched with additives such as starch or dyes. This mixture is refined and freed of foreign substances to ensure the quality of the subsequent paper.

The heart of production: the paper machine processes the prepared fiber pulp into paper in a continuous process. The paper web is fed through various stations at a speed of over 100 km/h.

In the headbox, the fiber slurry is applied evenly to the screen. Initially, the mixture consists of 99% water. Dewatering on the wire creates a fiber web – the first step towards a solid paper web.

The water is pressed out of the paper in the press section. High pressure and high speed reduce the water content to around 50%. The paper web slowly takes on its stability.

The still damp paper web is passed over heated cylinders, which quickly evaporate the moisture. After 32 drying cylinders, the paper has a residual moisture content of 3 to 4 % in order to remain supple and tear-resistant.

During the calendering process, the paper is smoothed by rolling. This treatment ensures an even surface and the desired paper thickness, an important step for high-quality end products.

During the production process, additives such as dyes and starch are incorporated. These give the paper specific properties such as gloss, stability or color – depending on customer requirements.

For specialty papers, the paper is refined, for example by a coating process in which a coating is applied. This improves the printability and feel.

After smoothing and drying, the paper web is ready. It is produced continuously in its full width and length – an impressive process of modern technology.

At the end of the paper machine, the paper web is wound into large reels. These huge rolls are then cut to the customer-specific dimensions in the winder.

The cut rolls are automatically packaged and prepared for transportation. From there, they are sent to print shops, which use them to produce magazines, newspapers or other products.

After further processing in print shops or other companies, the finished paper products reach the end consumer – whether as packaging, books or brochures.

Used paper products are collected from households and businesses and fed back into the recycling process. This closes the paper cycle.

In addition to waste paper, fibers from sustainable wood production are also used. These come from wood waste from sawmills and regional forestry – an environmentally friendly and resource-saving process.

Raw materials such as pulp, groundwood pulp and other additives are supplied in large quantities and efficiently integrated into the production process.

The collected waste paper is delivered in large batches, sorted and fed into the production process. Recycling is a central component of paper production at Perlen Papier.