Collected waste paper (cardboard or newspapers) is precisely weighted and put into the hydropulper. Here paper is mixed with water and within 15 to 20 minutes it is de-fibred to establish pulp. This mixture is pumped through a two-stage filtration where, in the first cycle, heavy impurities (small stones, sand, paperclips) are separated and, in the second cycle, all light impurities are separated (wood, plastic, polystyrene, and adhesive tapes). Pure pulp is stored in tanks and ready for subsequent use. The last step of the pulp preparation is its mixing to reach required operation parameters. The whole process is fully automatic.
The second production step is pumping of pulp into the forming line where it is sucked onto aluminium moulds. After residual water has been exhausted, the already finished product is transferred to a drying conveyor. The drying process is automatically monitored; during this process humidity, temperature, and volume of drying air is controlled. The product drying time ranges between 25 and 35 minutes, in relation to its size and thickness of material.
In the event a customer requires high surface quality or exact inside dimensions of a tray, products are after-pressed in a hot mould. The effect of a high temperature and of a multiple-ton press results in a smooth surface. To reach exact outside dimensions, product edges are trimmed, in relation to the size of a box. The waste from trimming is recycled for further production.