At Hakle, pulp or waste paper is processed into toilet and kitchen rolls on a paper machine. The materials used, which have short or long fibres, are dissolved with water and processed into a kind of paper pulp in large containers. The resulting paper pulp is passed over sieves and felts to sift out the water from the dissolved materials. The dewatered paper pulp is then passed over a steam-heated cylinder and dried. The result is a homogeneous, thin hygienic paper web that is wound up into a giant roll and is called a reel.
Such a reel has a diameter of about 2.4 m and a width of 5.2 m, with a weight of about 7000 kg. The finished reel from the paper machine consists of a single-layer paper web. Each reel is qualitatively examined during the running process by appropriate technical equipment. Likewise, pieces of paper are cut out of the finished reel spool, which are checked in a laboratory for the previously defined quality parameters. Further processing of the paper only takes place after quality approval.
We process the reel further on our doubling machine. Here, two single-layer paper webs are combined to form a new, two-layer paper web. The resulting paper rolls are called mother rolls, because smaller rolls are produced from them, which you can then buy. The mother rolls have a diameter of approx. 1.8 m, are 2.6 m wide and weigh 1700 kg. The giant rolls are now given a running card and are transported to the mother roll warehouse.
The next step is the further processing of the mother rolls into saleable products. In our paper processing department the reels are first taken from the warehouse to our winding machines. Depending on the end product, single or double-layer mother reels are hung in the converting machines. Here the smooth paper of the mother roll is turned into the final product. Printed, embossed and perforated, it leaves the processing machine as a roll trunk. The final diameter of the roll is now already available, but over a length of 2.6 m. A saw now cuts the log into many units. The result is toilet paper and kitchen rolls.
Before the cut rolls are finally packed, they still have a long way to go via different conveyor belts before they reach the corresponding packaging machines. This is necessary because the rolls are manufactured in different basic materials. Whether with or without printing, whether coloured paper or pure white, made of cellulose or waste paper – all the different products must be fed to the right packaging machine. On their way through processing, the rolls are subject to constant quality control by our employees and our laboratory.
In our packaging machines, the incoming rolls are packed into different containers according to the order specifications. We pack 2 rolls, 24 rolls and even large packages of 72 rolls. The prefabricated plastic bags are selected according to the production specifications and automatically fed to the packaging machine. The finished sales unit is transported by conveyor belts to the palletiser, which packs the goods onto the pallet according to a specified pattern. Now the finished pallet is quickly secured with foil and transported to the dispatch department. Here the forklift truck is already waiting to pick up the pallet and load it onto a truck. This is how our products get to the shops.