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Recycling Process of Cardboard at Celulosa Gallur
The manufacturing process of paper and cardboard is essentially the same, with the main difference being their weight per square meter. From 200g/m2 and above, it is considered cardboard, while anything below that is considered paper. For the production of cardboard, 100% recovered paper is used as raw material, with different qualities according to the UNE EN 643 standard, depending on the characteristics of the cardboard to be produced.
Process of Paper Pulp Formation
The manufacturing process involves mixing recycled cardboard and processed water. Different types of recycled cardboard used as raw materials are classified according to the UNE EN 643 standard. Depending on the desired quality, a mixture of cardboard is made, as the result varies based on the type of raw material used.
These components are introduced into stainless steel vats known as “pulpers” or mills, which have a rotor at the bottom that breaks down the cardboard with water.
It is a precise and controlled process aimed at obtaining a homogeneous and perfect paper pulp, while contaminants are separated and removed through screens to ensure a quality product and prevent contamination of the paper pulp.
The process of manufacturing recycled paper pulp is significant for waste reduction and environmental benefits.
The paper pulp is diluted to a concentration of 2.5% paper fiber and 97.5% water to ensure uniform machine formation.
Sheet Formation
The paper sheet is formed using a machine with round shapes. The sheet formation is based on filtering the fibrous suspension through a mesh covering a hollow cylinder that rotates semi-submerged in the pulp. Water drains into the interior, where it is evacuated, while the fibers remain on the surface, forming the sheet.
These machines are used for manufacturing higher grammage cardboards, and drainage occurs rapidly through a vacuum system, eliminating water and improving fiber uniformity, ensuring that the fibers intertwine into a compact layer.
Press Section
The next phase of water removal takes place in the press section, where the formed cardboard sheet is separated from the forming fabric and passes through large-diameter rollers. These rollers, along with pressure and a vacuum system, eliminate water.
This pressure also compresses the fibers, interlocking them to form a dense and smooth sheet. In this step, the water content is reduced to 45-55%.
Drying of the Cardboard Sheet
The drying zone consists of steam-fed drying cylinders where the cardboard sheet passes through, evaporating the remaining water.
The drying zone includes a Pre-Dryer operating at 3.5 bar pressure and a Post-Dryer operating at 6.5 bar pressure, reaching temperatures between 120°C and 130°C.
En esta zona eliminamos el agua sobrante hasta conseguir una humedad final entre el 6% y el 7%.
Winding of the Cardboard Sheet
Before winding the cardboard sheet into a cardboard roll, it passes through an automated measurement device to detect any imperfections in the sheet formation, weight, and moisture.
The production of high-quality cardboard relies on extremely careful control of the manufacturing process variables.
This control system is implemented at all stages of the process, from the pulp preparation area to the pre-winding zone, where the equipment performs a final check based on the initially provided variables and corrects any possible deviations.
Cutting and Finishing
In this phase, Celulosa Gallur adapts to the needs of its customers. Cutting is done according to the requests of different customers, which can include rewinding into smaller rolls or cutting into sheets on wooden pallets, tailored to specific measurements, or die-cut with corner shapes as specified by the customer’s use.
Once cut to the desired size, the sheets are weighed, plastic-wrapped, strapped, and labeled with information about weight, quality, measurement, grammage, and the customer’s name.
After completing the entire process, the finished product pallets are stored in two designated warehouses, and subsequently, the goods are dispatched to customers via trucks.
It is essential to prioritize that any organic waste, sludge, or different products that cannot be used for food or animal feed purposes should be directed towards energy recovery.
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El acceso a Celulosa Gallur ya no puede hacerse desde el pueblo de Gallur. Se debe tomar la calle Camino Real desde la Autopista A-127, ya que está prohibido el paso de vehículos de más de 10Tn por el puente sobre el canal Imperial.