Our plants manufacturing molded pulp products formed by 2 different process.
The wet-press process(also known as ''Thermoformed'') integrates forming and drying process in one mold, no oven curing is needed. This process produces high quality thin-walled items(from 0.6~1.3mm), with good dimensional accuracy, and smooth, rigid surfaces. The result resembles the appearance of thermoformed plastic items. The raw material is 100% virgin plant fiber such as bagasse/sugarcane, bamboo.
We have 6 automatic lines, 52 forming machine, 128 hot press, 38 trimming machine, 3 cross cuting machine, 3 V-grooving machine, 1 coating line, and 6 pulping system which able to make max.10 tons of product per day.
Dry pressed items manufactured using forming mold and transfer mold then oven dried or natural wind and after pressed, typical wall thickness ranges from 1.5mm to 3.0mm. The surface in contact with the mold is relatively smooth but not as smooth as thermoformed type, while the other side is rough. The raw material is typically OCC(Old Corrugated Container). They are usually used as support packaging, industrial packaging. The mold and product cost much cheaper than wet pressing process.
The entire creation process utilizes minmum amounts of energy. We built a 8 layers railing system which goes around our whole factory and the drying facility in order to help dry the products with natural wind and minimize the chance for the product to be deformed during the drying process. Daily capacity max. 40 tons of products.
The entire process utilizes recycling wastewater.
Water is one of the key element to make molded pulp products. There's tons of sewage water from production is ouput everyday, all sewage water is accessed to a biological wastewater treatment system make use of bacteria and other microorganism to remove contaminants and produce treated water that is safe enough for release into production for reuse, zero waste.
Waste Water Treatment Plant
1. Pulp Preparation
Put the raw material into the pulper with water and mixed until the desired pulp consistency has been achieved. Additives, such as AKD are introduced to produce the required functions, commonly utilized also in the papermaking industry.
The pulp through pipe arrive from forming machine converted into desired shape after it is vacuum formed on the custom-designed molds. The initial part is ready which is wet and soft.
The wet part is moved to a heated mold to be carefully dried. The surface becomes relatively smooth and good dimensional accuracy is achieved.
Our QC will random checking the parts' weight, size, appearance, strength, specific performance(such as waterproof, dustproof). Once problem be founded at this stage, will take immediate action to adjust and fix.
If clean edge is required on finished part, it will be tranferred to trimming machine. All the scraps or rejected parts are returned to the pulp mixture and re-used. Zero waste.
6. 100% Inspection
The finished part is finally 100% inspected for quality by well trained workers. Our final QC will checking by random at last stage, if AQL is not pass must fully re-checking until no any issue, we make sure with right quality before warehousing.
7. Packing & Warehousing
Normally packing incl. poly bag and shipping box, unless specific packing method is required, such as palletizing, or only pack in ploy bag without box for cost and space saving, then store into the warehouse and wait for delivery.
In-House Tool Manufacturing
We operate an in-house tool shop maintain tool making capabilities in the industry since 1994. We provide tools and technical support to worldwide as well as build tool for our exclusive utilization. Our team is completely staffed by highly skilled craftsmen with a strong industry reputation. We use 3D scanner to measure the tools regularly which enables us to manufacture your parts with great precision no matter how simple or complex your part designs may be.
How the tools be made
1. CNC machining
2. 3D scanning (normally apply to thermoform tool)
3. Drilling (by manual or 5 axis drilling machine)
5. Slight polishing
We create punching machine with high precision tools for our exclusive utilization.
Our in-house R&D team with capabilities of developing custom packaging. We can provide you innovative engineering and design solutions as fast as anyone in the industry.
A molded pulp project typically would move foward as following steps:
Step 1: Assessment & Analysis
We can design based on your samples provided and specific requirements, or if you have 3D design is available, our engineers will check the feasibility then provide you solutions.
Step 2: Design Finalization
We provide DFM if it is required, once DFM is finalized and we would move into the tool design and manufacturing phase.
Step 3: Prototype & Test
It is recommended prototype tool first in case of modification lead to mold become useless, at this stage customer can requires small change. Once sample is confirmed then move into mass production tool.
Step 4: Production Tooling
WINNER PULP in-house tooling shop is completely staffed by highly skilled craftsmen. Using advanced molding technology and 3D scanner to ensure accuracy and quality.