Preparing the pulp :
The paper is placed in a pulp machine. Water is added and mixed mechanically. A propeller insures the homogeneity of the water/cellulose fibers mix. No chemical additives are used. They could harm the operators and leave residuals. Preparation of the paste takes twenty minutes.
A wire-strainer covered mold is then dipped into the paste. The water and fiber mixture is quickly sucked through the mold. Fibers are stopped by the wire-strainer to take the form of the desired object. The excess water goes through the wire-strainer and is immediately recycled in the production process.
The products are then dried. Two drying methods exist. The first which is the most common, uses an oven. The pieces are put on a conveyer belt going through an oven where they are dried. The disadvantage of this method is that it does not guarantee the dimensional homogeneity. Pieces may vary in size of up to 10 millimetres. This makes stacking more difficult.
Ecofeutre uses a much less widespread drying technique. It is a high pressure technique using male and female molds. Each piece is inserted in-between two molds which are brought together by a press. The pieces are then dried through a combination of heat and pressure.
This method makes it possible to meet very stringent dimensional specifications (up to 0.1 millimetres) and it also reduces the thickness by a factor of two to three, depending on the pieces (a gain in storage space and in transportation cost).
Once dried, the press opens up and releases the products on a tray where they are stacked by an operator. The operator makes sure that all products are conformed to the clients’ specifications. He checks the product’s dimensions, weight, texture and flexibility.