Our production

For us and our employees, quality and the environmentally conscious use of sustainable resources are the first priority.

 

Our factory in Düsseldorf

At Hakle we produce over 70 different products, from toilet paper to kitchen roll.

But how is our Hakle paper created? Join 6 employees from our team in their daily work and learn firsthand how Hakle paper is made.

Our factory in Düsseldorf

Aerial Photo of the Factory location


Raw material

„My Motto: good paper start with the Raw Materials.”

At Hakle we process pulp or recycled paper for toilet and kitchen rolls on our paper machine. The materials used have short or long fibers and are dissolved with a lot of water and processed into paper pulp in large containers. The resulting pulp is passed over sieves and felts to remove the water from the dissolved materials. The dehydrated pulp runs over a steam-heated cylinder and gets dried more. The result is a homogeneous, thin hygienic paper web, which is rolled up into a giant roll and called a parent reel.

Raw material

Stefan Greszki - shift leader
In our team for 32 years


Paper production

„I have Quality under control”

Such a parent reel has a diameter of about 2.4 m and a width of 5.2 m, with a weight of about 7 tons. The finished parent reel consists of a single-ply paper web. Each roll is examined qualitatively during the ongoing process by specilaist technical equipment. Likewise, pieces of paper are cut from the finished parent reel, which are checked in a laboratory for the pre-determined quality parameters. Further processing of the paper takes place only after successfully passing the quality check.

Paper production

Rolf Otten - machine operator
In our team for 37 years


Roll winding

„Even in complex processes, I have the eye for detail ”

The parent reel is further processed on our plying machine. Here, two single-ply paper webs are combined to form a new two-ply paper roll. The paper rolls we have created are called parent reels, because they produce smaller rolls, which you can buy in your supermarket. These parent reels have a diameter of approximately 1.8 m, are 2.6 m wide and weigh 1.7 tons. The huge rolls get labelled and are transported to the parent reel warehouse.

Roll winding

Xenofon Bissiritsas - machine operator
In our team for 37 years


Paper converting

„A strong team stands behind our products”

The next step is to process the parent reels into saleable products. In our converting process, the rolls are first taken from the warehouse to our rewinders. Depending on the end product, one or two-ply parent reels are loaded into the converting machines. The Hakle finished product is produced from the flat paper of the parent reel. Printed, embossed and perforated, it leaves the converting machine as a paper log. The final diameter of the log is already the same as the finished product, but it is 2.6 m long. A saw cuts the log into many units. The result is toilet paper rolls and kitchen rolls.

Paper converting

Bert Stuhlmann - Converting Manager
In our team for 35 years


Roll production

„My Quality requirement is valid for every roll”

Before the cut rolls are finally packaged, they have a long way to go back over various conveyor belts until they reach the appropriate packaging machines. This is necessary, because the rolls are made in different variants. Whether printed or unprinted, whether colored paper or pure white, made of pulp or recycled paper, all the different products have to be delivered to the right packaging machine. On their way through the process, the rolls are subject to constant quality control by our employees and our laboratory.

Roll production

Jörg Muth - mechanic
In our team for 31 years


Packaging / distribution

„My premium packaging brings the goods to the customer!”

In our packaging machines, the incoming rolls are packaged in multiples of 2 rolls up to 24 rolls to large multipacks with 72 rolls. The prefabricated plastic bags are selected according to the production specification and are automatically fed to the packaging machine. The finished package is transported via many conveyor belts to the palletizer, which packs the goods onto the pallet according to a predetermined pattern. Finally, quickly secure the finished pallet with stretchwrap and transport it to the dispatch department. The forklift truck is already waiting to pick up the pallet and load it onto a truck. In total more than 70 different products reach our customers.

Packaging / distribution

Andreas Pazdzior - mechanic
In our team for 16 years