Receiving the Mother Rolls

The first step is receiving the master rolls, also known as mother rolls or master bobbins, from the paper mill. These rolls are shipped in a sea container to our facility, measuring approximately 40 centimeters wide by 10,000 meters long.

Once received, the rolls are loaded onto the watermarking machine for the next phase of production.

Watermarking

The watermarking machine is one of the most unique aspects of our production process. Unlike traditional watermarking methods that use clear ink, we apply a method using only heat and pressure—no chemicals are added. This method is environmentally friendly and enhances the purity of the product.

Here’s how it works: The master roll is loaded into the machine, which uses a stainless steel drum with an etched watermark design. The drum is pressed against the paper using heat and pressure, under carefully controlled climate conditions. This ensures the watermark is transferred seamlessly onto the master roll.

Gumming and Slitting

After watermarking, the master roll moves to the gumming and slitting machine. The machine applies a gum line that is approximately 10 millimeters wide, which is essential for the rolling paper’s usability.

We use 100% natural acacia gum, also known as Arabic gum, which is sourced from non-conflict zones in Somalia and Sudan. The gum granules are bought, melted down, and through a proprietary process, we convert it into liquefied gum, which is then applied to the paper.

The gum line is divided evenly so that when the paper is slit, each sheet of rolling paper has the perfect 5 millimeter width. The slitting process ensures that the gummed bobbin can be cut into individual sheets of paper.

Rewinding the Bobbin

Once the gumming and slitting are completed, the bobbin is rewound into its position, preparing it for the next step in the production line.

Interleaving

Next, the rewound bobbins are loaded into the fully automatic, multi-bobbin interleaving machine. This machine can hold up to 100 gummed bobbins, which are interleaved into a zigzag or stack formation.

The interleaving process is crucial for the final product. It allows for a smooth transition of sheets of paper that are stacked together into the required format, such as a king-slim size booklet. Each sheet is cut to the desired length, depending on the production shift’s specification.

Booklet Packing

After the interleaving process, the paper sheets are passed into our state-of-the-art, fully automated booklet packing machine. This machine is capable of packing up to 250 booklets per minute.

The rolling paper booklet covers are loaded into the machine, and the bundle of paper sheets is carefully packed into the booklet. This fully automated system ensures that every booklet is consistently packed to the highest standard.

Display Box Assembly

Once the booklets are packed, they are automatically transferred to the box assembly machine. This machine forms the display boxes, such as for the king-slim size booklet (44 millimeters by 109 millimeters in length), which is packed with 50 booklets per box.

Once the boxes are formed, the booklets are dropped into the printed display box, ready for shipment.

Shrink Wrapping

The final step involves the shrink-wrapping process. After the booklets are packed into their respective display boxes, the boxes are automatically shrink-wrapped. This protects the boxes and ensures that the product is ready for retail.

Our machine is truly one-of-a-kind, allowing us to go from gummed bobbin to a ready-for-retail, packed point-of-sale display box. This fully automated process ensures consistency, quality, and efficiency.

Booklet with Tips (Optional Line)

For certain customer requirements, where a booklet needs to include tips, we have a separate interchangeable line. This additional line allows us to assemble the booklet with the rolling paper, outer wrap, tips, and magnet if needed. This gives us extreme flexibility—our automated line can be used solely for booklet packing, or we can use this extra line to add tips and a magnet to the booklet as required by the customer.