At PaperShell, innovation and efficiency drive our production processes, our production process is both conceptually straightforward and intricately advanced.

Pressing for perfection

We start with craft paper and a bio-binder, both sourced from forest and agriculture waste streams. The craft paper is impregnated with the bio-binder, forming the foundation of our sustainable material.

Next, we cut and stack the impregnated paper sheets before subjecting them to high heat and pressure in hydraulic presses. This melds the sheets into a uniform material, taking on the desired shape from a mold within the press. If needed, we make precise cuts and holes for fittings, but there’s no surface treatment unless our clients request it, which they can handle themselves.

Automation, capacity and scaling

Pilot Plant – fast-tracking prototypes

Our pilot plant is an innovation hub where we fine-tune our testing capabilities and perfect prototype production internally or with our clients. This facility is fully equipped to efficiently for joint R&D, supply prototypes, 0-series, and small-volume orders. Our production lines are rapidly growing. In Q2 2023, we introduced the Small Line (S-Line) in the Tibro Pilot facility.

Factory One – Pioneering high-volume automation

In Q2 2024, Factory One will redefine high-volume production with automation and adaptability yet pushing us further to create energy efficient and super sustainable future factories. Designed for versatility across various business segments, it aims to deliver highly automated processes and robust Overall Equipment Efficiency (OEE). A 3,200 sqm facility in Tibro will house the Medium Line (M-Line), Large Line (L-Line), and an impregnating line. We’re also planning a Flat Panel line (F-Line) for facade materials and potential circuit board substrates like FR4.

Expanding for the future

Our aim is efficient production for both high and low-volume items, allowing us to explore multiple market segments simultaneously. We’re refining production lines, enhancing Overall Equipment Effectiveness (OEE), and preparing for target markets high volume demand. In 2024-2025, we’ll focus on expanding production even further for specific markets and products, increasing output.

Our Production team with years of experience in the global automotive Tier 1 supplier industry, underscores the potential of our unique production setup, inspired by and fusion of automotive, textile, and composite industries, tailored for PaperShell‘s material and clients components regardless of market segment.