Paper Block Production Process

The craftsmanship of Custom Paper Block is not complicated, but every link emphasizes stability. Domestic manufacturers that are better at it generally follow the following processes, though equipment scales differ.

1. Selection of base paper

The base paper must be stable — paper block are not just stacked sheets.

Factories usually choose:

• 70–100g white card or specialty paper

• Smooth surface (to avoid burrs during cutting)

• Stable moisture content (or "fried edges" and warped corners may occur)

Good factories spend the most time here because this step determines the stability of all later processes.

2. Proofing and size confirmation

The size (length, width, height) must be finalized before production, otherwise machines cannot adjust accurately.

Key confirmations:

• Single page size

• Total thickness (calculate sheet quantity to reach desired height)

• Whether a cover or base card is needed (many customized models include this)

Adjustments are made repeatedly until the customer confirms.

3. Cutting large sheets (initial cutting)

Raw paper comes in rolls or large sheets and must be cut to base size.

Equipment used:

• Single blade cutter

• Hydraulic double-knife cutter

Requirements:

• Size tolerance within ±0.5mm

• No burrs or “exploded edges”

Cutter skill matters — dull blades cause uneven paper block later.

4. Stacking and alignment

More difficult than it seems.

Paper must be:

• Stacked sheet by sheet

• Aligned edge-to-edge precisely (misalignment cannot be fixed later)

• Kept in proper humidity to avoid deformation

Large factories use automatic stackers, small ones mostly align manually.

5. Pressing and shaping

This step determines how solid a paper brick is.

A high-tonnage press compresses the paper stack to target density.
Uneven pressing results in:

• Bulging center

• Collapsed corners

• Inconsistent indentation

Most manufacturers press twice for stability.

6. Three-side precision trimming

A key process affecting appearance.

Using high-speed trimmers to refine three edges requires:

• Mirror-smooth blade surface

• No tearing, burrs, or rippling

• 90° clean cut lines

Good factories produce surfaces smooth as real bricks.

7. Cover & bottom card (optional)

Some bricks require:

• A printed cover (brand / logo / pattern)

• A bottom card for stability

Covers often use special or coated paper, requiring foil stamping, lamination, or embossing before assembly.

8. Dust removal & quality check

Cutting leaves paper debris. Factories usually:

• Blow with an air gun

• Remove dust manually

• Check edge flatness

• Randomly check sheet count

Key inspection points:

• Black edge lines

• Tilting

• Size deviation

• Insufficient thickness

  

  9. Shrink film packaging

  Paper block are mostly packaged by shrink-seal machines.

  Shrink film requirements:

  • Tight but not deforming

  • Neat seal lines

  • Clear, crease-free surface

  Big brands often use high-clarity OPP film.

  

10. Packing & warehousing

Finished units are boxed, labeled (specs, batch, quantity), then stored for dispatch.