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Fibercel's molds and parts are produced in our own plants
located in Portville, New York and Cookeville, Tennessee.
The basic process involves creating a vacuum formed plastic
mold representative of the item surface to be protected. This
"tooling" is mounted on a plate which is subsequently
mounted in the pans of our pulp molding machines.
These machines include a tank which is continuously supplied
with a slurry of corrugated kraft and newsprint pulp. The
pans are attached to a rotating wheel and as the wheel revolves,
the pans are submerged in the pulp tank. The molds are attached
to a vacuum, which draws the pulp solids onto the mold and
removes the water.
At the end of a rotation, the individual pan reaches the
unload station where an air blast blows the semi-solid pulp
off of the mold and onto a negative fixture. The part is then
transferred directly to the belt of a large multi-zone gas
fired drying oven, which removes the remaining moisture. At
the end of the oven, the parts are packed for shipment to
the customer.
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