Manufacturing Process
Six clean steps
from quarry to finished roll.
A water-free, bleach-free, pulp-free production process engineered for consistency, traceability and minimal environmental impact.
Overview
A process closer to mineral engineering than to pulp-mill chemistry.
Traditional paper requires deforestation, tens of liters of water per sheet, and aggressive chemical bleaching. Stone paper does none of that. Instead, we treat paper as a mineral-based product, built from calcium carbonate powder and a small amount of non-toxic HDPE resin, then shaped using precision extrusion and calendering equipment.
The entire production line is closed-loop: off-cuts and out-of-spec material are ground down and reintroduced into the process. No wastewater treatment plant is required because the process uses virtually no water. Emissions are limited to those of a standard thermoplastic extrusion line, significantly lower than a conventional pulp and paper mill.
24,000
m² facility
70 km
from Berlin
≈ 0 L
water per ton
100%
German engineering
Product Showcase
Write on stone paper and experience the quality.
See how our stone paper performs with pen, showcasing its smooth surface and superior writing experience directly from our Luckau facility.
Product Demo
See how our stone paper performs. Write with pen and experience the difference.
Step by Step
From raw limestone to certified rolls in six steps.
Limestone Sourcing
Raw calcium carbonate is sourced from certified European quarries. Only high-purity limestone (CaCO₃ ≥ 98%) is accepted into the production line, ensuring consistent whiteness and mechanical strength.
Grinding & Micronization
The limestone is crushed and milled into an ultra-fine powder, typically 1–3 microns in particle size. Uniform particle size is critical for the paper's smoothness, printability and tensile performance.
Compounding with HDPE
The mineral powder is blended with 18–20% food-grade, non-toxic HDPE resin and a small percentage of processing aids. The HDPE acts purely as a binder without bleaches, acids, solvents or optical brighteners.
Extrusion
The compound is melted and extruded under precise thermal control into a continuous film. This is where stone paper gets its characteristic uniform thickness and opacity without requiring a single drop of water.
Calendering & Surface Treatment
The film passes through heated calender rolls which fix its final thickness, density and surface finish. A surface treatment optimizes the material for offset, digital, UV and inkjet printing.
Cutting, QC & Packaging
Final rolls are slit, sheeted and quality-tested for whiteness, basis weight, tensile strength and water resistance. Certified batches are then palletized and shipped from our Luckau facility across Europe.
Quality Control
Every batch is tested. No batch leaves without a certificate.
We apply German industrial QC standards across every production run — measuring whiteness, basis weight, tensile strength, water resistance and print surface consistency before release. Each certified batch is fully traceable from raw limestone supplier to delivered pallet.
Visit Or Learn More
Want to see the process in person?
Qualified partners can arrange a guided tour of our Luckau facility. Get in touch and we'll coordinate a visit with our production team.