We buy paper leftovers and offcuts from the printing and packaging industry. We also purchase offcuts of wood from the furniture industry.
This paper is cut into the correct sizes to make the core of our paper pots. For precision cutting of these components, it’s perhaps the only process where we turn to technology i.e. laser cutter.
The pieces are bundled and distributed amongst the mothers who work from home. They also receive the necessary materials to fabricate the paper cores.
Once returned, several layers of natural latex tapped from the rubber trees is applied to waterproof the pots.
The offcuts from our laser cutters are collected and soaked in water for 24 hours (without any chemicals). The mix is stirred until it forms into a smooth paper slurry.
This slurry is now diluted with more water. The pulp is now scooped onto a deckle leaving a thick layer.
Our skilled artisans now remove the excess water by sponging the layer of pulp. The layer of paper pulp is then transferred onto a cotton cloth for drying.
The cotton and paper are placed onto a mould. A pattern is now pressed into a stack of moist paper sheets.
The cotton sheets are hung to dry. Drying can take between 12 to 48 hours depending on Sri Lankan weather.
When completely dry the paper sheets are carefully peeled off the cotton and our paper is good to go.
We cut the paper to size. The offcuts are collected and used again by mixing them in the next batch of pulp - a complete zero waste process!
The paper is now applied to the paper core and another unique zero-waste pot is ready!
Watch the video here: