Inside the Production of Stable Custom Paper Blocks

The production process of Custom Paper Block products is not overly complex, but every stage focuses on consistency and stability. Experienced domestic manufacturers generally follow a similar workflow, even though the size and automation level of their equipment may vary.

1. Selecting the base paper

Everything starts with the right base paper — a paper block is not just a random pile of sheets.

Most factories will choose:

• 70–100g white card or specialty paper as the core material

• A smooth surface to prevent burrs and rough edges when cutting

• Paper with stable moisture content to avoid “fried edges” or warped corners

Professional manufacturers spend a lot of time on this step, because the performance of all later processes depends on the stability of the base paper.

2. Proofing and size confirmation

Before mass production, the final size of the block (length, width and height) must be confirmed. Otherwise the machines cannot be adjusted accurately.

The main points to verify include:

• Exact single sheet size

• Total thickness: calculating how many sheets are needed to reach the designed height

• Whether to add a cover or bottom card, which is very common for customized models

Samples are adjusted and fine-tuned several times until the customer approves the dimensions and appearance.

3. Initial cutting of large sheets

The incoming raw paper is usually in large sheets or rolls, which must be cut down to the base size before stacking.

Typical equipment includes:

• Single-blade guillotine cutters

• Hydraulic double-knife cutters

Basic requirements during this stage:

• Size tolerance controlled within ±0.5 mm

• No obvious burrs, “exploded edges,” or torn fibers

The operator’s cutting skill and blade sharpness are crucial — dull blades will directly lead to uneven and unstable paper blocks later.

4. Stacking and alignment

This step looks simple but is actually very demanding.

During stacking, the paper must be:

• Neatly stacked sheet by sheet

• Aligned precisely on all edges — once misaligned, it is almost impossible to correct later

• Handled in a controlled humidity environment to reduce deformation or waving

Large factories often use automatic stackers, while smaller workshops still rely heavily on skilled manual alignment.

5. Pressing and shaping

This is the key stage that determines how firm and solid the final paper block feels.

A high-tonnage press is used to compress the stacked sheets to the target density. If the pressure distribution is not even, it may cause:

• A bulging center area

• Collapsed or sunken corners

• Uneven indentation or a “wavy” look

To improve stability, many manufacturers will press the stack more than once to ensure the entire block is uniformly compact.

6. Three-side precision trimming

This process has a big impact on the visual effect and touch of the paper block.

High-speed trimmers are used to refine three exposed edges. During trimming, the following points are important:

• The blade surface must be mirror-smooth

• Edges should be clean, without tearing, burrs or rippled textures

• All cut angles should be close to a perfect 90°

After proper trimming, the sides of the paper block appear flat and smooth, similar to a real brick.

7. Cover and bottom card (optional)

Depending on the brand and design, some paper blocks will be fitted with:

• A printed cover that carries the logo, brand name or custom graphics

• A bottom card to enhance stability and improve presentation

These covers usually use coated or specialty paper, which may need foil stamping, lamination, embossing or other finishing processes before being mounted onto the block.

8. Dust removal and quality inspection

Cutting and trimming inevitably produce fine paper dust, so cleaning and inspection are essential.

Factories typically will:

• Use air guns to blow away dust

• Wipe and remove remaining particles by hand

• Check that all edges are flat and smooth

• Randomly count sheets to confirm the quantity per block

Main quality checkpoints include:

• Whether there are dark edge lines or dirt

• Any visible tilt or skewing of the block

• Size deviations beyond tolerance

• Insufficient thickness compared with the approved sample

9. Shrink-film packaging

Most paper blocks are wrapped using shrink-seal packaging machines.

For shrink film, the typical requirements are:

• The film should cling tightly without deforming the block

• Sealing lines should be straight and neat

• The film surface should be clear and free of heavy creases

Well-known brands often specify high-clarity OPP film to better display the colors and printing of the product inside.

10. Packing and warehousing

Finally, the finished paper blocks are packed into cartons, labeled with specifications, batch numbers and quantities, and then moved into the warehouse, ready for shipment to distributors or end customers.