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http://www.kliptech.com/paperstone.htm

 
KlipTech Composites
2999 John Stevens Way - Hoquiam, WA 98550
Office: 360.538.9815, Fax: 360.538.1510
For more information contact: joel@kliptech.com
 
     
     

 
How Paperstone countertops are made
 
Paperstone has pushed the envelop to develop a lower toxic countertop using recycled materials. Paperstone impregnates paper with cashew nut, oil based resin, heats and dries it, and then presses and again heats it to yield uniform sheets. The paper used in this countertop is made from a minimum of 50% post consumer recycled paper. Instead of using a phenolic resin, they use a cashew nut and water-based resin that acts as a binding agent for the paper in the product.

The cashew nut, oil-based resin, known as cashew nut shell liquid (CNSL) is an organic, renewable resource. The cashew nut grows in its own kidney shaped hard shell at the end of the cashew nut tree's pear-shaped pseudofruit. For hundreds of years, CNSL was discarded as a waste product of the kernel cash crop due to the fact that CNSL is a blistering liquid, adept at keeping insects, birds and human hands away. In 1923, a roasting process was discovered, turning CNSL into a viable commodity for the paint, varnish and resin industries.

This resin also uses water instead of methanol, a chemical wrestling match worth undertaking in order to remove the photo-reactive volatile organic compounds associated with methanol.
 

Who does this kind of custom work in this area?  Bruce Shaver, the finish carpenter for our home.  Can't say enough good things about him!