WHAT IS PAPER ?

•  Paper mainly consists of extracted vegetable fibres

which first is broken down in water.
•  Water acting as the intermediary, spread thinly and evenly
over a mesh screen to form an interlaced sheet of fibres
and finally dried.
•  Paper and Board may be thick or thin, smooth or rough,
one sided or two sided, with a matt or gloss coated finish.
•  There are hundreds or different grades suitable for every job
and purpose.

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•  There have different chemical composition, colors, thicknesses
absorption properties.

•  Of all vegetable fibres, wood provide the main source of fibre

for making paper.

•  When the grammage of the paper exceeds 250gsm ( in the UK

usually in the region of 220 – 225gsm) or the thickness exceeds
250 microns), the substrate is considered to be a board.

The quality, printability and general characteristics of paper

and board produced are determined by two important
features related to their manufacture:

- THE FURNISH
- THE SURFACE FURNISH

Furnish – the mixture of various materials blended in the

stock or raw material from which paper and board is made.
The chief constituents are the wood and others pulps,
sizing materials, fillers, dyes and other additives.

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 Major Source of Raw Material for Paper

Hardwood
Wood plants (Deciduous)
(Vegetable fibres)
Softwood
(Coniferous)

Rag
Raw Materials Non Wood plants
(Vegetable fibres) Esparto grass

Cereal straw

Bamboo
Recovered Paper
(Recycle fibre)

Major Source of Raw Material for Paper

Poplar, eucalyptus
Beech, chestnut, birch

Short fibres
(Fibre length 1 – 2mm)
Hardwood pulps
Good bulky, opacity
and smoothness

Wood plants
(Vegetable fibres) Pine, spruce, Cedar,
Hemlock & cypress

Long fibres
Softwood pulps (Fibre length 3 – 6mm)

Yield paper of high strength

Major Source of Raw Material for Paper

Obtained from cotton and
Linen rags

Rag Very long fibres

(Fibre length 10 - 60mm)
Produces high grades paper
Banknotes, legal documents

Obtained from North Africa

& Spain
Non Wood plants Esparto grass Short fibres
(Vegetable fibres) (Fibre length 1- 2mm)
Produces paper with good bulk
Opacity & flatness

Obtained from wheat, oats

Cereal straw
& barley

short fibres
(Fibre length 1- 2mm)
Produces low opacity paper
(banks & bonds)

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 Major Source of Raw Material for Paper
•  Fibre obtained from trees to be
made into pulp is known as virgin fibre
or primary fibre.

•  Fibre obtained from reusing paper

is known as secondary fibre.

Major Source of Raw Material for Paper

•  Fibre obtained from espartor grass produce
a clean, smooth sheet, good opacity, high
bulky, but lack strength (short fibre).

•  Rag paper are expensive because the supply

of rags – produce extremely durable & strong
paper.

Major Source of Raw Material for Paper

Obtained from printing plant –
Paper allowance for make ready

Rag
White waste
(pre-consumer waste) Softwood
(Coniferous)

Recovered
Non WoodPaper
plants
(Recycle
(Vegetable
fibre)fibres) Esparto grass

Ink is removed from paper in

Printed waste A process called de-inking.
(post-consumer waste)
Bamboo
Fiber can typically be
Cereal straw Recycled 5 – 7 times

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 How Paper is Made ?
1 Wood is chipped into small pieces 3
Cut down the trees from woodland 2 Chemicals are added to separate
The wood into individual fibers

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The pulp slurry is sprayed onto a huge
Flat wire screen in the paper machine.
Blend the pulp with the others
ingredients
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The web of paper is pressed between rolls
The paper is slit into Which squeeze out more water. Heated rollers
smaller rolls. Then dry the paper.

PAPER MANUFACTURE

Stage 1 – Pulp preparation

PULPING
•  The cellulose based constituents are required for making paper,
and the lignin constituents are impurities that must be removed
during pulping.
•  The objective of all pulping processes is to separate the
wood into individual Fibers.
•  Three broad classifications of pulping methods:
•  Mechanical (groundwood), Chemical, and a combination of
these two (chemi – mechanical).

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 PULPING
•  Mechanical (groundwood) : the fibers are physically
separated by mechanical action.
•  Debarked logs are taken to a large grindstone that physically
rips the fibers from the logs.

•  The logs are forced against the stone by pressure. The fibers
that are ground off mix with the cooling water sprayed on the
stone and form a slurry of pulp.
•  The rough surface of the stone breaks down the wood into
fibers of 1 to 4 mm long.

A Large Grindstone

PULPING
Advantages & Disadvantages of this method -
Mechanical (groundwood)

•  Mechanical wood pulp uses wood very efficiently as is uses

about 90 - 95% of the debarked trees.

•  Produced the cheapest type of paper.

•  It does not use chemicals with their associated costs and

disposal problems.
•  Papers made from mechanical pulp are higher in opacity than
papers manufactured from chemical pulp.

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 PULPING
Advantages & Disadvantages of this method -
Mechanical (groundwood)

•  Physical damage to the fibers by the mechanical action –

produce paper lacking in strength.
•  Lignin not removed from the pulp, resulting in paper that
discolor rapidly in sunlight and becomes brittle with age.
•  Papers made from mechanical pulp are lower in color and
brightness than papers manufactured from chemical pulp.

PULPING
•  Chemical pulping : the non-cellulose material which cements
the fibers together is chemically extracted.
•  The aim of chemical pulping is to separate each fiber from
its bonding material – wood substance is composed of
cellulose fibers held together by a glue-like material called
“lignin”
•  Chemical pulping dissolves the lignin binding agent, freeing the
fibers.
•  Chemical pulping has a yields of 45 – 55% cellulose fibers,
compared to the yields of 90% with mechanical pulping methods.
•  Chemical pulping processes use acids such as sulfurous acid,
and alkalis, such as caustic soda.
•  Chemical pulping yields the purer and stronger forms of pulp
known as Woodfree (free of groundwood pulp)

PULPING
Properties and characteristics of chemical pulp
•  Has a higher proportion of fibers in their original length, and
thus has much higher strength than mechanical pulp.
•  Fibers is more resilient (flexible).
•  Chemical pulps produce papers that are whiter, brighter and
stronger.
•  Do not yellow (discolor) with ageing.
•  Both coniferous and deciduous are suited for chemical pulp.

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 BLEACHING
•  The next stage in the manufacture of pulp is bleaching.
•  Bleaching removes all residual lignin and impurities in the fibers
•  Bleaching a pulp makes paper whiter, which improved printing
contrast and make paper more light-fast.
•  Enables a reduction in the chemical digestion processes –
without too much damage to the fibers.
•  Most modern bleaching is carried out as a multi-stage process.
•  Two main sets of chemicals are used:
- Those based on chlorine (chlorine dioxide)
- Those based on oxygen, ozone or hydrogen peroxide

Oxygen and hydrogen peroxide are more environmentally

friendly and are growing in use.

BLEACHING
•  Once the bleaching process is complete, the pulp is ready for
delivery to the stock preparation plant.

•  The following stages of blending and stock preparation are

determined by the type, properties and end-use of the finished
paper.

Debarking in a rolling drum debarker

• After felling, the trees are selected, cut into suitable length
and debarked in a rolling pen drum called a tumbler
drum debarker.
Several hundred million acres of the forests of the united state are available for
Papermaking.
Several year a ago, they used power chain saw to cut down the tree but now a day,
Used forest tractors (skidder).
Logs must be debarked (since bark is unsuitable as a fiber source for papermaking)
And converted to chips.
Mill which receive their logs in longer lengths, use a “slasher saw” to cut them into
Shorter lengths for debarking.
A hollow debarking drum 40’ to 50’ long and 10’ to 12’ in diameter is used to rubbed
Free of bark. After debarking, the logs are conveyed to a chipper.
The chipper dimension (length and thickness and uniformity is of critical concern in
Future pulping operations. Oversize chips – recycles / undersize – salvaged and
Burned in the boiler
PULPING :

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 Stages of Papermaking
Debarking
Cutting logs into chips

Pulping

Bleaching/Breaking

Refining
Stock preparation

Paper machine

STOCK PREPARATION
•  The fibers obtained by pulping must receive further treatment is
called stock preparation.
•  This stage entail with fibers refining and the mixing of fibers with
non fibrous materials to produce of a desired properties.
•  Refining stage – using disk refiners to make fibers swell and
soften and their surface develop fine hairs, all of which promote
bonding and make a stronger paper.
•  During stock preparation, the cellulose fibers are mixed with
fillers, internal sizing, dyes and color pigments, and others
additives that impart properties of paper.

FILLERS
•  Adding the Fillers during stock preparation (furnish), improve
the finish of the paper, improve its print quality, control absorption
of printing ink and increase opacity, softness, weight and
dimensional stability of the paper.

•  Paper need to be dimensionally stable for printing.

- To achieve prints that is in register.
- To produce prints with a perfect color register
- Dimensionally stable paper is one of the prerequisites for
preventing doubling.

Mineral fillers
China Clay - To achieve smoothness and printability qualities
Titanium Dioxide - To improves opacity and whiteness.
Calcium carbonate - Produces paper with low acidity and high strength.

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 SIZING
•  Adding the sizing during stock preparation (furnish), to reduce
the absorbency of the paper. Unsized paper resembles blotting
paper.

Added Sizing to the furnish:

1.  Intended to give the paper the desired water resistance.

2.  To improve strength.

3.  Reduces the picking of surface fibres.
4.  Increase ink “Hold-Out”

Sizing can be divided into 2 categories:

1.  Internal Sizing (Beater or engine) – added fibre mix just
before it goes into paper machine.
2.  Surface/External Sizing (Tub). – applied by a size press
that is part of the paper machine.

Sizing classfication
1.  Waterleaf (unsized) – Blotting Paper

2.  Slack Sized - Newsprint

3.  Hard Sized - Bond Paper

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 PAPER MANUFACTURE

Stage 2 – Paper Machine

The Fourdrinier paper machine can be divided into two areas :

1) Wet End : consisting of a wire section and the press section
2) Dry End : consisting of a dryer section and a calender
section

1) The Wet End :

The Fourdrinier paper machine can be divided into two areas :

1) Wet End : consisting of a wire section and the press section

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 - stock – consists of 99.5% water and 0.5% furnish
(Head Box)

- Head Box ; releases the stock evenly on to the

surface wire.
- Suction Boxes ; the water drained rapidly away.

- Dandy Roll ; Its purpose to compress and

smooth the fibres ; to impose the pattern into the
paper if this is wanted.
- Press section ; comprises a number of rollers set in
pairs – squeeze more water from the web as the
paper passes between them.

- The water content at this point (press section) will be

around 80%.

2) The Dry End :

- Dryer section ; a long series of steam-heated drums – dry the web
using heat and pressure.
- Size press unit ; a coating unit which applies a surface spray to the
paper
- This process is known as surface sizing or external sizing – helps the
paper’s resistance to water penetration. The popular ingredient –
starch.
- Calenders ; a sets of horizontal rolls, usually of steel, gives
smoother finish to the paper.
- Finally reeled up to form Jumbo reel.
- Web paper ; contains no more than 4 – 6 % water ( a standard
moisture contain for finished paper).

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 Added fillers to the furnish:
1.  Improve the finish of the paper (Brightness & smoothness)
2.  Improve print qualities. (ink receptivity)
3.  Control absorption of printing ink.
4.  Increase the opacity (reduce strike through)
5.  Increase the softness
6.  Increase the Weight
7.  Increase the dimensional stability of the paper

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