CHEMICAL PROCESS INDUSTRIES

PAPER
CHE 320E

Presented by:
Dingcong, R.
Pacheo, N.
WOOD you believe?!
Paper can be made from
• Cotton
• Bagasse (waste of Sugar)
• Bamboo
• Rice Straw
• Wheat Straw
• Grass

or almost anything made from CELLULOSE!

WOOD you believe?!
The process begins with the
raw wood, which is made up of fibers called "
cellulose."

The cellulose fibers are stuck together with a

natural glue called "lignin." When the lignin is
removed and the cellulose fibers are separated and
reorganized, paper can be made.
WOOD you believe?!
WOOD you believe?
How to make paper?
To make paper from trees, the raw wood must first
be turned into "pulp." Wood pulp is a watery “soup"
of cellulose wood fibers, lignin, water, and the
chemicals used during the pulping process.
 Paper Manufacturing
Paper manufacturing is the process of converting raw materials,
such as wood fiber, recycled fiber, and other materials, into paper
products. The process involves a series of mechanical, chemical,
and other treatments that transform the raw materials into pulp,
which is then formed into continuous sheets of paper.

The paper manufacturing process typically includes several stages,

including preparation of raw materials, pulping, refining, forming,
pressing, drying, and finishing. During each of these stages, the
pulp mixture undergoes various treatments to improve its
properties, such as strength, brightness, and printability, and to
create the final paper product.
 Paper Manufacturing
The paper manufacturing process can vary depending on the
intended use of the paper product, as different types of paper require
specific properties and characteristics. For example, newsprint
paper requires high porosity and low density, while fine writing
paper requires high smoothness and uniformity.

Paper manufacturing is a complex and highly automated process,

and it requires advanced technologies, equipment, and skilled
workers to ensure that the final paper product meets the desired
quality and performance requirements.

The industry has made significant advances in recent years to

improve the efficiency and sustainability of the process, such as
reducing water and energy consumption, increasing the use of
recycled fibers, and minimizing waste and emissions.
 History of Paper

2500 and 2000 BC

Writing paper first appeared between 2500 and 2000 BC, made from a tall reed called papyrus
which grows along the Nile river in Egypt. Strips from the reed were glued together with starch.

A.D. 105
The Chinese invented good processes for paper manufactured from bamboo and cotton about A.D.
105 and continue to make good paper by hand today.
PAPYRUS CAI LUN
 N

History of Paper

NEAR END OF 14TH CENTURY

Southern Europe learned of the process and began to manufacture rag paper near the end of the
fourteenth century.

17TH CENTURY
English manufacturers became established in the seventeen century, and a paper mill was
established in the United States in 1690. At this time all European paper was made from cotton and
linen rags. Book printing began with Gutenberg’s bible and greatly increased the demand for
paper.
RAG PAPER
PAPER MILL
 History of Paper

1750
About 1750 the beater was developed and adopted in Holland, hence it became the Hollander.

1799
In 1799, a Frenchman, Robert, invented the process for forming sheet paper on a moving wire
screen. During evolution and improvement, this became today’s Fourdrinier machine.
FOURDRINIER MACHINE
FOURDRINIER MACHINE
FOURDRINIER MACHINE
 History of Paper

1809
In 1809 the cylinder machine was invented by Dickinson and forced the Fourdrinier into the
background, but by 1830 the Fourdrinier’s superiority for making fine papers was established.

1826 and 1827

In 1826, steam cylinders were first used fro drying and the first Fourdrinier was received in
the United States in 1827.
CYLINDER MACHINE
CYLINDER MACHINE
STEAM CYLINDER
STEAM CYLINDER
 History of Paper

1851
Paper demand increased with lower prices and advancing general education, so a rag scarcity
developed. Keller of Saxony developed a mechanical process for making pulp from wood was
developed by Watt and Burgess in 1851.

1857
In 1857, the American chemist, Tilghman was granted the basic patent (U.S. 70.845) for the sulfite
process, which produced good, readily bleachable pulp.
 History of Paper

1884
The kraft process (from the German word kraft = strong) resulted from basic experiments
conducted by Dahl in 1884 in Danzig. This process is commonly also referred to as the sulfate
process because sodium sulfate is used as a make-up chemical for the cooking liquor. The
dissolving agent, however, is not Na2SO4.

1909
In 1909, the sulfate process was introduced into the United States. At the time, pulp introduction
was divided into 48 percent mechanical, 40 percent sulfite, and 12 percent soda.
KRAFT PROCESS
 PROPERTIES OF PAPER
Basis Weight or Grammage Machine and Cross Direction

Bulk Moisture

Caliper or Thickness Smoothness

Curl Temperature and Humidity

Dimensional Stability Wire Side and Felt Side

Friction
Basis Weight or Grammage
All paper machines are designed to manufacture paper in a given basis
weight range. Tighter the range and more efficient will be the machine.

Basis weight of paper is the weight per unit area. This can be expressed as
the weight in grams per square meter (GSM or g/M2), pounds per 1000
sq. ft. or weight in Kgs or pounds per ream (500 sheets) of a specific size.

The basis weight is what determines, how much area the buyer gets for a
given weight. e.g. if basis weight is 50 g/m2, for every 1 kg weight, the
buyer gets 20 m2.

When the basis weight is expressed as ream weight, it tells the buyers how
many reams he/she getting for a given weight.
Basis Weight or Grammage
Typical Grammage Values

Grade g/m2

Newsprint 40-50

Cigarette Tissue 22-25

Bond 60-90

Paperboard 120-300

Accepted Trade Tolerance +/- 5%

Bulk
Bulk is another very important parameter of paper particularly for printers.

Bulk is a term used to indicate volume or thickness in relation to weight.

It is the reciprocal of density (weight per unit volume).

It is calculated from caliper and basis weight.

Bulk (cubic centimeter/g) = Thickness (mm)* Basis Weight (g/m2) *

1000.

Decrease in bulk or in other words increase in density makes the sheet

smoother, glossier, less opaque, darker, lower in strength etc.

High bulk is desirable in absorbent papers while lower bulk is preferred

for printing papers particularly bible paper, dictionary paper etc.
Bulk
High bulk is desirable in absorbent papers while lower bulk is preferred
for printing papers particularly bible paper, dictionary paper etc.

Book Bulk: Book bulk is defined as the overall thickness in mm of a

given number of paper sheets.

The bulking number is defined as number of sheets required to bulk 25

mm or approximately 1".
Bulk
Typical Thickness Values

Grade µm

Newsprint 60-80

Office/Business Paper 105-110

Blotting Paper (230g/m2) 540-590

Tracing Paper (90/g/m2) 78

Label Paper (79 63

Tissue 125

Accepted Trade Tolerance +/- 10%

Caliper or Thickness
For a given basis weight, thickness determines how bulky or dense paper
is.

A well beaten/refined pulp, short fiber pulp such as hard wood or straw
pulp, highly filled or loaded paper will show lower thickness for given
basis weight.

Thickness or Caliper of paper is measured with a micrometer as the

perpendicular distance between two circular, plane, parallel surfaces under
a pressure of 1 kg./CM2.

Uniform caliper is for good roll building and subsequent printing.

Variations in caliper, can affect several basic properties including strength,

optical and roll quality. Thickness is important in filling cards, printing
papers, condenser paper, saturating papers etc.
Curl
Paper curl can be defined as a systematic deviation of a sheet from a flat
form.

It results from the release of stresses that are introduced into the sheet
during manufacture and subsequent use.

Paper curl has been a persistent quality issue and is increasingly important
for paper grades being subjected to high speed printing, xerography and
high precision converting processes.
Curl
Three Basic Types:

Mechanical curl - when one side of the paper is stretched beyond its
elastic limits. One example of this is the curl in the sheet which forms near
the centre of a roll.

Structural curl - two-sidedness in the sheet, that is a difference in the

level of fines, fillers, fiber area density or fiber orientation through the
sheet thickness.

Moisture curl - when the paper sheet is being offset printed. One side of
the sheet may pick up more moisture than the other, the higher moisture
side releases the built in drying strains and the paper will curl towards the
drier.
Dimensional Stability
Cellulose fibers (main constituent of paper) swell in diameter from 15 to
20% from dry condition to saturation point.

Most of the fiber in paper sheet are aligned in the machine run direction,
absorption and de-absorption of moisture by paper causes the change in
CD dimension.

Such changes in dimension may seriously affect register in printing

processes and interfere with the use of such items as tabulating cards.

Uneven dimensional changes cause undesirable cockling and curling.

Change that occurs in the dimensions of paper with variation in the

moisture content is an important consideration in the use of paper.
Dimensional Stability
All papers expand with increased moisture content and contract with
decreased moisture content, but the rate and extent of changes vary with
different papers.

Dimensional stability of paper can be improved by avoiding fiber to

absorb moisture. Well sized papers have better dimensional stability.
Dimensional Stability
Typical Values

Grade MD (%) CD (%)

Carbonless Paper 0.050-0.150 0.200-0.400

Bond Paper 0.100-0.200 0.200-0.400

Coated Art Paper 0.090-0.150 0.150-0.350

(under 200 g/m2)

Gasket Paper 0.400-1.000 0.500-1.100

Friction
Friction is the resisting force that occurs between two paper or paperboard
surfaces in contact when the surfaces are brought to slide against each
other.

This property is measured as a coefficient of friction, which is the ratio of

the frictional force, to a force acting perpendicular to the two surfaces.

Two Components of Friction:

Static friction is the force resisting initial motion between the surfaces

Kinetic friction is the force resisting motion of the two surfaces sliding
against each other when already sliding at a constant speed.
Friction
Measurement of the coefficient of friction has applications in packaging
where a high coefficient will indicate that containers such as sacks, bags
and paperboard containers will resist sliding in unit loads or on packaging
lines.

Important in printing papers, since a specific coefficient of friction is

needed so that individual sheets will slide over each other, otherwise
double press feeding may result.
Friction
Typical Coefficient of Friction Values using Horizontal Plane Method

Grade Static Friction Kinetic Friction

Office/Business 0.50-0.65 0.35-0.5

Paper

Silk Coated Paper 0.45-0.55 0.30-0.45

Gloss Coated 0.40-0.50 0.30-0.40

Paper
Machine and Cross Direction
In paper machine approach flow system, when stock passes through
pressure screen, the fibers are oriented lengthwise.

If the stock velocity from headbox slice is equal or less than wire speed,
fibers which are already oriented lengthwise, will align in the direction of
wire run.

Fiber alignment can be altered to some extent if stock velocity is less than
wire speed.

So all papers have a definite grain direction due to greater orientation of

fibers in the direction of paper machine run.

This grain direction is known as machine direction.

Machine and Cross Direction
The cross direction is the direction of paper at right angles to the machine
direction.

Some of the properties vary with the MD and CD and hence the values are
reported in both the directions.

The sheet which have all relevant properties same or almost same in both
direction are known as 'square sheet'.
Machine and Cross Direction
While sheeting the paper, machine and cross direction are to be kept in
mind and the sheet cutting to be done to suit the end use requirements.

1. All printing papers are to be cut in long grain (The biggest dimension in
the grain direction).

2. Book papers fold better and the book stays open better if the sheets are
out so that the machine direction runs up and down the pages.

3. Wrap around labels for metal cans and bottles are to be cut with the
machine direction vertical to obtain greater flexibility about the can.
Machine and Cross Direction
While sheeting the paper, machine and cross direction are to be kept in
mind and the sheet cutting to be done to suit the end use requirements.

1. All printing papers are to be cut in long grain (The biggest dimension in
the grain direction).

2. Book papers fold better and the book stays open better if the sheets are
out so that the machine direction runs up and down the pages.

3. Wrap around labels for metal cans and bottles are to be cut with the
machine direction vertical to obtain greater flexibility about the can.
Machine and Cross Direction
Long grain and Short grain : The sheet is in long grain if the larger
dimension is parallel to grain (MD) direction. The sheet is said to be in
short grain if the larger dimension is parallel to cross direction (CD).

There is no sure way to determine the MD or CD of a sheet but one crude

method which work is; cut a strip of about 1" wide and 2" long paper and
moist it.

Put this moist sheet on a smooth surface or hand.

As sheet will dry it will curl.

The direction of curl is CD as paper contract in CD more than MD while

drying.
Moisture
All grade of paper has some percentage of moisture.

Moisture in paper varies from 2 - 12% depending on relative humidity,

type of pulp used, degree of refining and chemical used.

Most physical properties of paper undergo change as a result of variations

in moisture content.

Water has the effect of plasticizing the cellulose fiber and of relaxing and
weakening the inter-fiber bonding.

The electrical resistance and the dielectric constant of paper both vary
with moisture content.
Moisture
The absorption and reflectance of certain bands of infrared and microwave
radiation by paper are affected by its moisture content.

The amount of water present in a sheet of paper is usually expressed as a

percent.

The amount of water plays an important role in calendaring, printing and

converting process.

The absolute moisture content is expressed as a % of the paper/paperboard

weight.

The sample is generally not conditioned while doing this test.

Moisture
Typical Moisture Value

Grade %

Newsprint 7.5-9.5

Office/Business Paper 4-4.5

Marketing Wood Pulp 10

Printing Paper 6-7

Tissue 2-7

Accepted Trade Tolerance +/- 10%

Smoothness
Smoothness is concerned with the surface contour of paper.

It is the flatness of the surface under testing conditions which considers

roughness, levelness, and compressibility.

It is common to say that paper has a "smooth" or a "rough" texture.

The terms "finish" and "pattern" are frequently used in describing the
contour or appearance of paper surfaces.

Smoothness is important for writing, where it affects the ease of travel of

the pen over the paper surface.

Finish is important in bag paper as it is related to the tendency of the bag

to slide when stacked.

Smoothness of the paper will often determine whether or not it can be

successfully printed. Smoothness also gives eye appeal as a rough paper is
unattractive.
Smoothness
Smoothness (Bekk Method): This test is an indirect measure of paper
smoothness when it is under moderate pressure( 100 kPa). The standards
test procedure is described in TAPPI T 479.

Roughness (Sheffield Method): This test is an indirect measure of paper

smoothness or roughness. It is a measurement of air flow between the
specimen (backed by flat glass on the bottom side) and two pressurized,
concentric annular lands that are impressed in to the sample from top. The
standards test procedure is described in TAPPI T 538.

Roughness (Print-surf Method): Very similar to Sheffield methods. The

standards test procedure is described in TAPPI T 555.
Smoothness
Typical Smoothness Value

Grade Parker Print Surf Bendtsen

(µm) (mls/min)

Newsprint (40-49 2.6-4.5 80-140

g/m2)

Stationary (45-135 0.8-2.6 50-300

g/m2)

Business Papers 100-300

(80g/m2)

Test Liner (186 1750

g/m2)
Temperature and Humidity
Conditioning of Paper

It is important to control the moisture content of paper and keep it stable

during converting operation.

To keep moisture content constant, it is important that paper is

conditioned. In addition to the effect of moisture content on physical
properties, it also determines the build up of static of the paper sheet
subjected to pressure and to friction.

The tendency for paper to develop static becomes greater with increasing
dryness.
Temperature and Humidity
Cellulose fibers are hygroscopic i.e. they are capable of absorbing water
from the surrounding atmosphere.

The amount of absorbed water depends on the humidity and the

temperature of the air in contact with the paper.

Hence, changes in temperature and humidity, even slight changes, can

often affect the test results.

So, it is necessary to maintain standard conditions of humidity and

temperature for conditioning.
Wire Side and Felt Side
The side which is in contact with the paper machine wire during
manufacturing is called the wire side.

The other side is top side.

Before a thin layer of fibers deposit on machine wire, fines and fillers
drain out hence wire side has less fines and fillers compared to top side.

Properties such as smoothness, texture and ink absorbency differ between

wire and felt side and it is customary to measure these properties on both
sides.
Wire Side and Felt Side
This difference of properties on two sides of paper is known as two-
sidedness.

Highly filled or loaded or paper made from short fiber pulp will show
higher two-sidedness.

In case of paper to be printed on one side only, best results are obtained by
printing on felt side.

Postage stamps are printed on wire side and then gummed on felt side,
where the smoothness is helpful for attaining an even application.

Wire side and top side described above are in reference to single ply paper.
Wire Side and Felt Side
In case of multi-ply paper/board, every ply will have wire side and top
side.

The top side of top most layer will be top side and wire side of bottom
most layer is wire side of multi-ply board.

Different type of fibers, fillers and chemicals are used in different layers
for techno-economical reasons.

The standards procedure is described in TAPPI T 455

TABLE
PAPER MAKING PROCESS
PAPER MAKING PROCESS
MANUFACTURING PROCESS
Preparation of the Fiber Drying

Pulping Bleaching

Refining Calendering

Forming Coating

Pressing Cutting and Packaging

PREPARATION OF THE FIBER
The preparation of the fiber is the first step in the paper manufacturing process. It
involves breaking down the raw material, typically wood chips, into small fibers that
can be used to make paper.

The preparation of raw materials is a crucial step in the paper manufacturing process,
as it affects the quality and properties of the final paper product. The main raw
materials used in papermaking are wood fiber, recycled fiber, and other materials such
as pulp substitutes, fillers, and chemicals.

The preparation of wood fiber involves harvesting trees, transporting them to the pulp
mill, and converting them into wood chips. The wood chips are then subjected to a
series of mechanical and chemical treatments to separate the cellulose fibers from the
lignin and other impurities. This process is known as pulping, and it can be done using
various methods, such as chemical pulping, mechanical pulping, or a combination of
both.
PREPARATION OF THE FIBER
Recycled fiber is another important raw material used in papermaking, and it involves
collecting used paper and converting it into pulp. The recycled fiber is then blended
with virgin fiber to create a pulp mixture that meets the desired quality and
performance requirements.

Other materials, such as pulp substitutes, fillers, and chemicals, may also be added to
the pulp mixture to improve the paper's properties, such as strength, brightness, and
printability. These materials can include clay, talc, starch, dyes, and various chemical
additives.
Once the raw materials are prepared, they are typically transported to the paper mill,
where they undergo further processing, such as refining, forming, pressing, drying, and
finishing, to create the final paper product.
PREPARATION OF THE FIBER
Overall, the preparation of raw materials is a critical step in the paper manufacturing
process, and it requires careful attention to detail and quality control to ensure that the
final pulp mixture meets the desired quality and performance requirements. This will
ensure that your customers are satisfied, leading to improved customer retention and
customer loyalty.
PULPING
Pulping is a crucial step in the paper manufacturing process, during which wood chips,
recycled paper, or other raw materials are turned into pulp, which is then used to make
paper.

The pulping process can be divided into two main types: mechanical pulping and
chemical pulping.

Mechanical pulping involves grinding the wood chips or other raw materials using
mechanical force to separate the fibers. This method is fast and efficient but produces a
lower-quality pulp that is not suitable for all paper types.
PULPING
Chemical pulping, on the other hand, uses chemicals to break down the lignin that
binds the fibers together, resulting in a higher-quality pulp. There are two main types
of chemical pulping: sulfite and kraft pulping.

• Kraft pulping: This is the most common method of chemical pulping. The wood
chips are cooked in a solution of sodium hydroxide (caustic soda) and sodium
sulfide (white liquor) at high temperatures and pressure. This breaks down the
lignin and separates the fibers, leaving a pulp that is strong and versatile.

• Sulfite pulping: This method uses a solution of sulfurous acid to break down the
lignin and separate the fibers. Sulfite pulping produces a pulp that is softer and
more flexible than kraft pulp.
PULPING
KRAFT PULPING
REFINING
Refining is an important step in the paper manufacturing process that occurs after the
pulping stage. It involves mechanically treating the pulp to further separate and refine
the fibers to create a pulp with the desired properties for the specific paper product
being produced.

The refining process typically involves passing the pulp through a series of conical or
cylindrical refiners, which use rotating discs or bars to mechanically refine the fibers.
The refining process can be adjusted to control the degree of fiber separation and the
resulting fiber characteristics, such as fiber length, strength, and flexibility.

The goal of refining is to create a pulp that is suitable for the specific type of paper
being produced, whether it is newsprint, printing and writing paper, packaging
materials, or specialty papers. The refining process can be adjusted to create pulps with
different characteristics, such as higher or lower tensile strength, porosity, or
smoothness.
PAPER MANUFACTURING
FORMING
Forming is a critical step in the paper manufacturing process that involves
transforming the pulp into a continuous sheet of paper on a paper machine.

The paper machine is a complex piece of equipment that typically consists of several
sections, including the forming section, press section, drying section, and calendering
section. The forming section is where the pulp is transformed into a continuous sheet
of paper.

In the forming section, the pulp slurry is pumped onto a moving mesh screen or wire.
As the pulp travels along the screen, water is drained off, and the fibers begin to bond
together to form a wet web of paper. The consistency and speed of the pulp flow are
carefully controlled to ensure that the paper sheet has the desired properties, such as
strength, smoothness, and thickness.
FORMING
The wet web of paper is then passed through the press section, where it is squeezed
between two or more rolls to remove more water and improve the paper's density and
strength.

Next, the paper is dried in the drying section using steam-heated cylinders, and then it
may pass through the calendering section to improve its surface finish and smoothness.

The forming process is critical to the quality of the final paper product, as it can affect
the paper's surface properties, such as smoothness, porosity, and formation. Proper
formation of the paper sheet is essential to ensure that it has the desired physical and
mechanical properties for its intended use.
PAPER MANUFACTURING
PRESSING
Pressing is an important step in the paper manufacturing process that occurs after the
pulp is formed into a continuous sheet of paper on the paper machine.

The pressing stage involves passing the wet paper web through one or more sets of
rollers or presses, which squeeze out water and flatten the paper. This process helps to
improve the paper's density, strength, and smoothness by removing excess water and
consolidating the paper fibers.

The pressing stage typically follows the forming stage and precedes the drying stage in
the paper machine. The number of press sections and the pressure applied during
pressing can vary depending on the desired properties of the final paper product.
PRESSING
The pressing process helps to remove the majority of the remaining water from the wet
paper web, which can account for up to 50% of the paper's weight. As the paper web is
squeezed between the rollers, the fibers are flattened and compacted, resulting in a
denser and stronger paper product.

After pressing, the paper web typically enters the drying section of the paper machine,
where it is dried using heated cylinders or other drying methods. The pressing stage
helps to prepare the paper web for efficient drying and can significantly impact the
final quality of the paper product.

Overall, pressing is an essential step in the paper manufacturing process, as it helps to

improve the paper's strength, density, and smoothness, which are critical factors in the
final paper product's quality and performance.
DRYING
Drying is a crucial step in the paper manufacturing process that occurs after the pulp
has been formed into a continuous sheet of paper and pressed to remove excess water.

The drying stage involves passing the paper web through a series of heated cylinders
or other drying methods to remove the remaining water and bring the paper to its final
moisture content. The drying process is carefully controlled to ensure that the paper is
dried uniformly and without any damage to its structure or surface properties.

The drying section of the paper machine typically consists of several sets of heated
cylinders arranged in a specific sequence to gradually reduce the moisture content of
the paper web. As the paper web travels through the drying section, it is subjected to
increasing temperatures and decreasing humidity levels, which cause the remaining
water to evaporate.
DRYING
The drying process can significantly impact the final quality of the paper product, as it
can affect the paper's strength, smoothness, and surface properties. Proper control of
the drying temperature, humidity, and airflow is critical to ensure that the paper is dried
uniformly and without any defects.

After the paper has been dried to the desired moisture content, it may go through
additional processing, such as calendaring, coating, or surface sizing, to further
improve its surface properties and enhance its performance for specific applications.

Overall, drying is a critical step in the paper manufacturing process, and careful control
of the drying conditions is essential to ensure that the final paper product has the
desired quality and characteristics. When this stage is carried out properly, it will help
you in avoiding additional manufacturing costs, which will lead to higher gross profits.
PAPER MANUFACTURING
BLEACHING
Bleaching is an optional step in the paper manufacturing process that is used to
improve the brightness and whiteness of the paper. Bleaching removes residual lignin
and other impurities from the fibers, which can cause the paper to turn yellow over
time. There are several methods of bleaching used in the paper industry:

• Elemental chlorine bleaching: This method uses chlorine gas to bleach the pulp.
While effective, it can produce harmful byproducts such as dioxins and furans,
which are toxic and persistent in the environment.
• Chlorine dioxide bleaching: This method uses chlorine dioxide gas, which is less
harmful than elemental chlorine. Chlorine dioxide is a powerful oxidizing agent
that breaks down the lignin and other impurities in the pulp.
BLEACHING
3. Oxygen delignification: This method uses oxygen gas to break down the lignin in
the pulp. It is less effective than chlorine-based bleaching but produces fewer harmful
byproducts.

4. Peroxide bleaching: This method uses hydrogen peroxide to bleach the pulp. It is a
relatively mild and environmentally friendly method of bleaching.

5. Ozone bleaching: This method uses ozone gas to bleach the pulp. Ozone is a
powerful oxidizing agent that breaks down the lignin and other impurities in the pulp.
It is an effective and environmentally friendly method of bleaching but is more
expensive than other methods.
BLEACHING
After bleaching, the pulp is washed and screened to remove any remaining chemicals
or impurities. The resulting pulp can then be used to make paper or further refined to
improve its properties. Many paper manufacturers have shifted towards using chlorine-
free or totally chlorine-free (TCF) bleaching methods in order to minimize
environmental impacts.
PAPER MANUFACTURING
CALENDERING
Calendering is a post-processing step in the paper manufacturing process that is used to
improve the surface properties of the paper, such as smoothness, gloss, and printability.
The calendering process involves passing the paper sheet through a series of heated
rollers under high pressure. The rollers are typically made of steel or cast iron and are
either smooth or embossed with patterns or textures.
CALENDERING
The calendering process can be divided into two types: soft calendering and hard
calendering.

• Soft calendering: This process uses a series of heated rollers with relatively low
pressure. Soft calendering is used to improve the surface properties of coated
papers, such as magazine paper or coated paperboard. It can also be used to add
texture to specialty papers, such as wallpaper or gift-wrapping paper.
• Hard calendering: This process uses a series of heated rollers with high pressure,
which can be up to 1000 pounds per linear inch (PLI). Hard calendering is used to
improve the surface properties of uncoated papers, such as printing and writing
papers. It can also be used to improve the bulk and stiffness of the paper, making it
more resistant to tearing and wrinkling.
CALENDERING
The calendering process can also be combined with other surface treatments, such as
coating or supercalendering, to further enhance the surface properties of the paper. The
calendered paper is then wound onto rolls and can be further processed into various
paper products, such as books, magazines, or packaging materials.

While calendering can improve the surface properties of the paper, it can also decrease
the bulk and opacity of the paper, making it thinner and more transparent.

Therefore, the calendering process must be carefully controlled to ensure that the paper
meets the desired specifications for strength, thickness, and other properties.
COATING
The coating is a common process in paper manufacturing that involves applying a
layer of material to the surface of the paper to enhance its properties, such as
brightness, opacity, smoothness, and printability. The coating can be applied on one or
both sides of the paper and can be either aqueous-based or solvent-based.

The coating process typically occurs after the paper has been produced and before it is
rolled into finished products. There are various methods of applying coatings,
including blade coating, air knife coating, rod coating, and roll coating.

Blade coating is the most common method used in the paper industry, which involves
applying a thin layer of coating onto the paper surface using a blade. Air knife coating
uses a pressurized air stream to atomize the coating and apply it to the paper surface.
Rod coating involves using a metering rod to apply a controlled amount of coating to
the paper. Roll coating applies the coating using a rotating roller.
COATING
Once the coating is applied, the paper is typically dried using heated rollers or by
passing through a drying oven. The finished paper can then be cut, packaged, and
shipped to customers.

Coated paper is commonly used in printing applications, such as magazines, catalogs,

and brochures, as well as in packaging materials, such as food packaging and labels.
The coating enhances the paper's visual appeal and improves its performance
characteristics, such as ink holdout and resistance to smudging and tearing.
BLADE COATING
AIR KNIFE
ROD COATING
CUTTING AND PACKAGING
Cutting and packaging are important steps in the paper manufacturing process, as they
ensure that the finished product is of the desired size and shape and is packaged in a
way that protects it during shipping and handling.

After the paper is made, it is typically rolled onto large spools called jumbo rolls,
which can be several meters wide and weigh several tons. These jumbo rolls are then
transported to a converting facility, where they are cut down into smaller rolls or sheets
and packaged for sale.

The cutting process typically involves feeding the jumbo roll through a series of large
cutting blades, which slice it into smaller rolls or sheets of the desired size. These
cutting blades can be adjusted to produce rolls or sheets of different widths and
lengths, depending on the requirements of the customer.
CUTTING AND PACKAGING
Once the paper has been cut to size, it is typically packaged in protective wrapping to
prevent damage during shipping and handling. This wrapping can be made of materials
such as plastic or paper and may be printed with information about the paper product,
such as its weight, grade, and manufacturer.

Overall, cutting and packaging are essential steps in the paper manufacturing process,
as they ensure that the finished product meets the specific needs of customers and is
protected during transportation and storage.

This is the finishing stage of the paper manufacturing process. Finishing is the final
stage of the paper manufacturing process, which involves a variety of processes to
improve the paper's appearance, performance, and functionality for specific
applications.
CUTTING AND PACKAGING
Overall, finishing is a critical step in the paper manufacturing process, as it helps to
improve the paper's appearance, performance, and functionality for specific
applications. The finishing process can significantly impact the final quality and value
of the paper product, and it requires careful attention to detail and quality control.

When this stage is carried out properly, you will be able to avoid additional
operating costs, while also increasing the ratio of operating income to
operating expenses.
CUTTING AND PACKAGING
 CLASSIFICATIONS OF PAPER

COPY PAPER Bond Paper

Copy paper is a type of paper that is commonly used for Bond paper is a type of high-quality paper that is commonly
everyday printing needs, such as in offices, schools, and used for printing professional documents, such as business
homes. letters, resumes, and legal documents.
 CLASSIFICATIONS OF PAPER

CARDSTOCK Glossy Paper

Cardstock is a type of paper that is thicker and more durable Glossy paper is a type of paper that has a shiny and
than regular paper. It is commonly used for a variety of reflective surface. It is often used for printing high-quality
projects that require a sturdier material. photographs and other types of images that require vibrant
colors and sharp details.
 CLASSIFICATIONS OF PAPER

MATTE PAPER Newsprint

Matte paper is a type of paper that has a non-reflective, dull Newsprint is a type of thin, low-costpaper used for printing
surface. It has a flat finish that is smooth to the touch and is newspapers, magazines, and other periodicals.
often used for printing text-heavy documents, such as books,
manuals and brochures.
 CLASSIFICATIONS OF PAPER

TISSUE PAPER CONSTRUCTION PAPER

Tissue paper is a lightweight, delicate paper that is used for a Construction paper is a type f colored paper that is
variety of purposes due to its soft texture and absorbency. commonly used for art and craft projects.
 CLASSIFICATIONS OF PAPER

WATERCOLOR PAPER VELLUM

Watercolor paper is a type of paper that is specifically Vellum is a type of paper that has a unique texture and
designed for use with watercolor paints. appearance.
 CLASSIFICATIONS OF PAPER

TRACING PAPER PARCHMENT PAPER

Tracing paper is a thin, translucent paper that is used for a Parchment paper is a type of paper that is specially treated
variety of creative and technical purposes. with silicone, which gives it a non-stick surface and makes it
resistant to moisture and grease.
USES OF PAPER
Paper is generally used for writing puposes.

It is used to produce eco-friendly and reusable carry bags.

It is used for packaging and wrapping objects.

It has applications in different construction and industrial

procedures.

It is used as a cleaning product.

It is used in the manufacturing of tickets, money, cheque,

etc.
It is used for printing books, newspaper, etc.
 References
Samani, N. (2023, March 15). Paper Manufacturing Process: How
Paper is Made? Deskera Blog. https://www.deskera.com/blog/paper-
manufacturing-process-how-paper-is-made/#paper-manufacturing-
process-how-paper-is-made
 Paper

Thank You
CHE 320E