PAPER PRODUCTION

LESTER DAVE C. DAGUYO

ROGELYN C. JOSOL
HAZEL L. EYANA

DIOMEDES T. GABULE JR.

 INTRODUCTION

The word paper is derived from the word papyrus, a grasslike aquatic plant.
About 4,000 years ago, the Ancient Egyptians pounded the papyrus leaves flat and used
them as paper. The Romans also used the papyrus stems in their papermaking process:
slicing, soaking, and then pressing them under heavy rocks. The juice of the plant acted
like glue, bonding the stem strips together. The sheet was then hammered flat and dried
in the sun.

In 2nd Century paper was made by the Chinese. A Chinese court official named Cai
Lun. His paper was made from such things as tree bark and old fish netting. As it was
recognized as a valuable secret it takes 500 years before the Japanese acquired
knowledge of the method.

18th century A.D., papermaking was known in Islamic World. Then the knowledge
of papermaking eventually moved westward. The 1st European mill was built about
1150 at Jativa, in the province of Valencia, Spain. Paper mills existed in Italy, France,
Germany and England by the end of the 15th Century. And by the end of the 16th century
paper was being made throughout Europe.

Paper is made up of connected fibers whether produced in the modern factory or by

hand methods. Sources of fibers includes cloth rags, cellulose fibers from plants and
most notably trees. Using cloth in the process produces high-quality paper. Today,
many excellent papers for special uses from wedding invitation paper stock to special
 paper for pen and ink drawings come in the mix created from large proportion of cotton
and linen fibers.

Today, probably half of the fiber used for paper comes from wood that has been
purposely harvested. The remaining material comes from the wood fiber from
sawmills, recycled newspaper some vegetable matter, and recycled cloth. Increasing
demand for paper and improvements in pulp processing technology, almost any species
of tree can now be harvested for paper. Some plants other than trees are suitable for
papermaking. In areas without significant forest, bamboo has been used for paper pulp,
as has straw and sugarcane. Cotton and linen rags are used in fine-grade papers such as
letterhead and resume paper, and for bank notes and security certificates. Usually rages
are cuttings and waste from textile and garment mills. The rags must be cut and cleaned,
boiled and beaten before they can be used by the paper mill.

METHODS OF PAPER PRODUCTION

1. Manual Papermaking

All paper was made by hand, formed or laid one sheet at a time by specialized
laborers before the invention and current widespread adoption of automated machinery.
Originally it was developed in China, Asia and modified in Europe by hand use tools and
existing technologies hundreds of years ago. Almost all paper today is manufactured using
industrial machinery but manual paper production is still appreciated for its distinctive
uniqueness and the skilled craft involved in making each sheet, in contrast with the higher
degree of uniformity and perfection at lower prices achieved among industrial products.

Example:
Xuan or Shuen Paper
It is type of paper produced from the tough bark of the Tara Wing-Celtis or
Blue Sandalwood tree and rice straw. It is manufactured in the Jing County, Anhui
Province of China an area hosting mild climate and abundant rainfall making it
perfect for Xuan paper production. Moreover, it is known for its great tensile
strength, resistance to decay, steadfast color and ability to withstand being folded
many times. It is used commonly for Chinese calligraphy as the finished paper is
also white, soft and very smooth.

The paper was originally produced during ancient Chinas Tang Dynasty
(618-907 AD) in tribute to the emperor at the time; the production methods were
refined during the Ming Dynasty (1368-1644 AD) and further grew in popularity
during and after the Qing Dynasty (1644-1911 AD).
 Along with winning the Golden Award at the Panama International
Exposition in 1915, the procedure for making the paper has been listed as a world
intangible cultural heritage by UNESCO in 2009.

Washi Paper

Washi is traditional handmade Japanese paper made from the bark of the
paper mulberry (Kozo), the gampi tree and the mitsumata shrub (Edgeworthia
papyrifera). The name Washi comes from wa meaning Japanese and shi
meaning paper.

Later, the custom started of using washi for sliding doors and screens. With
its excellent air permeability, washi is well suited to Japans hot and humid climate.
That is why it came to be used as a material for architectural purposes. Some
100,000 households made paper in the mid 1800s. Now only about 400 continue
the tradition.

Washi is most often made during the winter months (December January)
in order to prevent bacteria from ruining the fibers; the cold also helps contract the
fibers which results in a crisper feel of the resulting paper.

Mulberry Paper Pi Kozo Paper Ecuadorian Kozo Paper

Close up of Washi
Close-up of Edges
papers

2. Industrial Papermaking

The paper machines used in todays paper mills are extremely sophisticated production
plants in their technology. They can measure more than ten meters across and up to 120
meters in length. Their design and various elements are determined by the nature of the
paper and board grades to be produced, and by the raw-material input. Every minute, the
machines produce up to 1,400 metres of paper.

Many modern papermaking machines are based on the principles of the Fourdrinier
Machine, which uses a specially woven plastic fabric mesh conveyor belt (known as a wire
as it was once woven from bronze) in the forming section, where a slurry of fibre (usually
wood or other vegetable fibres) is drained to create a continuous paper web. After the
forming section the wet web passes through a press section to squeeze out excess water,
then the pressed web passes through a heated drying section.

The original Fourdrinier forming section used a horizontal drainage area, referred to as
the drainage table.

Paper machines have four distinct operational sections:

Forming section, commonly called the wet end, is where the slurry of fibres filters out
fluid a continuous fabric loop to form a wet web of fibre.
Press section where the wet fibre web passes between large rolls loaded under high
pressure to squeeze out as much water as possible.
Drying section, where the pressed sheet passes partly around, in a serpentine manner,
a series of steam heated drying cylinders. Drying removes the water content down to a
level of about 6%, where it will remain at typical indoor atmospheric conditions.

Calender section where the dried paper is smoothened under high loading and pressure.
Only one nip (where the sheet is pressed between two rolls) is necessary in order to
hold the sheet, which shrinks through the drying section and is held in tension between
the press section (or breaker stack if used) and the calender. Extra nips give more
smoothing but at some expense to paper strength.

Paper machines are long-lived assets that usually remain in service for several decades. It
is common to rebuild machines periodically to increase production and improve quality or
to change the paper grade.

Diagram showing the sections of the Fourdrinier machine.

 PROCESS AND EQUIPMENT OF PAPER PRODUCTION

Manual Papermaking Production

a. Raw Material Preparation.

This includes sorting, cleaning and weighing of raw materials.

b. Digestion and Cooking.

Fibrous materials are cooked and subjected to high temperature and pressure in a
stationary or rotary digester.

c. Blow Tank/Blow Pit.

This is where the cooked fibers are discharged to drain off the excess cooking liquor.

d. Screening/Washing.

The cooked fibers are screened to separate the uncooked fibers from the pulp. They are
washed thoroughly with water in drum washers to remove the chemicals adhering to the fibers.

e. Bleaching/Washing.

The pulp produced is bleached (depending on its intended use) using closed vessels
usually made up of stainless steel. They are then washed thoroughly with water to remove excess
bleaching chemicals.

f. Centricleaning.

This is to eliminate dirt, minute impurities, and other foreign matters, which cannot be
separated by the screen.

g. Sheet Forming.

The pulp is formed into sheets.

h. Pressing.

The wet pulp lap is pressed to remove excess water.

i. Drying.

This is to further remove the water and to maintain only the required percentage of
moisture. The pulp is dried with the use of steam.
j. Layboy.

The pulp sheet is cut to the desired length, baled, weighed, and then brought to the
storage area.

Industrial Papermaking Process

Papermaking uses raw material including water, energy, chemicals and woodchips through
process which contains cellulose. Cellulose is a component of wood that has fiber which most
plant life naturally exists.
 These cellulose fiber passes through a paper mill boiler which produces steam for
turbines which make electricity for pumps and motors. The steam also used to dry the
paper and to cook the wood chips in the digester during pulping. Mostly bark and wood
by product are used as fuel.

Often, wood fibers comes from the chips at lumber mills to paper mills or as logs
which are debarked and then sent into a chipper. Chips and chemicals go into a
digester, which is a big pressure cooker. After cooking with chemicals and steam, the
wood chips are separated into wood fiber and lignin, the chemical binding the cellulose
together. Then, the mixture is blown out of the pressurized digester into a non-
pressurized blow tank. Washers clean the mixture by removing the cooking chemicals
and lignin, turning it into pulp. The cooking chemicals and lignin, called black liquor,
is pumped to evaporators, which remove water. The concentrated black liquor is
pumped into a recovery boiler where its bio-based content is burned to generate the
majority of steam and electricity needed to power the facility. The organic material in
the liquor burns and provides energy, while any inorganic material becomes a molten
stream that is drained from the boiler, dissolved in water and prepared for reuse in the
digester to cook more wood chips. Lime is added in the causticizer from a lime kiln
and the chemicals are pumped to a clarifier to allow the solids to settle. Clean cooking
chemicals are sent to the digester for re-use, and residuals are washed and sent to the
lime kiln to be turned into lime.

The naturally brown pulp is made white through a bleaching process . Bleached
paper is used for books and magazines, food packaging, tissues, and hundreds of other
uses. Some unbleached pulp is used to make grocery bags, and corrugated shipping
containers or cardboard boxes. The pulp fibers are then prepared for the paper machine
in refiners. Recovered paper is often used for additional fiber, or instead of wood
fiber from trees. This fiber is pulped and cleaned, just like the fiber from the digester
and the pulper, to ensure a uniform sheet of paper.
To make paper, a pulp mixture of 1 percent fiber and 99 percent water flows from the
headbox onto a moving former, a wire screen that drains some of the water into a wire
pit. The sheet that is formed is carried into a press section where more water is
removed. The paper passes over dryers enclosed in a hood. Some specialty papers get
coated with liquid clay or chemicals in a coating machine, to improve the surface and
printability of the paper.
The calendar smoothes the paper, which is then wound on a reel. The reel is either
cut into smaller rolls on a slitter or made into sheets of paper on a sheeter. Then lastly
the finished product is then shipped to our customers around the world.
 Questions

1. Paper was derived from the word __________, a grass like aquatic plant.
Answer:
PAPYRUS

2 4. Give atleast 3 raw materials of paper production

Answers:
a. Trees
b. Wood fiber from sawmills
c. Recycled newspaper
d. Recycled cloth
e. Cotton
f. Linen rags

5. It is located at the beginning of the paper machine.

Answer:
Head-box

6. What are the methods of paper production?

Answers:
a. Manual Papermaking
b. Industrial Papermaking

7-8. Name 2 process of manual papermaking.

Answers:
a. Raw Material Preparation.
b. Digestion and Cooking.
c. Blow Tank/Blow Pit.
d. screening/Washing.
e. Bleaching/Washing.
f. Centricleaning.
g. Sheet Forming.
h. Pressing.
i. Drying.
j. Layboy.

9-10. Give 2 distinct operations of Fourdinier industrial papermaking.

Answers:
a. Forming section
b. Press section
c. Drying section
d. Calendar Section
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