PAPER PRODUCTION PROCESS

PREPARED BY:

SHIVANI SIROHI
SOURCES OF PAPER
PULP MANUFACTURING PROCESS
There are three methods of manufacturing pulp:
• Mechanical Pulp (yield 90%): It uses mechanical abrasion to separate
cellulose fibers which are held together by a material called lignin.
In the process called “Groundwood” wet wood is ground by large
stones and in Thermo Mechanical Pulping (TMP), metallic plates rub
steam heated chips at high speeds, separating fibers.
• Chemical Pulping (yield 50%): It uses chemicals to dissolve lignin.
Kraft pulp is most common pulp.
• Semichemical Pulp: Uses chemicals to soften lignin, and mechanical
abrasion in refiners – Chemi Thermo Mechanical Pulping.
Before the pulp is shipped, it is dried on a machine called a Flakt
Dryer. The Flakt Dryer has multi-level decks or webs with steam-
heated air jetted through the pulp and rollers that squeeze it to
remove the water.
 PAPER MACHINES
• The paper machine line can be used to produce a
hundred different kinds of paper, depending on the
kind of pulp, thickness and line speed. Paper can vary
from very thin, high quality "Bible Paper" to very
heavy, low quality box or kraft paper used to make
'cardboard boxes'.
• Typically mills are broadly separated according to
"High Quality Papers" or "Kraft Mills".
Kraft mills make the same paper all the time, with small
variations for basis weight or coatings.
Quality Paper mills tend to make a variety of papers that
mostly serve the printing industry. Newsprint falls
someplace in the middle.
FOURDRINIER PAPER MACHINE
Calendar
Flow
Dryer Stack
Spreader
Section
Head Fourdrinier Press Reel
Box Table Section
FOURDRINIER PAPER MACHINE
•Head Box - receives the liquid pulp, with all ingredients
ready to make the paper.
•Flow Spreader - controls the pulp distribution on the Table.
•Fourdrinier Table - a perforated conveyor belt that supports
the pulp solids and allows the water to drain through.
•Press Section - rollers that squeeze water from the pulp.
•Dryer Section - typically steam drums (cans) that
progressively dry the pulp as it turns to paper; the drying
section may also include electric or gas infrared heaters and
convection heating hoods.
•Calendar Stack - metal rollers that compress the paper to
form uniform thickness; may be smooth or include some sort of
pattern or texture.
•Reel - takes up the paper as it is finished.
 PAPER COATING
Many papers require a "coating" to be
complete. The coating process may be
connected to the paper machine where the
machine is dedicated to making only one kind
of paper, or may be a complete separate
process in a totally different location. Common
coatings improve whiteness of paper and
release for things like labels.
PAPER REALS
 TISSUE MACHINES
Tissue Machines are very similar to paper
machines in over-all process, but they are much
smaller in size and have a different kind of dryer
section. Tissue is what is used to make toilet
paper, paper towels, napkins, etc. Like paper,
tissue is made from a pulp material, but is more
often recycled and much lower quality materials.
It is made in large rolls and later in a separate
process "converted" to its final product.
 PAPER RECYCLING
• Paper recycling is the process of
manufacturing old paper products and turning
them into new, reusable paper products.

• Recycling old paper products uses 60% less

energy than manufacturing it from new
materials.
 RECYCLING PROCESS

SEPARATION

RE-PULPING
PAPERMAKING

RECYCLING
PROCESS SCREENING

REFINING

CLEANING
DE-INKING
 PAPER RECYCLING PROCESS
There are seven steps of recycling the paper:
1. Separation
After paper for recycling is collected and brought to a
recycling facility, it is sorted by type.
2. Re-pulping
The different types of paper products to be recycled are
moved by conveyor belt to a vat that contains water and
chemicals as well as blades that chop the paper down
into small pieces.
3. Screening
The pulp is pushed through a series of screens that strain
away bits of other matter such as glue or bits of plastic.
 CONTD…
4. Cleaning
The pulp is then cleaned by feeding it into a cone-shaped
cylinder that spins the pulp around at high velocities.
5. De-inking
De-inking removes the ink residue from the paper products, and
is done by a process called "flotation”.
6. Refining
The pulp is then beaten to make the paper fibers swell and turn
any bundles of fibers into individual fibers.
7. Papermaking
The pulp is now ready to be recycled and remade into new
paper products, and is either blended with pulp or used alone
to create recycled paper.
BENEFITS OF RECYCLING THE PAPER
• Recycling newspaper saves 14% of landfill space
• For every ton of newspaper recycled you can save
enough energy to power a television for 31 hours
• Recycling one ton of paper can save 17 trees
• Reduces sulphur dioxide emissions
• Most paper can be recycled up to 8 times to
create new products
• Leaves more trees for the sustainability of our
environment
• Saves energy
 HANDMADE PAPER MAKING
PROCESS
There are 10 steps including in the handmade paper making process:
1.Paper Making: The process began by reducing cotton waste to pulp. the pulp is diluted with
water and put into a masonry. The lifting mould is then dipped into the trough, shaken
evenly and lifted out with the pulp on it.
2.Rose Plucking: Roses are selected and plucked, Flower petals are added to the pulp which is
then transferred to large tanks and submerged and then taking pulp from the tank, and
emptied it into the tray.
3.Pressing: After inverting the tray and the muslin, the sheet of pulp now on top is added to a
pile. The pile is then pressed to drive out most of the water. Pressing reduces the bulkiness
of the paper i.e. the sheets become more compact. 
4.Separation: Small dirt particles are removed manually with a sharp instrument. The cleaned
sheets are given a coating with starch to improve the physical properties of the paper and
prevent feathering. This is called sizing and can be done manually with a brush.
 CONTD…
5. Natural Drying: After Separation the sheets are dried by hanging them
in open areas of sunlight to remove the rest of the moisture.
6. Calendaring: Then Dried Paper is passed through a series of metal
rolls at the end of a paper machine which increases its smoothness
and glossy surface.
7.  Inspection: Calendared paper is hand- sorted, edges trimmed with
the help of a hand- /power-operated cut- ting machine.
8. Sorting: At this point the sheets are sort and cut to whatever sizes the
customer desires and then packed for shipment.
9. Envelope Making: Sheets are cut to appropriate sizes according to size
of envelope being made and folded with a glue stick, to seal the three
sides.
10. Screen Printing: Screen printing uses silk or other fabric stretched
tightly over a frame. Images are created by blocking parts of the screen
with stencils created by hand-drawn or photographic techniques.
INDUSTRIES INVOLVED IN THE
PAPER PRODUCTION PROCESS
• Savio Texcone(P) Ltd. ( Hapur, U.P)
• Shree Gajanan Papers & Boards Pvt. Ltd. (Vapi, Gujarat)
• ZX Global (Panckula, Haryana)
• Vanshika Overseas (Ambala Cantt)
• Abeille Print and Pack (Noida, U.P)
• Murli Industries Ltd. (Nagpur, Maharashtra)
• Parijat Paper Products (Borivali(w), Mumbai)
• Mahima Multicolour Pvt. Ltd. (Udaipur, Rajasthan)
• Krishna Carbon Paper Co. (Lakhimpur-Kheri, U.P)
• Hiren Paper Company (Goregaon Maharashtra)
 CONTD…
• I.T.C. Bhadrachalam Paperboards Ltd. (Andhra
Pradesh)
• Prism Papyrus Pvt. Ltd. (New Delhi)
• Saawariya Enterprises (Ujjain, M.P)
• Vedadri Paper Mills Pvt. Ltd. (Vijayawada)
• Premium Paper & Board Ind. Ltd. (Mumbai)
• Handmade Paper Sales Center
• G S Paper Industries & Products (Vishakhapatnam)
• Modi Graph India Pvt. Ltd. (Chennai)
• Unitech Paper & Board Industries Pvt. Ltd. (West
Bengal)