Paper Industry

Engr. Kenneth A. Ibasco

Topic outline
What is paper?
What is Paper made of?
Paper Manufacturing
Processes
History of Paper
Uses of paper
 PAPER
A Material manufactured in thin sheets from the pulp of
wood or other f ib rous substances, used for writing,
drawing, or printing on, or as wrapping material
 Types of Paper
PRINTING PAPERS
Color: White | Weight: 70-120 GSM | Texture: Matte or Glossy | Usage:
Everyday Printing and Documents | Opacity: >90% | Tensile Strength: 30-50
lb/in | pH level: 7-8.5 | Composition: Fiber, Wood, Cotton
RECYCLED PAPER
Color: Generally Off-White, Can Vary | Weight: 60-120 GSM | Texture: Matte |
Usage: All Purpose Paper | Opacity: 80-90% | Tensile Strength: 10-40 lb/in |
pH level: 7-8.5 | Composition: Post Consumer Waste
 Types of Paper
TRACING PAPER
Color: Translucent | Weight: 60-90 GSM | Texture: Smooth | Usage: Tracing
and Sketching | Opacity: 20-40% | Tensile Strength: 1-3 lb/in | pH level: 6-7.5 |
Composition: Wood Pulp, Cotton, Wax
GLOSS – COATED PAPER
Color: White | Weight: 35-350 GSM | Texture: Glossy | Usage: Magazines,
Brochures, and Photographs | Opacity: >90% | Tensile Strength: 25-50 lb/in |
pH level: 5.5-7.5 | Composition: Base paper coated with glossy finish
 Types of Paper
BOND PAPER
Color: White, Cream, Blue | Weight: 0-200 GSM | Texture: Matte | Usage:
Resume, Letterheads, Stationery | Opacity: 85-95% | Tensile Strength: 20
-40 lb/in | pH level: 7-8.5 | Composition: Wood Pulp, Cotton fiber
TISSUE PAPER
Color: White | Weight: 10-35 GSM | Texture: Smooth, Crepe | Usage:
Wrapping delicate items, crafting | Opacity: <40% | Tensile Strength: 1-5
lb/in | pH level: 5-6.5 | Composition: Lightweight paper, often wood pulp
 Types of Paper
Kraft Paper
Color: Brown, White | Weight: 60-120 GSM | Texture: Matte | Usage:
Packaging | Opacity: 60-80% | Tensile Strength: 40-80 lb/in | pH level: 7 |
Composition: Unbleached wood pulp
Parchment paper
Color: Off-White | Weight: 03-120 GSM | Texture: Waxy | Usage: Baking,
Calligraphy | Opacity: 60-80% | Tensile Strength: 10-20 lb/in | pH level: 5.5-7 |
Composition: Wood pulp, cotton, or specialty fibers
How Paper is Made?
 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
process
main raw materials used in papermaking are wood fiber, recycled fiber, and other
materials such as pulp substitutes, fillers, and chemicals.
 Pulping
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.
Pulping can be done by:
1. Chemical pulping
2. Mechanical pulping,
3. Combination of both.
 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.

Chemical pulping,
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.
 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
to further and
separate refine
and thethe
refine fibers to create
fibers a pulp
to create with
a pulp thethe
with desired
desired
properties for the specific paper product being produced.

The refining process can be adjusted to control the degree of fiber

separation and the resulting fiber characteristics:
- fiber length
- strength
- flexibility
 Bleaching (Optional Step)

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.
 Bleaching (Optional Step)

. There are several methods of bleaching used in the paper industry:

Elemental chlorine bleaching
Chlorine dioxide bleaching
Oxygen delignification
Peroxide bleaching
Ozone bleaching
 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.
 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.
 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.
 Calendering (Optional Step)

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.
 How to Ensure Quality Control in the
Paper Manufacturing Process?
Raw Material Quality Control:
Control: Raw materials used in paper manufacturing should be
checked
be checkedfor for
quality before
quality being
before used.
being TheThe
used. quality of wood
quality pulp,
of wood recycled
pulp, paper,
recycled paper,
and other raw materials should be checked for impurities, moisture, and other
factors that can affect the quality of the final product.
Process Control: The manufacturing process should be monitored to ensure that it
is within the acceptable range of parameters. Control charts can be used to track
key process parameters such as temperature, humidity, and pressure, and
deviations from the standard parameters should be addressed promptly.
Quality Testing: Quality testing should be performed at various stages of the
manufacturing process to ensure that the product meets quality standards. Tests
may include tensile strength, tear resistance, brightness, and other parameters.
 How to Ensure Quality Control in the
Paper Manufacturing Process?
Calibration and Maintenance: The equipment used in the manufacturing
process should be calibrated and maintained regularly to ensure accurate
readings and prevent breakdowns that can affect the quality of the final
product.
Statistical Process Control: Statistical process control can be used to
monitor the manufacturing process and detect any deviations from the
standard parameters. This can help identify potential quality issues before
they affect the final product.
Quality Audits: Regular quality audits should be conducted to ensure that
the manufacturing process is meeting quality standards and to identify
areas for improvement.
Challenges Associated with the Paper
Manufacturing Process
Raw material availability: The paper industry relies on a finite supply of natural resources, such as
wood fiber, and the availability and cost of these resources can vary significantly depending on
factors such as climate, geography, and market demand. This can create supply chain challenges
and affect the cost and quality of the final paper product.
Changing market demand: The paper industry is facing increasing competition from digital media,
which has reduced demand for certain types of paper products, such as newspapers and
magazines. This has led to a shift in the industry towards higher value and specialty paper
products, such as packaging materials, tissue paper, and fine writing paper.
Quality control: The paper manufacturing process requires strict quality control measures to
ensure that the final product meets the desired quality and performance requirements. This can
be a challenge, particularly as the process involves multiple stages and variables.
Cost competitiveness: The paper manufacturing industry faces intense global competition,
particularly from low-cost producers. This can be a challenge for companies to remain cost-
competitive while maintaining high-quality standards.
Challenges Associated with the Paper
Manufacturing Process
Environmental impact: The paper industry is a significant consumer of natural resources,
such as water and wood fiber, and it generates large amounts of waste and emissions,
including greenhouse gases, wastewater, and solid waste. This can have a significant
impact on the environment, and the industry is facing increasing pressure to reduce its
environmental footprint and adopt more sustainable practices.
Energy consumption: Paper manufacturing requires significant amounts of energy,
particularly in the drying and refining stages. This can lead to high energy costs and
greenhouse gas emissions, and the industry is working to improve energy efficiency and
adopt renewable energy sources to reduce its impact on the environment.
Water consumption: The paper manufacturing process also requires a large amount of
water, particularly in the pulping and papermaking stages. Efforts are being made to reduce
water
reduceconsumption throughthrough
water consumption the use the
of more
use ofefficient technologies
more efficient and water
technologies andrecycling.
water
recycling.
New Trends in the Paper Manufacturing
Process
Digitalization: Digitalization is rapidly transforming the paper
manufacturing process, with new technologies such as the Internet of
Things (IoT) and Artificial Intelligence (AI) being used to optimize
production, quality, and efficiency.
Circular Economy: The concept of the circular economy is gaining traction
in the paper manufacturing industry, with companies seeking to minimize
waste and maximize resource efficiency by reusing and recycling materials.
Bio-based materials: Bio-based materials, such as cellulose nanofibers
and lignin, are being explored as potential alternatives to traditional
materials, such as petroleum-based plastics.
New Trends in the Paper Manufacturing
Process
Energy Efficiency: The focus on energy efficiency continues to be a key trend in the paper
manufacturing process, with companies investing in new technologies to reduce energy
consumption and greenhouse gas emissions.
Smart packaging: Smart packaging, which incorporates sensors and other technologies to provide
information about the
provide information contents
about of the package,
the contents is becoming
of the package, increasingly
is becoming popular popular
increasingly in the paper
in the
manufacturing industry,
paper manufacturing as it enhances
industry, product
as it enhances safety safety
product and traceability.
and traceability.
Sustainable Forestry: Sustainable forestry practices, such as reforestation and conservation, are
becoming increasingly important in the paper manufacturing process as companies seek to
ensure a reliable supply of raw materials and minimize the environmental impact of their
operations.
Digital Printing: Digital printing is becoming more prevalent in the paper manufacturing industry,
as it enables faster turnaround times, reduced waste, and greater flexibility in product design.