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Paper Mill Production Process
A step-by-step guide from Waste Paper to Finish Paper:
Paper Manufacturing Process
Invention of paper played a critical role in the development of human race. From enabling smoother communication, archiving events and sharing knowledge to acting as environment friendly packaging option, paper has transformed the world.
Production of paper has also changed over the years, from being hand made to use of industrial machinery. However, the essence of the process lies in making a dilute suspension of cellulose fibers and draining it through a screen to make an interwoven mat.
All of our products are made from sustainable fibres and 100% recyclable.
Production Process Steps
Generally, an agent or dealer collects waste paper from home, office, shopping malls, markets, etc. Then at the warehouse, the collected paper is wrapped in tight bales and then transported to our paper mill, where it is recycled into new paper.
Paper is sorted into different grades such as newspapers, duplex, white cutting, boards, core pipes, etc suitable for manufacturing different grades of papers. Afterwards, the bales are transferred to the conveyors
At the wet end of the paper machine sits the headbox, which distributes a uniform jet of watery stock.The liquid falls onto the wire or forming fabric. Beneath the wire, foils (short for hydrofoils) remove water and improve
fibre uniformity, ensuring that the fibres weave together in a tight mat. The wire passes over suction boxes that vacuum out the water, leaving a soft mat of pulp that forms the paper sheet, also known as the paper web. By now the wire has travelled 30-40 meters. In a couple of seconds, the water content has dropped to 75-80%, and the web has lost its wet sheen.
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The next stage of water removal consists of passing the paper web through a series of nip rollers that squeeze the water out of the pulp mat. This pressure also compresses the fibres so they intertwine to form a dense, smooth sheet.
At this stage, the water content has reduced to between 45 and 55%.
Read moreThe paper web now travels through an enclosed space containing a number of steam-heated drying cylinders. They are warmed up to 130ºC using steam heat to ensure that the paper is now 80 to 85% dry. Wet sizing solution is now applied to
the paper in order to add a thin layer of starch to the surface.Starch contributes to stiffness and the bonding of the fibres within the sheet of paper. After the sizing is applied, the paper passes through another set of heated drying cylinders. In all, the paper web may travel 400 meters through the dry end. In the process, it will lose roughly 93% of its water.
Read moreTo give the containerboard a smooth and glossy surface to optimise it for printing, the paper passes through a set of smooth rollers, which can be hard or soft, that press the paper, embossing a smooth face on the paper surface.
Producing high-quality paper depends on maintaining extremely fine control over the variables in the manufacturing process. The sheet of paper is now inspected by an automated measuring device that detects imperfections.
After completing its 500-metre journey, the paper exits from the paper machine and is automatically wound onto a jumbo reel, which can weigh 50 tonnes and be up to eleven metres wide. The jumbo reel is lifted by crane to a nearby winder,
where the paper is unwound and cut into smaller rolls as required by the customer.
Read moreOn a regular basis, samples of containerboard are taken to our Quality Control laboratories, to ensure that our paper is of the highest quality possible.
The Finish Paper Rolls are Shrink Packed to ensure that the material do not get damaged in transit and customers receive the goods in proper condition. The bar code lables are then put on every roll and the material is stocked in the godown ready for shipment.
The material is loaded into containers or trucks with the help of installed cranes and forklifts. After proper weighment and issue of Tax Invoice, the material is dispatched.