l04 MSC Nutra Paper 1

M.Sc.
(Nutraceuticals) 2011
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PAPER
DEFINITION OF PAPER Paper is defined as a matted or felted sheet usually composed of plant fiber. Paper has been commercially made from such fiber sources as rags (linen), bagasse (sugar cane), cotton, and straw. Modern paper is made almost exclusively from cellulose fiber derived from wood. Although the word paper is derived from the Egyptian term, papyrus was not a true paper in the modern sense.
INVENTION OF PAPER The invention of paper by blending cellulose fibers didnt occur until the beginning of the second century A.D.
M.Sc.(Nutraceuticals) 2011 CSP TRG AIDS
HISTORY
Tsai Lun, a member of the court of the later Han Dynasty, is generally credited with developing the first real papermaking process in 105 A.D. The Fourdrinier machine was the first on the market and produced a homogenous (single-ply) sheet of boxboard in various thicknesses. It was soon joined by the Cylinder machine which formed a multi-layered (multi-ply) type of paperboard. These machines were first installed in the United States around 1830.
M.Sc.(Nutraceuticals) 2011
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PAPER & PAPERBOARD

Paperboard, boxboard, cardboard, and cartonboard are all
terms used to describe heavier paper stock.

The International Organization for Standardization (ISO) states that material weighing more than 250 grams per
square metre shall be known as paperboard.

U.S. practice calls material that is more than 300 micron (0.30mm) thick paperboard.
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PAPER MANUFACTURE
Basic principles of paper and paperboard making have not changed for more than two thousand years. Fibres taken from timber are evenly distributed in water. Multiple layers of furnish are applied one after another on a wire. Water is drained from the pulp and the layers are formed into a strong fibre mat. Smooth surface is achieved by coatings and calendering.
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PAPER MANUFACTURE
PAPER IS A CELLULOSIC MATERIAL. WOOD HAS 50% CELLULOSE & 50% MIXTURE OF HEMI CELLULOSE COMPOUND & LIGNIN WHICH BIND CELLULOSIC FIBRES TOGETHER
50% CELLULOSE
WOOD
25% HEMICELLULOSE + 25% LIGNIN
PAPER
LIGNIN IS A PHENOLIC COMPOUND WHICH GIVES THE COLOUR TO PAPER AND BINDS THE HEMI CELLULOUSE & CELLOLOSE
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PAPER MANUFACTURE
HARD WOOD WOOD
CONIFEROUS TEMPERATE 3.5-4 mm
SOFT WOOD
DECIDIOUS TROPICAL 1 1.5mm
FOR PAPER MAKING,THESE FAIBRES ARE SEPERATED FROM EACH OTHER TO BECOME DISCRETE ENTITIES THROUGH A DRASTIC ACTION AND LATER MATTED
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PAPER MANUFACTURE
PULPING SECTION
STAGE 1 MAKE READY WOOD SOAKING DEBARKING
PAPER MAKING SECTION

STAGE 4 SHEETING FORMATION PRESSING & DRYING
STAGE 2 PULPING
CHIPPING DIGESTING BEATING REFINING SIZING FILLERS STAGE 5 FINISHING
COATING CALENDERING WINDING
STAGE 3 STOCK PREPARATION
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PAPER MANUFACTURE
PAPER MILLS CAN TAKE UP TWO ROUTES 1. INTEGRATED FROM STAGE 1 TO STAGE 5 1. NON INTEGRATED FROM 3 TO 5 NON INTEGRATED MUST BRING THE PULP EITHER SLURRY FORM OR SOLID FORM FOR PAPER MAKING
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PAPER MANUFACTURE
STAGE 1 MAKE READY
TREE CUT TO LOGS TIMBER
WOOD
SOAKING
SOAKED TO MAKE IT SOFT
DEBARKING
DRY OUTSIDE LAYER (BARK) REMOVED
TO STAGE 2
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PAPER MANUFACTURE
STAGE 2 PULPING
FROM STAGE 1
CUT TO SMAILL PIECES FOR EASY COOKING
CHIPPING
PULPING
(DIGESTER/ COOKING) MECHANICAL, CHEMICAL & SEMI-CHEMICAL PROCESSES
TO STAGE 3
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PAPER MANUFACTURE
PULPING SECTION
PROCESS OF CHANGING WOOD INTO AN AQUEOUS PULP SOLUTION
MECHANICAL
CHEMICAL
SEMI CHEMICAL KRAFT PULPING
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PAPER MANUFACTURE
MECHANICAL PULPING
SIMPLY GRINDING WOOD CRITICAL AS FIBRES GET DESTROYED NO PURIFICATION OF PULP COMPOSITION OF WOOD UNCHANGED LIGNIN PRESENT LESS STRENGTH YIELD 90% OF WOOD MASS e.g. Newsprint paper
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PAPER MANUFACTURE
CHEMICAL PULPING
PROCESS FOR MOST PAPER PRODUCED FULL CHEMICAL TREATMENT REMOVE NON CELLULOSE KEEP CELLULOSE INTACT IN PRACTICE, 100% NOT POSSIBLE YIELD 50% WOOD MASS YIELD BETTER STRENGTH EASY BLEACHING BECAUSE LIGNIN REMOVED e.g. Most of paper used
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PAPER MANUFACTURE
SEMI CHEMICAL PULPING
SOME MECHENICAL AGITATION AFTER CHEMICAL DISINTEGRATE THE WOOD CHIP RECOGNISED AS YIELDING BETTER QUALITY YIELD 60% OF WOOD MASS BETTER STRENGTH THAN CHEMICAL PULP e.g. Most of todays papers
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PAPER MANUFACTURE
KRAFT PULPING
MOST OF PAPER MAKINGS IN USA LOG COVERTED TO EVEN SIZE CHIPS CHIPS AND CHEMICAL SOLUTION ARE COOKED CHEMICALSOLUTION IS WHITE LIQUOR COOKING IN DIGESTER(HIGH TEMP & PRESSURE) COOKING DISSOLVES 50% OF MASS (LIGNIN) WASHING AFTER COOKING SEPERATES LIGNIN WASHED OUT LIQUID IS BLACK LIQUOR RECOVERY OF SPENT LIQUOR POSSIBLE YIELD 50% OF WOOD MASS
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PAPER MANUFACTURE
STAGE 3 - STOCK PREPARATION
FROM STAGE 2
BEATING REFINING SIZING FILLERS
TO STAGE 4
STOCK PREPARATION IS THE PROCESS OF MECHANICALLY BEATING THE PULP SO AS TO MAKE THE FIBRES MORE READILLY SUITED FOR LAYING IT IN A UNIFORM WEB AND TO INTER CONNECT SO AS TO MAKE IT STRONGER SHEET. e.g. FIBRES CAN BE KINKED/CURLED, CUT/SHORTENED, MADE FLEXIBLE, FIBRILLATE TO LOOK FUZZY. ALL THESE AFFECT THE WAY FIBRES BOND TOGATHER IN SHEET. IT STRONGLY INFLUENCES STRENGTH AND ITS LIGHT SCATTERING PROPERTIES.
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PAPER MANUFACTURE
FROM STAGE 2
TO STAGE 4
UNBEATEN
BEATEN
FIBRILLATED
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PAPER MANUFACTURE
FROM STAGE 2
TO STAGE 4
THE FURNISH (AS ITS REFERRED TO NOW), CAN ALSO BE TREATED WITH MANY CHEMICAL ADDITIVES LIKE RESINS FOR STRENGTH AND DYES AND PIGMENTS FOR COLOUR., FILLERS LIKE TALC AND CLAY TO IMPROVE OPTICAL PROPERTIES, SIZING AGENTS TO CONTROL PENETRATION OF LIQUIDS AND IMPROVE PRINTING PROPERTIES.
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PAPER MANUFACTURE
STAGE 4 SHEETING
FROM STAGE 3
FORMATION PRESSING & DRYING
TO STAGE 5
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PAPER MANUFACTURE
STAGE 4 SHEETING
FROM STAGE 3
TO STAGE 5
Fourdrinier Machines Fourdrinier machines pump furnish from a headbox directly onto a moving wire screen through which the water is continuously drained. Fourdrinier machines may have a second head box situated downstream of the first head box to add further quantities of furnish onto the partially dewatered initial lay-down.
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PAPER MANUFACTURE
STAGE 4 SHEETING
FROM STAGE 3
TO STAGE 5
Furnish Headbox
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PAPER MANUFACTURE
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PAPER MANUFACTURE
Cylinder Machines A cylinder machine (Figure 3.3) rotates a screen drum in a vat of furnish. (The paper is sometimes called vat paper.) As the water pours through the screen, fiber accumulates on the outside of the screen. This thin layer of matted fiber is transferred onto a moving felt belt that passes sequentially over further rotating cylinders, each of which deposits another fiber layer.
A single cylinder station on a cylinder-type machine
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PAPER MANUFACTURE
A single cylinder station on a cylinder-type machine

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PAPER MANUFACTURE
Cylinder machines dewater furnish at the cylinder and paste a thin layer of fiber against the felt.
A cylinder machine with six cylinders at which a paper layer can be formed
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PAPER MANUFACTURE
The fibers of subsequent layers do not intermingle, and therefore the bond between the layers is weak. The dry end is similar to that of the fourdrinier machine. Cylinder machines do not have the fourdrinier machine's limitation on the number of stations, and six-or seven-station machines are common. Higher-caliper boards for folding and setup cartons are usually cylinder boards. Generally, papers are made on fourdrinier or twin-wire formers, whereas heavier paperboard products are made on cylindertype machines. Extremely heavy boards are made by laminating several thinner sheets. A typical cylinder board construction (Figure 3.5):
Cylinder boards are multiply boards. An advantage is that the plies can all be different
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PAPER MANUFACTURE
Twin-Wire Machines Vertiformers and twinwire formers (Figure 3.6) inject the furnish between two moving wire screens. The advantage is that dewatering takes place on both sides of the paper and is therefore fast. These machines can produce single and multi-ply sheets with identical formation at both faces.
Water can be simultaneously removed from both sides of the paper on a twin-wire paper former
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PAPER MANUFACTURE
Surface or Dry-End, Treatments and Coatings After the paper is formed and dried, it is usually passed between multiple sets of heavy rolls (Figure 3.9.). This "calendering" operation has many variations, but the prime objective is to iron and smooth out the surface of the paper stock to make it more suitable for printing. Calendering also compresses the paper sheet, giving a denser product and a glossier surface. Starch is a typical surface sizing used to fill surface voids and reduce liquid penetration rate.
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PAPER MANUFACTURE
Calendering consists of passing the formed dried paper between sets of heavy rolls. The paper surface may be dampened to help in smoothing it
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PAPER MANUFACTURE
STAGE 5 FINISHING
FROM STAGE 4
COATING CALENDERING WINDING
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PAPER MAKING AT A GLANCE
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DRYERS
FOURDRINIER PAPER MACHINE

Invented by Nicholas Louis Robert of France in 1798 the
continuous paper machine was not placed into commercial operation until about 1804, though debate exists between the dates of 1804 and 1807, in England by the Fourdrinier brothers and has since been known as the Fourdrinier paper machine. Fourdrinier machine comprised of 4 sections:
first the wet end, the press section, the drier section, and the calendar section.
Hendry Fourdriner (1766 1854)

Paper Machine - Wet End
The wet end of the machine is where the refined pulp, spilling from the headbox section is laid out to align its fibers across the width of the wire or screen of the wet end to begin the process of aligning fibers in the machine running direction and to remove water from the refined pulp which is a much as 99% water content at this stage of production. Various configurations of the wet end of the machine exist today to service different paper grade requirements but all adhere to the same principles of manufacturing.

Paper Machine - Press Section
The press section can comprise of two or more presses. The still wet web of paper is transferred from the wire of the wet end onto the felt at the couch roll, and is then carried through the presses on the felts; the texture and character of the felts may vary depending on the various surface structures which can be applied here. Sometimes a linen pattern or other types of surface structure are introduced to the paper depending on the grade of paper being made. The main function of the press is to continue to remove water from the pulp fibers and to smooth the surface characteristics of the felt and wire sides (top and bottom sides) of the paper web running the length of the machine.

Paper Machine - Drier section
The drier section consists of a series of driers, which are normally steamheated cylinders. The web of paper is transported firmly against the driers by the fabric drier felts which are used to move the paper continuously along the length of the paper machine once past the wet end. As the web passes from one drier to another, first the felt side (top side) and then the wire side (bottom side) are pressed against the heated surface of the drier. The web of paper enters the drier section with water content of approximately 65%; most of the remaining water is removed in this section of the paper machine. Within the drier section there can be a breaker stack used for imposing a finish to the paper surface and for the final machine drying stage. The breaker stack normally consists of a pair of chilled metal or rubber-surfaced rollers. The cooling process of the chilled rollers brings the paper web into a more normal temperature range. When the paper manufacturing process is completed the paper will typically have a moisture range of 4-7% depending on the grade of paper being manufactured and on the end use requirements of the grade.

Paper Machine - Calender section
The calender section, the final section, consists of calender stacks with a winding mechanism for gathering the paper web onto a roll as it leaves the end of the paper machine. The calender section smoothes the paper and imparts, finish, thickness, or gloss. Water or starch, may also be used within the calender section to obtain specific surface finishes and improve printing and other application characteristics. After the calender stack the paper web exits the paper machine and is rolled into a master machine roll where it can be removed from the end of the paper machine and sent to a converting station where the paper will be either slit into smaller rolls or where it may be sheeted for use in offset printing.
Representative Papermaking Machines
Figure 3.3 A single cylinder station on a cylinder-type machine

Cylinder machines dewater furnish at the cylinder and paste a thin layer of fiber against the felt. (Figure 3.4.)
Figure 3.4 A cylinder machine with six cylinders at which a paper layer can be formed

The fibers of subsequent layers do not intermingle, and therefore the bond between the layers is weak. The dry end is similar to that of the fourdrinier machine. Cylinder machines do not have the fourdrinier machine's limitation on the number of stations, and six-or seven-station machines are common. Higher-caliper boards for folding and setup cartons are usually cylinder boards. Generally, papers are made on fourdrinier or twin-wire formers, whereas heavier paperboard products are made on cylinder-type machines. Extremely heavy boards are made by laminating several thinner sheets. A typical cylinder board construction (Figure 3.5):
Figure 3.5 Cylinder boards are multiply boards. An advantage is that the plies can all be different
Twin-Wire Machines Representative Papermaking Machines
Vertiformers and twin-wire formers (Figure 3.6) inject the furnish between two moving wire screens. The advantage is that dewatering takes place on both sides of the paper and is therefore fast. These machines can produce single and multi-ply sheets with identical formation at both faces. Machine Direction and Cross Direction Depositing a fiber-and-water slurry onto a moving wire belt tends to align fibers in the direction of travel, known as the machine direction (MD). The direction across the apermaking machine and across the fiber alignment is the cross direction (CD) (Figure 3.7). Because of this fiber alignment, paper is an anisotropic material; measured properties differ depending on the direction in which the property is measured.

Figure 3.6 Water can be simultaneously removed from both sides of the paper on a twin-wire paper former
Figure 3.7 Fibers in a manufactured paper sheet tend to align themselves in the machine direction
Figure 3.8 shows the relationship of tear, stiffness, Representative Papermaking Machines
and fold endurance to machine direction. Paper specification sheets normally show physical values measured in both directions. Package designers need to be aware of paper's directionality. Cylinder machines tend to align fibers more than fourdrinier machines. Tensile strength ratios in MD and CD for a typical fourdrinier board are about 2:1, whereas for a cylinder board the ratio might be 4:1 or higher, meaning that the MD tensile strength is four times greater than the CD tensile strength. The greater the degree of fiber alignment, the greater the difference in a given property when measured in MD and CD. The ratio of a property in the two directions is often used as a gauge of fiber alignment.

Figure 3.8 The relationsh ip between MD and tear, stiffness, and fold enduranc e properties

Cylinder machines tend to align fibers more than fourdrinier machines. Tensile strength ratios in MD and CD for a typical fourdrinier board are about 2:1, whereas for a cylinder board the ratio might be 4:1 or higher, meaning that the MD tensile strength is four times greater than the CD tensile strength. The greater the degree of fiber alignment, the greater the difference in a given property when measured in MD and CD. The ratio of a property in the two directions is often used as a gauge of fiber alignment

Surface or Dry-End, Treatments and Coatings After the paper is formed and dried, it is usually passed between multiple sets of heavy rolls (Figure 3.9.). This "calendering" operation has many variations, but the prime objective is to iron and smooth out the surface of the paper stock to make it more suitable for printing. Calendering also compresses the paper sheet, giving a denser product and a glossier surface. Starch is a typical surface sizing used to fill surface voids and reduce liquid penetration rate.
Figure 3.9 Calendering consists of passing the formed dried paper between sets of heavy rolls. The paper surface may be dampened to help in smoothing it

To meet the highest opacity, gloss, brightness, and printingdetail requirements, papers are coated with pigments such as clay, calcium carbonate, and titanium dioxide. Coated papers are usually called "clay-coated" regardless of the actual formulation. Coated papers are calendered to maintain a high-quality, smooth surface. In addition, highly sized and clay-coated boards can be difficult to bond with water-based adhesive because of poor liquid penetration and the inability of the adhesive to bond to the underlying fibers. Where necessary, coated boards should have perforations in the adhesive-bond areas so that adhesive can penetrate to the body of the paper.
THINK
END OF LECTURE 04
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l04 MSC Nutra Paper 1

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M.Sc.

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PAPER & PAPERBOARD

terms used to describe heavier paper stock.

square metre shall be known as paperboard.

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PAPER MAKING SECTION

CHIPPING DIGESTING BEATING REFINING SIZING FILLERS STAGE 5 FINISHING

COATING CALENDERING WINDING

STAGE 3 STOCK PREPARATION

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SOAKED TO MAKE IT SOFT

DRY OUTSIDE LAYER (BARK) REMOVED

SEMI CHEMICAL KRAFT PULPING

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A single cylinder station on a cylinder-type machine

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A single cylinder station on a cylinder-type machine

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PAPER MAKING AT A GLANCE

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FOURDRINIER PAPER MACHINE

FOURDRINIER PAPER MACHINE

FOURDRINIER PAPER MACHINE

FOURDRINIER PAPER MACHINE

FOURDRINIER PAPER MACHINE

Representative Papermaking Machines

Figure 3.3 A single cylinder station on a cylinder-type machine

Representative Papermaking Machines

Representative Papermaking Machines

Representative Papermaking Machines

Twin-Wire Machines Representative Papermaking Machines

Representative Papermaking Machines

Representative Papermaking Machines

Representative Papermaking Machines