The Full paper making process   
      
 Timber
 Timber used for  papermaking comes from well managed forests where more trees are planted than  harvested to ensure sustainable growth. 
 Papermakers  usually use only the parts of the tree that other commercial industries don't  want - such as saw mill waste and forest thinnings. 
 Go to  publications for details of a Trees used for Papermaking Poster.
  
 De-Barker
 Bark is stripped  from the logs by knife, drum, abrasion, or hydraulic barker. The stripped bark  is then used for fuel or as soil enrichment.
 Chipping Machine
 Stripped logs are  chipped into small pieces by knives mounted in massive steel wheels (used in  chemical pulping process). 
 The chips pass  through vibrating screens, whereby both undersized chips, dust etc and oversized  chips are rejected. 
 Accepted chips  are then stored in huge bins ready for the next process.
  Chemical Pulping Process
   Chips from the storage bins are fed into a digester to which chemicals have been  added. The woodchips are then 'cooked' to remove lignin. Lignin is the binding  material which holds the cellulose fibres together. 
  The chips are 'cooked' by heat and pressure in caustic soda and sulphur.  
  The chemical process is energy self-sufficient as nearly all by-products can be  used to fire the pulp mill power plant. The chemical pulping process produces  lower fibre yield than mechanical pulping, typically 50-60%.
 Mechanical Pulping Process
  Mechanical pulp yields over 90% of the wood as fiber is produced by forcing  debarked logs, about two meters long, and hot water between enormous rotating  steel discs with teeth that literally tear the wood apart. Alternatively, logs  can be pressed against grindstones which is why this process is also known as  ground wood pulp. 
  Trees contain up to 30% lignin, a material which is sensitive to light and  degrades, and turns brown in sunlight, which explains why papers made from  mechanical pulp will discolor. An example of this is newsprint. Newsprint is  designed to have a short life span, and if left for a long period of time will  lose its whiteness and strength. The special advantages of mechanical pulp are  that it makes the paper opaque and bulky.
 Hydrapulper
   When  the bales of wood pulp or waste paper arrive at the paper mill they are loaded  onto a conveyor and passed into a circular tank containing water. This has a  very powerful agitator at the bottom which breaks up the bales into small  pieces.
When  the bales of wood pulp or waste paper arrive at the paper mill they are loaded  onto a conveyor and passed into a circular tank containing water. This has a  very powerful agitator at the bottom which breaks up the bales into small  pieces. 
 The pulp mass  created begins to look like thick porridge. This machine is known as a  Hydrapulper. It operates automatically and when the disintegrating process is  complete it discharges the pulp into large storage tanks. 
  Hydrapulpers used mainly for handling waste paper are fitted with special  devices for removing unwanted contraries such as wire, plastic, paper clips,  staples etc.
  Blend Chest
  The  stock passes to a blend chest where numerous chemicals can be added to obtain  the required characteristics to the finished paper. Dyes are also added, as  necessary, to color the paper. Dyes fix themselves to the cellulose fibers and  are fast to light and water.
  Each grade of paper and board requires a very accurate blend of pulps and  additives and the properties of the paper are continually monitored by computers  during manufacture.
 
 Waste Paper
 Waste paper is  collected from Waste Paper Banks and Commercial collections. When you deposit  your used papers into a waste paper bank, you are sorting the paper into grades  before the merchant collects it. This is why you can only put certain papers  into a particular bank. 
 Many offices have  in place an office recycling scheme. Again the waste paper is usually segregated  ready to be collected. 
 Waste paper  currently represents 67% of the raw material used in the UK to make paper and  board. 
 The waste paper  merchant collects the used paper which is then sorted by hand into different  grades. Paper not suitable for recycling is removed. 
 The waste paper  merchant will then bale the waste paper ready to be taken to the paper mill
 De-inking
 Before printed  paper, such as office waste and newspapers, can be recycled the ink needs to be  removed, otherwise it will be dispersed into the pulp and a dull grey paper  would result. 
 There are two  main processes for de-inking waste paper - these are known as washing and  flotation. 
  Washing
The waste paper is placed into a pulper with large quantities of water and  broken down into a slurry. Contraries -such as staples - are removed using  centrifugal screens. Most of the water containing the dispersed ink is drained  through slots or screens that allow the dispersed ink particles through, without  taking the pulp. Adhesive particles, known as 'stickies' are removed by fine  screening. 
  Flotation
Again the waste is made into a slurry and contaminants removed. Special  surfactant chemicals are added which makes a sticky froth on the top of the  pulp. 
 Air bubbles are  blown through the pulp and these carry the inks to the surface. As the bubbles  reach the top a foam layer is formed that traps the ink. The foam must be  removed before the bubbles break or the ink will go back into the pulp. Because  the ink is removed from the flotation machine in a concentrated form, the  flotation system does not require a large water treatment plant.      
             Refining
 This is where the  cellulose fibers pass through a refining process which is vital in the art of  papermaking. Before refining, the fibers are stiff, inflexible and form few  bonds. The stock is pumped through a conicle machine which consists of a series  of revolving discs. The violent abrasive and bruising action has the effect of  cutting, opening up and declustering the fibers and making the ends divide. This  is called fibrillation. In this state, the fibers are pliable and have greater  surface area, which significantly improves the fiber bonding. The properties of  the paper are directly related to the refining process. Refining used to be  called beating.
  
  Screening and Cleaning
 Pulps contain  undesirable fibrous and non-fibrous materials, which should be removed before  the pulp is made into paper or board. 
 Cleaning involves  removing small particles of dirt and grit using rotating screens and centrifugal  cleaners. 
  
  Papermaking Machine
  
   
           The Paper Machine is a very large piece of machinery. A typical machine is  about the length of two football pitches and around 4 metres wide. It can      run up to speeds of 2000 m per minute - or 60 miles per hour! The machine      itself consists of 7 distinct sections. The flow box, wire, press section,      drier section, size press, calendar and reeling up.
           The first section of the machine is called the 'Wet End'. This is where the      diluted stock first comes into contact with the paper machine. It is poured      onto the machine by the flow box which is a collecting box for the dilute      paper stock. A narrow apperture running across the width of the box allows      the stock to flow onto the wire with the fibres distributed evenly over the      whole width of the paper machine.
               The machine is operated by computer control. The computer will monitor the      paper for moisture content, weight etc and computer screens will show      pictures of the process and should any adjustments need to be made, an alarm      will sound.
          
               
 Conversion and Printing
 Once the paper is  made, a great deal of it is converted into a product. Converters specialize in  transforming reels and sheets of paper and board into a vast array of finished  products for distribution such as boxes, cartons and stationery. Converters sell  their products to the public or to other manufacturers.
 Not all paper and  board is processed by converters. Some papermakers do their own converting, for  example, the manufacturers of soft tissues market their own products and sell  directly to the public. 
 The printing  industry converts large quantities of paper and board, much of which reaches the  customer as newspapers, magazines or books.