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1 Chapter 1 : How Is Tissue Paper Made? Bizfluent Sofidel produces and markets tissue paper, namely paper for hygienic or domestic use, in and away from the home: toilet paper, kitchen paper, paper napkins, paper handkerchiefs, tissues, etc. The companies in the group oversee the entire production process, from tissue production to processing, all the way to the finished product. A tissue paper production business manufactures, packages, and distributes different forms of soft, hygienic papers. It is a lucrative long-term investment that requires substantial initial capital for production. Starting a small or medium-scale business can cost as much as N2 million â N7 milion. Large-scale tissue companies begin production with about N15 â N20 million naira. Tissue papers are also called toilet papers, toilet rolls, and tissue rolls. The raw materials for the production of toilet papers are various quantities of whitened wood pulps or recycled papers which are processed into soft, bulky, and absorbent disposable paper. The production process involves either manual or automated machines. Business Opportunities In Tissue Production Business Around The World Some of the lucrative opportunities of the tissue paper production business in Nigeria and other parts of the world are: Toilet Rolls Production Business: Toilet rolls manufacturers have the largest tissue paper consumers in Nigeria and most parts of the globe. It is a sanitary product found in most homes, offices and public restrooms. These yearly upturns provide an excellent business opportunity for potential entrepreneurs in Africa. Still, establishing a successful tissue roll factory requires information, sufficient funds, and some technical training. These tissue papers have one to four interwoven layers plies with varied designs, sizes, colours, and textures. In recent years, the tissue table napkins production business has experienced remarkable market growth and increased profitability. This is because they are a more affordable and low maintenance form of table napkins. Tissue napkins are used to clean up the mouth and fingers during and after a meal. And, they can be folded and bent into different decorative shapes. The food service industry i. Event decorators also buy different types of these napkins and use them to enhance the beauty of table centrepieces. Unlike cloth towels, it does not require frequent washing, making it an easier and more hygienic option. Because of its lightly woven fibre structure, paper towels absorb liquid better than toilet rolls. Its uses include cleaning, dusting, wiping, and drying various surfaces. Tissue factories manufacture paper towels, package them in folded stacks or rolls and then sell them to wholesalers and retailers. These towels have the second largest consumer base in the tissue paper production industry. The market for paper towels is divided between domestic and public buyers. Domestic buyers are consumers who buy directly from retailers and use these products in their homes or personal spaces. Commercial consumers buy in bulk from factories, wholesalers, or large retail outlets. Paper towels bought for commercial uses are found in public restrooms, hotels, restaurants, and their kitchens. Some manufacturers combine both pulp and fibre raw materials in production. The result is a more durable and stronger paper towel stack. Another lucrative tissue paper product is the wrapping tissue paper. These are lightweight, semi-transparent papers between 17 to 40 grammages. There are several kinds of wrapping tissues; soft, shining, hard, and rough. Some are a combination of textures and looks. An example are the soft and shiny tissues found in bags. Wrapping tissues are personalized with colours, logos, and brand names of the companies that buy them. This variety of tissues is usually mass-produced and supplied to businesses that package their goods by cushioning or wrapping them. Clothing lines also use these tissues to protect garments from creases and keep them safe. Customised Wrapping Tissue Business: The market for customized wrapping tissues is expanding due to the rising levels of demand. Customization companies make considerable profits from producing personalized wrapping tissues. Their client base includes boutique owners, fashion product companies, retail outlets, and domestic consumers. Durable customized printed tissue wrapping papers are printed with soy-based ink on non-acidic tissue papers. Face Wipes Production Business: Facial tissues are the ultra-soft, absorbent, and disposable substitutes of cloth handkerchiefs. This variety of tissue rolls are used for facial cleansing, hands, and nasal wiping. This business has a considerable market size; online retail outlets, supermarkets, shops, and pharmacies. As a result of its high-quality requirements, base tissues are made from pure chemical pulp. In some cases, recycled fibre might be added to it for strengthening. A facial tissue has two to three plies and is lightly calendered to Page 1

2 achieve a light, smooth surface. Some producers add fragrances, lotions, softeners, and liquefied herbs to give it a certain texture or scent. Also, facial tissues come in different boxes or portable sachet packs with partial openings as dispensers. Tissue factories make huge profits from producing and distributing wet wipes in bulk to wholesale or large retail outlets. Wet wipes are small, moist tissue paper used to clean surfaces and for personal hygiene. It also comes in small cardboard boxes or plastic packages with dispense openings at the top or sides. Wet wipes are recommended by experts for other baby care activities such as cleaning pukes, and wiping dirty hands, or faces. Special baby wipes come with cleansing agents that are either mild or alcohol-based. Other types of special wet wipes are industrial wipes, cleansing pads, and medical wipes. Page 2

3 Chapter 2 : The Toilet Paper Manufacturing Process Click numbers above to find more information of each tissue production phase. Basic facts of tissue production process. The process sections[ edit ] Paper machines usually have at least five distinct operational sections: Forming section, commonly called the wet end, is a continuous rotating wire mesh which removes water from the paper by sucking it out of suspension. Press section where the wet fibre web passes between large rolls loaded under high pressure to squeeze out as much water as possible. Drying section, where the pressed sheet passes partly around, in a serpentine manner, a series of steam heated drying cylinders. Infra-red driers are also used to supplement cylinder drying where required. Calender section where the dried paper is smoothened under high loading and pressure. Only one nip where the sheet is pressed between two rolls is necessary in order to hold the sheet, which shrinks through the drying section and is held in tension between the press section or breaker stack if used and the calender. Extra nips give more smoothing but at some expense to paper strength. Reel section where paper coming out of the machine is wound onto individual spools for further processing. There can also be a coating section to modify the surface characteristics with coatings such as china clay. History[ edit ] Before the invention of continuous paper making, paper was made in individual sheets by stirring a container of pulp slurry and either pouring it into a fabric sieve called a sheet mould or dipping and lifting the sheet mould from the vat. While still on the fabric in the sheet mould, the wet paper is pressed to remove excess water and then the sheet is lifted off to be hung over a rope or wooden rod to air dry. Fourdrinier machine[ edit ] In, Louis-Nicolas Robert of Essonnes, France, was granted a patent for a continuous paper making machine. Didot thought that England was a better place to develop the machine. But during the troubled times of the French Revolution, he could not go there himself, so he sent his brother-in-law, John Gamble, an Englishman living in Paris. Through a chain of acquaintances, Gamble was introduced to the brothers Sealy and Henry Fourdrinier, stationers of London, who agreed to finance the project. Gamble was granted British patent on 20 October The Fourdrinier machine used a specially woven plastic fabric mesh conveyor belt known as a wire, as it was once woven from bronze in the forming section, where a slurry of fibre usually wood or other vegetable fibres is drained to create a continuous paper web. The original Fourdrinier forming section used a horizontal drainage area, referred to as the drainage table. With the help particularly of Bryan Donkin, a skilled and ingenious mechanic, an improved version of the Robert original was installed at Frogmore Paper Mill, Apsley, Hertfordshire, in, followed by another in The Fourdriniers also bought a mill at St Neots intending to install two machines there and the process and machines continued to develop. Thomas Gilpin is most often credited for creating the first U. S cylinder type papermaking machine at Brandywine Creek, Delaware in This machine was also developed in England, but it was a cylinder mould machine. Pulp paper The plant fibres used for pulp are composed mostly of cellulose and hemi-cellulose, which have a tendency to form molecular linkages between fibres in the presence of water. After the water evaporates the fibres remain bonded. It is not necessary to add additional binders for most paper grades, although both wet and dry strength additives may be added. Rags of cotton and linen were the major source of pulp for paper before wood pulp. Today almost all pulp is of wood fibre. Cotton fibre is used in speciality grades, usually in printing paper for such things as resumes and currency. Sources of rags often appear as waste from other manufacturing such as denim fragments or glove cuts. Fibres from clothing come from the cotton boll. Bleach and other chemicals remove the colour from the fabric in a process of cooking, usually with steam. The cloth fragments mechanically abrade into fibres, and the fibres get shortened to a length appropriate for manufacturing paper with a cutting process. Rags and water dump into a trough forming a closed loop. A cylinder with cutting edges, or knives, and a knife bed is part of the loop. The spinning cylinder pushes the contents of the trough around repeatedly. As it lowers slowly over a period of hours, it breaks the rags up into fibres, and cuts the fibres to the desired length. The cutting process terminates when the mix has passed the cylinder enough times at the programmed final clearance of the knives and bed. Another source of cotton fibre comes from the cotton ginning process. The seeds remain, surrounded by short fibres known as linters for their short length and resemblance to lint. Linters are too short for successful use in Page 3

4 fabric. Linters removed from the cotton seeds are available as first and second cuts. The first cuts are longer. The two major classifications of pulp are chemical and mechanical. Chemical pulps formerly used a sulphite process, but the kraft process is now predominant. Kraft pulp has superior strength to sulphite and mechanical pulps. Both chemical pulps and mechanical pulps may be bleached to a high brightness. Chemical pulping dissolves the lignin that bonds fibres to one another, and binds the outer fibrils that compose individual fibres to the fibre core. Lignin, like most other substances that can separate fibres from one another, acts as a debonding agent, lowering strength. Strength also depends on maintaining long cellulose molecule chains. The kraft process, due to the alkali and sulphur compounds used, tends to minimize attack on the cellulose and the non-crystalline hemicellulose, which promotes bonding, while dissolving the lignin. Acidic pulping processes shorten the cellulose chains. Kraft pulp makes superior linerboard and excellent printing and writing papers. Groundwood, the main ingredient used in newsprint and a principal component of magazine papers coated publications, is literally ground wood produced by a grinder. Therefore, it contains a lot of lignin, which lowers its strength. The grinding produces very short fibres that drain slowly. Thermomechanical pulp TMP is a variation of groundwood where fibres are separated mechanically while at high enough temperatures to soften the lignin. Between chemical and mechanical pulps there are semi-chemical pulps that use a mild chemical treatment followed by refining. Semi-chemical pulp is often used for corrugating medium. Bales of recycled paper normally old corrugated containers for unbleached brown packaging grades may be simply pulped, screened and cleaned. Recycling to make white papers is usually done in a deinking plant, which employs screening, cleaning, washing, bleaching and flotation. Deinked pulp is used in printing and writing papers and in tissue, napkins and paper towels. It is often blended with virgin pulp. At integrated pulp and paper mills, pulp is usually stored in high density towers before being pumped to stock preparation. Non integrated mills use either dry pulp or wet lap pressed pulp, usually received in bales. The pulp bales are slushed in a [re]pulper. Stock pulp preparation[ edit ] Stock preparation is the area where pulp is usually refined, blended to the appropriate proportion of hardwood, softwood or recycled fibre, and diluted to as uniform and constant as possible consistency. The ph is controlled and various fillers, such as whitening agents, size and wet strength or dry strength are added if necessary. Additional fillers such as clay, calcium carbonate and titanium dioxide increase opacity so printing on reverse side of a sheet will not distract from content on the obverse side of the sheet. Fillers also improve printing quality. Historically these were made of special ceramic tile faced reinforced concrete, but mild and stainless steels are also used. Low consistency pulp slurries are kept agitated in these chests by propeller like agitators near the pump suction at the chest bottom. In the following process, different types of pulp, if used, are normally treated in separate but similar process lines until combined at a blend chest: From the unrefined stock chest stock is again pumped, with consistency control, through a refiner. The discs have raised bars on their faces and pass each other with narrow clearance. This action unravels the outer layer of the fibres, causing the fibrils of the fibres to partially detach and bloom outward, increasing the surface area to promoting bonding. Refining thus increases tensile strength. For example, tissue paper is relatively unrefined whereas packaging paper is more highly refined. Refined stock from the refiner then goes to a refined stock chest, or blend chest, if used as such. Refining can cause the softwood fibre tube to collapse resulting in undesirable properties in the sheet. From the refined stock, or blend chest, stock is again consistency controlled as it is being pumped to a machine chest. It may be refined or additives may be added en route to the machine chest. The machine chest is basically a consistency levelling chest having about 15 minutes retention. This is enough retention time to allow any variations in consistency entering the chest to be levelled out by the action of the basis weight valve receiving feedback from the on line basis weight measuring scanner. Many paper machines mistakenly control consistency coming out of the machine chest, interfering with basis weight control. The forming section makes the pulp into the basis of for sheets along the wire. The press section, which removes much of the remaining water via a system of nips formed by rolls pressing against each other aided by press felts that support the sheet and absorb the pressed water. The dryer section of the paper machine, as its name suggests, dries the paper by way of a series of internally steam -heated cylinders that evaporate the moisture. Calenders are used to make the paper surface extra smooth and glossy. In practice calender rolls are normally placed vertically in a stack. Page 4

5 Diagram showing the sections of the Fourdrinier machine Forming section or wet end[ edit ] A worker inspecting wet, bleached wood pulp on an old-fashioned Hollander pulper or "beater". From the machine chest stock is pumped to a head tank, commonly called a "head tank" or stuff box, whose purpose is to maintain a constant head pressure on the fiber slurry or stock as it feeds the basis weight valve. The stuff box also provides a means allowing air bubbles to escape. Flow from the stuff box is by gravity and is controlled by the basis weight valve on its way to the fan pump suction where it injected into main flow of water to the fan pump. The main flow of water pumped by the fan pump is from a whitewater chest or tank that collects all the water drained from the forming section of the paper machine. Before the fiber stream from the stuff box is introduced, the whitewater is very low in fiber content. The whitewater is constantly recirculated by the fan pump through the headbox and recollected from the wire pit and various other tanks and chests that receive drainage from the forming wire and vacuum assisted drainage from suction boxes and wet fiber web handling rolls. On the way to the head box the pulp slurry may pass through centrifugal cleaners, which remove heavy contaminants like sand, and screens, which break up fibre clumps and remove over-sized debris. Page 5

6 Chapter 3 : Paper Making and Paper Manufacturing Process Production of the tissue paper Tissue paper is produced on a paper machine that has a single large steam heated drying cylinder (yankee dryer) fitted with a hot air hood. The yankee cylinder is sprayed with adhesives to make the paper stick. printed. Tissue with Lotion Background Facial tissues belong to a class of paper products used extensively for personal hygiene in modern society. Other products of this type include paper towels, napkins, and sanitary or toilet tissue. These products are designed to be highly absorbent, soft, and flexible. These pleasant tactile properties are especially important for facial and bathroom tissues, considering their use. To optimize pleasant skin feel, tissues have been developed with softening agents or lotion-type ingredients to reduce any chafing effect on delicate parts of the body. Tissues of this type are made by a process in which the nonwoven fabric is made from a solution of cellulose fibers and water, formed into a sheet, then coated with softening agents. Finally, the coated fabric is cut into individual tissues, folded, and packaged for sale. Historically it has been difficult to soften the tissue surface without interfering with other properties of the fabric. For example, softness can be increased by adding agents that interfere with the way the fibers within the tissue interact, making them less closely bonded to each other. These are known as debonding agents. However, these materials tend to decrease the tensile strength of the fabric and may irritate skin on contact. Enhanced softness can also be achieved by coating the fabric with oily materials. However, this limits the amount of moisture the tissue can absorb. In fact, the coating can also make the fabric so hydrophobic water hating that it can not be processed properly in sewage plants. Another problem is that some coating materials may decrease the strength of the fabric to the point where the tissue is not usable. To overcome this problem, fabric strength may be increased by adding certain resins or by mechanical processes which ensure the fibers bond together better. However, increasing strength tends to make the fabric stiffer and harsher to the touch. Rising to these challenges, tissue manufacturers have designed methods that successfully balance softness with absorbency and strength to create a product that consumers find acceptable. Raw Materials Nonwoven tissue paper Tissue paper is a nonwoven fabric made from cellulosic fiber pulp. Common fibers used in tissue paper pulp include wood from either deciduous or coniferous trees, rayon, bagasse a type of sugar cane stalk, and recycled paper. These fibers are macerated in a machine known as a hydropulper, which is a cylindrical tank with a rapidly revolving rotor at the bottom that breaks fiber bundles apart. In this process the fibers are mixed in a cooking liquor with water and either calcium, magnesium, ammonia, or sodium bisulfite. This mixture is cooked into a viscous slurry containing about 0. Bleaching agents are added to this mixture to whiten and brighten the pulp. Common bleaching agents include chlorine, peroxides, or hydrosulfites. The pulp is then washed and filtered multiple times until it is the fibers are completely free from contaminants. This mixture of pulp and water, known as a "furnish," is then ready for the papermaking process. Lotion Softening additives Softening agents are oily or waxy materials that are coated onto the tissue fabric to improve its tactile properties. These materials are too concentrated to coat directly on the paper, so they must be diluted with water first. However, these oils do not dissolve in water, they must be dispersed in water with the aid of chemicals known as surface active agents, or surfactants. A mixture of water, oils, and a surfactant is known as an emulsion. Mayonnaise is an example of a food product emulsion. The oily materials used in lotions typically include vegetable and mineral oil, plant or animal derived waxes, fatty materials, and silicone-based oils. While theoretically all of these materials would be appropriate tissue paper softening agents, experience has shown that many of them do not function well because they interfere with other desirable properties of the paper, like its absorbency. The tissue industry has had to develop its own patented combinations of lotion materials which, when blended and applied in the correct ratio, provide appropriate softening without negatively affecting the tissue. These materials include polyhydroxy compounds with multiple oxygen-hydrogen groups that allow them to interact with water. Therefore, these compounds are able to soften the paper surface without blocking too much water. Examples of polyhhydroxy compounds include glycerine, propylene glycol, polyoxyethlyne glycol, and polyoxypropylene glycol. They are employed at concentrations between 0. Other useful agents include Page 6

7 mixtures of petroleum- and silicone-based oils, which are judiciously added to further soften the paper. These oils must be used at low levels to avoid waterproofing the web and robbing it of absorbency. Surfactants are added to disperse the oils in water. A typical surfactant used in paper treatment emulsions is cetyl alcohol, a fatty material whose chemical structure allows it to combine oil and water. The Manufacturing Process Preparation of the nonwoven A variety of specialized equipment is used to press the pulp mixture, or furnish, into a nonwoven sheet of fabric-like paper. Nonwoven fabrics are different from traditional fabrics because of the way they are made. Traditional fabrics are made by weaving fibers together to create an interlocking network of fiber loops. Nonwovens are assembled by mechanically, chemically, or thermally interlocking the fibers. There are two primary methods of assembling nonwovens, the wet laid process and the dry laid process. The wet laid process is employed for making the type of nonwoven used in tissue production. The Fourdrinier is a continuous wire belt, approximately 50 feet 15 m or more in length, which is stretched out like a table. As the fibers are travel down this belt much of the water drains through the holes in the wire mesh. The wet sheet of fibers is carried by a series of woolen blankets, called felts, between several sets of rolls, which further compress it and remove more water. At this point the sheet is strong enough to be transferred to a drying machine that is especially adapted for making tissue papers. The wet sheet is carried by a heavy canvas felt, which is threaded over and around the rollers. With each successive pass, the rollers remove more water until the paper is adequately dried. If desired, a pattern may be imprinted in the tissue by juxtaposing the web on an array of supports during the dewatering process. Alternately, the web can be dewatered and transferred to a separate imprinting line. The raised supports on the line create bumps and valleys on the fabric. These are regions of varying fiber density and are visible as tiny patterned "pillows" on the final sheet. If necessary, these high bulk areas can be densified even further by applying a vacuum to selected portions of the sheet. After the fabric been compressed to the desired thickness, it is referred to as a "web. It may be coated or stored on large vertical rollers, known as calendar stacks, to await further operations. Lotion preparation and application 3 The lotion is prepared in steam-heated batch tanks equipped with high speed mixing blades. The oils and water may be preheated and are blended together with high shear to form an emulsion. The completed lotion is ready to be applied to the paper surface and is pumped from the batch tanks to a holding vessel connected to the coating equipment. As it travels over the belts the web comes into contact with an emulsion distributing roller, which pulls lotion out of the holding tank and coats a thin film onto the web. Ideally low amounts of lotion are applied 0. However, higher levels can be used if the coating is designed with additional surfactants that will act as wetting agents to help the tissue absorb moisture through its hydrophobic layer. After passing through the coating rollers, the web continues along the belts to other rollers, which strip excess lotion from the fabric. In between processes the belts are kept clean by belt-cleaning showers that remove paper fibers, adhesives, and other additives. Forming operations and packaging 5 The web passes through a series of rotating knives that cut it to the desired width. The coated tissue is then sliced at tissue-sized intervals, folded, and packaged in boxes or cellophane wrap. Waste fibers from the pulping process can be washed and reused. The water used in the slurry and in subsequent operations can be recycled. Unfortunately, there is little or no recovery of the chemicals used in coating and other treatments, and the disposal of the various spent solutions is a problem for the industry. Quality Control There are many quality control measures used in the tissue paper industry. The ones related to lotion application include analytical testing and subjective panel evaluations. Since the amount of material deposited on the tissue is critical, the industry has established various tests to measure how much is actually present on the tissue surface. For example, the amount of polyhydroxy compounds present can be determined by stripping the compounds from a tissue sample using a method known as the Webul solvent extraction. The amount of compound is then measured on a spectroscope or chromatograph. The concentration of surfactants can be established in a similar manner. While these analytical techniques can precisely determine the levels of specific chemicals, they can not evaluate fabric softness. This tactile property is assessed by subjective evaluation by trained panelists. Panelists are then asked to feel swatches and rate the degree of softness, flexibility, and smoothness. Subjects are presented with samples on a blind basis and required to choose one on the basis of tactile softness. Absorbency, the ability of the tissue to be wetted with water, is quantified by measuring the period of time Page 7

8 required for dry tissue to become completely saturated with water. This measurement is known as wetting time. Once again, the fabric is equilibrated to a specified temperature and humidity. It is then cut into small squares, crumpled into a ball, and placed on surface of a 3-qt beaker of water. A timer is started when the ball hits the water and the amount of time for the ball to be completely wetted by the water is measured. Five sets of five balls are tested to obtain an average measurement. Absorbency is measured on fresh tissue samples immediately after manufacture and on samples aged at least two weeks. This is important because absorbency will decrease over time, as the coating agents cure on the surface of the tissue. The density of the tissue is also measured with a thickness tester to evaluate how thick cloth is, then its mass, volume, and area are calculated. Linting the amount of loose lint which detaches from the tissue is measured by abrading a sample against a piece of black wool by a motor driven device known as the Sutherland Rub Tester. Colormetric analysis can then be used to determine the quantity of lint transferred to the wool. The Future The increased environmental concern about waste chemicals may lead to improved lotion formulations employing biodegradable or recyclable raw materials in the future. The industry is continually researching ways to make the manufacturing process faster and more energy efficient. Finally, methods may be developed to improve the strength of nonwoven fabrics without sacrificing the pleasant tactile characteristics that make lotion-coated tissues so desirable. Page 8

9 Chapter 4 : The Toilet Tissue Paper Manufacturing and converting process - Africa Recruitment Tissue paper production and consumption is predicted to continue to grow because of factors like urbanization, increasing disposable incomes and consumer spending. In, the global market for tissue paper is growing at per annum rates between % (China, currently 40% of global market) and % (Europe). The Toilet Paper Manufacturing Process The Toilet Paper Manufacturing Process The biggest difference between toilet papers is the distinction between virgin paper products formed from chipped wood and those made from recycled paper. So there are two kind of manufacturing process for the toilet paper. The toilet paper manufacturing process starts by creating a paper. Paper is sometimes created from recycled materials, but materials like virgin tree pulp is also used. The toilet paper we use today is usually a paper made from trees, but the paper from hemp plant is used too. Materials needed to make toilet paper are: Trees Chemicals for extracting fiber Bleaches like chlorine dioxide For paper recycling, companies use oxygen, ozone, sodium hydroxide, or peroxide to whiten the recycled paper. Toilet paper is often perforated, scented, embossed and colored. There are several differences in manufacturing process depending on what materials are used to make toilet paper. If toilet paper is made of recycled paper, process starts by many different kinds of paper being mixed together. Next step is choosing a solution to remove ink. Recycled paper needs to be washed and is often deinked prior to being pulped. Toilet paper is then pulverized and reformed into very thin and soft paper. At the end of process toilet paper is bleached and scented. The paper manufacturers try to find a compromise between durability and a fine writing surface on their product. Other materials for final product of toilet paper include water, chemicals and bleaches. Preparing trees a combination of softwood and hardwood trees. Trees are stripped of their bark. The logs are carefully debarked with machine to leave as much wood as possible. The logs pass through machines that chip them into small pieces. The wood chips are separated into batches. A massive pressure cooker a digester cooks the wood chips with other chemicals for approximately 3 hours. The moisture in the wood is evaporated and the mass is reduces to cellulose fibers, lignin and other substances. Result is usable fiber, called pulp. The pulp is what paper is made from. The pulp is then washed clean of the lignin and the cooking chemicals 7. The washed pulp is bleached until all the color is removed. The adhesive that binds fibers together lignin must be removed from the pulp or the paper will become yellow over time. The pulp is mixed with a lot of water to produce paper stock The paper stock is sprayed onto screens of mesh that drain the water. The paper is scraped off with metal blades and wound on jumbo reels. Then the paper is moved to machines that cut it into long strips and perforate it into squares. Finally, the paper logs are cut into rolls and wrapped packages. Page 9

10 Chapter 5 : Tissue paper making machine, Tissue Paper Manufacturing Machine Cost, Paper Napkin Maki blog.quintoapp.com Production of Toilet Paper Rolls, Facial Tissue & Paper Napkins Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market. Pressing Once the pulp is ready, it is poured over fast moving belts these can be metres wide made from highly porous materials that are driven on huge drums heated by steam. All the water escapes through the pores leaving just the fibres on the belt in the form of a delicate fabric. The tissue is transferred on to a massive heated roller called a Yankee. The Yankee roller is very hot and the fabric is dried almost instantly. The tissue paper is then transferred to a core to form a jumbo roll. You can adjust the draw speed of the jumbo roll to get a thicker or thinner tissue. The jumbo rolls are put onto the converting machine. Converting jumbo rolls to toilet rolls When making multi ply toilet tissue, the plies of tissue are usually split and each ply is passed through a different embossing roller. Embossing softens the toilet tissue and creates a decorative pattern. The tissue plies are brought back together then held together with glue or pressure embossing, the tissue is then perforated by blade, this enables the sheets to be easily pulled apart. The tissue is then wound around a cardboard tube to create a long toilet roll the length of 23 to 25 individual toilet rolls, which are called logs. The logs have a line of glue applied to hold the end of the tissue closed. Many different roll sizes and sheet counts are produced on the winding machines. The logs are stored in an accumulator ready to be cut to length. The log is fed into a saw and cut by a large rotating blade into individual rolls that you have at home today. The rolls are then conveyed to wrapping machines then stacked onto pallets ready for sale. How are paper towels made? The tissue paper for towel is made in a similar manner to the tissue paper produced for toilet tissue. The towel tissue is thicker and heavier with conditioners added to give strength when the paper is wet. Paper towels are available 2 ply, 3 ply and 4 ply varieties. The plies are embossed with a synchronised pattern and bonded together using lamination adhesive to add strength. Converting jumbo rolls to toilet rolls in the Cottonsoft factory The jumbo roll being transferred to the converting machine. The jumbo roll is positioned at the beginning of the converting line. The toilet tissue paper is drawn off the jumbo roll by the winding machine. The tissue is wound around a cardboard tube to create a long toilet roll the length of 23 to 25 individual toilet rolls. These are called logs. The logs are stored on an accumulator, ready to be cut to length. The log is fed into a saw and cut by a large rotating blade into individual rolls. The first step in the process of making soft tissue paper is creating paper pulp, which can be generated from wood fibre or recycled materials. Trees are logged and cut into chips which are then ground into fine flakes. Tissue paper manufacturers create their pulp by stirring together these retted soaked and pulled apart fine flakes in a mixing tank with a large quantity of water. The type of tree fibre and how much water is mixed in depends on the particular product being made. Page 10

11 Chapter 6 : Tissue and Towel Manufacturing Solutions Solenis This video is about the Tissue Paper production / manufacturing process at a mill from pulp to paper. PJL "Behind the scenes" of the converting process: Perini Journal Starting form this issue of the Perini Journal, we would like to discuss some of the "behind the scenes" processes that concern converting and that are more closely tied to those operators who work in the preparation phase of the parent reel, necessary first step in the converting process. It is a section that is reserved for "authorized personnel only" and is intended to serve as a support article, to satisfy the technical curiosities of those who work in this realm. And - given its simplicity of explanations - can also serve as an introductory article supplying basic information to all those neophytes among us. What is a paper machine? In the global process of converting raw materials into finished product, paper machines represent the main instrument through which the parent reel is obtained. The manufacturing process of the parent reel can be simple from the descriptive point of view, but the complexity of the number of phases that comprise the process itself, the systems - specific for each phase - make its actual production a rather complex operation. Many problems can arise due to the numerous variables that come into play, such as the use of chemical products, the wear of the devices and equipment, percentage of humidity, high operation speeds, etc. These potential problems substantially complicate the production phase. So even though we can say that the process of converting fibrous substances into finished product is rather simple to understand, it is, instead, complicated to carry out. The Big Bang of the paper making phase is given by the breaking up of cellulose - or recycled fibres in water. These are the indispensable raw materials for the start of the process and this phase is carried out in the pulper, a machine whose function it is to break down these fibres. The sheet of paper produced is then dried in the Yankee dryer. The fibrous mixture obtained from the crushing of cellulose through the addition of water - fundamental element of the process - is distributed onto a wire and is then transported to be dried. The water contained in the mixture, bonding element and means of transport of the cellulose pulp, will have to be subsequently removed. It is at this phase of the production process that the paper machine plays a determining role. The PM allows the continuous formation and detachment of the sheet of paper. One, continuous phase where the raw material is crushed, distributed uniformly on a wire and the sheet of paper is dried. For this reason, it contains many devices headboxes, vacuum presses and Yankee dryer, etc. The Yankee dryer, a large cylinder heated by vapour and aided in its activity by vacuum hoods, heats the sheet, thus terminating the drying phase through the total elimination of the residual water concentration. The sheet thus obtained is wound on a large cardboard core to become a parent reel. Here is where the work of the paper machines end and the converting machines come into play. As can well be imagined, the start-up of a tissue PM presents several small potential problems to be resolved and kept under control. Describing these is very complicated and complex, considering that we are talking about a dynamic field, in constant and fast evolution. For this reason, writing an exhaustive article is complicated and rather difficult. In order to describe the complicated start-up phase of a tissue machine, we could use endless rivers of ink and we still would not have succeeded in being exhaustive. Therefore, we would like to limit ourselves to listing and describing some of the main factors that influence in particular the start-up procedure of the PM, especially the Crescent Former. This procedure can be thus summed-up as follows: Adjustment and control of fibre distribution inside the headbox 2. Vacuum line control vacuum boxes and press rolls, wire and felt rinses 3. Yankee dryer pre-heating 4. Pre-heating of the hoods 5. Coating preparation on the Yankee surface 6. This procedure consists in adjusting the aperture of the headbox, a mechanism that allows to uniformly distribute the fibre along the web width of the PM. The pulp, initially largely comprised of water and pulp the pulp concentration varies between about 0. Controlling the aperture is necessary in order to align the jet speed of the pulp with the speed of the wire. These devices can be: Efficiency control of the vacuum line is necessary both for the correct functioning of the water extraction operations from the pulp as well as for felt cleaning. The latter must always be in optimal conditions of permeability both to absorb water and to allow a better deposit of the paper fibres on its fine surface. Through evaporation, the Yankee dryer extracts the water humidity from the pulp. The web passes from the felt to the Yankee through contact. The internal Page 11

12 heating of the machinery ensures an adequate temperature of its external surface. The pre-heating phase of the Yankee, a large, thick metal cylinder, allows to obtain complete and uniform heat distribution, thus avoiding internal tensions of the materials comprising it. The hoods aid the activity of the Yankee as they contribute to the water vaporization within the sheet through air jets aimed directly on the sheet. The pre-heating phase is necessary for these machines because they are comprised of sheet metal tubing of various thickness and sizes. The coating, an ensemble of chemical products uniformly distributed on the Yankee dryer surface, reduces the friction created between the Yankee and the creping blades used to scrape the paper from the cylinder. Some chemical products of the coating aid the creping blades in the proper release of the sheet from the Yankee adhering and detaching products. The preparation in the proper percentages of such products and their correct distribution is very important for uniform release along the entire width of the sheet from the Yankee surface. The products are sprayed on the cylinder surface through fan nozzles located at a well-defined distance. This operation is necessary in order to avoid the formation on the sheet width of areas having different humidity levels. This can be caused by an imperfect cleaning of the felt, malfunctioning of the headbox, vacuum press, etc. The sheet must have a uniform humidity content in order to avoid malformations of the sheet bumps or depressions or wet ends on the reel during final winding on the pope shaft. This phenomenon can create problems wrinkles, breaks during the converting process of the parent reel into finished product and must therefore be avoided. A solution is to act on the drying hoods located above the Yankee dryer, reducing the hot air flow and addressing it appropriately through a computer-controlled humidity profile. The surface temperature of the Yankee must be kept under constant control according to the speed of the paper machine and the type of paper produced. The time elapsed between the approach of the headbox and the vacuum press of the felt against the Yankee surface, and the opening of the pulp valves must be sufficiently reduced so as to avoid part of the coating that has formed on the Yankee migrating onto the surface of the felt; If the coating becomes detached from the Yankee, the paper sheet that is to adhere to it will not find a uniform anchoring, thus creating problems both for the creping blades as well as for reel formation. The control of the chemical products used in the circuit anti-foaming, cationizing, etc. An excessive use of anti-foaming agents - aimed at avoiding the formation of air bubbles in the fan pump and in the headbox - may cause modification in the detachment of the sheet, thus altering its mechanical characteristics and its adherence to the Yankee. For a hygienic use of the products obtained - toilet rolls, table napkins, handkerchiefs, baby diapers, etc. The chemical products used have been studied so as to maximize their efficiency in environments having such a ph. It is very difficult to be exhaustive when describing the "behind the scenes" of the converting process, but in these few lines we have tried to introduce in a simple way some of the many aspects that we will face in the next publications. Page 12

13 Chapter 7 : "Behind the scenes" of the converting process: how a tissue paper machine works - Perini Jour The tissue paper for towel is made in a similar manner to the tissue paper produced for toilet tissue. The towel tissue is thicker and heavier with conditioners added to give strength when the paper is wet. The average American uses over single rollsâ about 21, sheetsâ each year. Manufacturers estimate that an average single roll lasts five days. Toilet paper, paper towels, napkins, and facial tissues are sanitary papers, personal products that need to be clean and hygenic. Sanitary papers are further distinguished from other papers in that they are creped, a process in which the paper is dried on a cylinder then scraped off with a metal blade, slightly crimping it. This softens the paper but makes it fairly weak, allowing it to disintegrate in water. Color, scents, and embossing may also be added, but fragrances sometimes cause problems for consumers who are allergic to perfumes. The biggest difference between toilet papers is the distinction between virgin paper products, which are formed directly from chipped wood, and those made from recycled paper. Most toilet paper, however, whether virgin or recycled, is wrapped around recycled cardboard cylinders. History Before paper was widely available, a variety of materials were employed. The Romans used an L-shaped stick like a hockey stick made of wood or precious metal; at public toilets people used sponges on sticks that were kept in saltwater between uses. In arid climates, sand, powdered brick, or earth was used. Until the late nineteenth century, Muslims were advised to use three stones to clean up. One favorite tool was a mussel shell, used for centuries. Until the early twentieth century, corn cobs were used. In the late fifteenth century, when paper became widely available, it began to replace other traditional materials. Sometimes old correspondence was pressed into service, as were pages from old books, magazines, newspapers, and catalogs. People also used old paper bags, envelopes, and other bits of scrap paper, which were cut into pieces and threaded onto a string that was kept in the privy. Toilet paper is a fairly modern invention, making its debut around when it was developed by the British Perforated Paper Company. Made of a coarser paper than its modern incarnation, it was sold in boxes of individual squares. The first rolls were not perforated, and lavatory dispensers had serrated teeth to cut the paper as needed. It was a nearly "unmentionable" product for years, and consumers were often embarrassed to ask for it by name or even be seen buying it. Timid shoppers simply asked for "Two, please," and the clerk presumably knew what they wanted. To keep things discreet, toilet paper was packaged and sold in brown paper wrappers. Recently, toilet paper manufacturers increased the number of sheets on a roll, allowing consumers to replace the roll less frequently. Raw Materials Toilet paper is generally made from new or "virgin" paper, using a combination of softwood and hardwood trees. Softwood trees such as Southern pines and Douglas firs have long fibers that wrap around each other; this gives paper strength. Hardwood trees like gum, maple and oak have shorter fibers that make a softer paper. Other materials used in manufacture include water, chemicals for breaking down the trees into usable fiber, and bleaches. Companies that make paper from recycled products use oxygen, ozone, sodium hydroxide, or peroxide to whiten the paper. Virgin-paper manufacturers, however, often use chlorine-based bleaches chlorine dioxide, which have been identified as a threat to the environment. These small pieces make it easier to pulp the wood. The batch of wood chipsâ about 50 tonsâ is then mixed with 10, gallons of cooking chemicals; the resultant slurry is sent to a ft The mixture is reduced to about 25 tons of cellulose fibers, lignin which binds the wood fibers together and other substances. Out of this, about 15 tons of usable fiber, called pulp, result from each cooked batch. The pulp goes through a multistage washer system that removes most of the lignin and the cooking chemicals. This fluid, called black liquor, is separated from the pulp, which goes on to the next stage of production. The washed pulp is sent to the bleach plant where a multistage chemical process removes color from the fiber. Residual lignin, the adhesive that binds fibers together, will yellow paper over time and must be bleached to make paper white. The pulp is mixed with water again to produce paper stock, a mixture that is The paper stock is sprayed between moving mesh screens, which allow much of the water to drain. This produces an ft 5. Next, the paper is creped, a process that makes it very soft and gives it a slightly wrinkled look. During creping, the paper is scraped off the Yankee Dryer with a metal blade. This makes the sheets somewhat flexible but lowers their strength and thickness so that they virtually disintegrate Page 13

14 when wet. The paper, which is produced at speeds over a mile a minute, is then wound on jumbo reels that can weigh as much as five tons. The paper is then loaded onto converting machines that unwind, slit, and rewind it onto long thin cardboard tubing, making a paper log. The paper logs are then cut into rolls and wrapped packages. Recycled toilet paper Toilet tissue made from recycled paper is made from both colored and white stock, with staples and pins removed. The paper goes into a huge vat called a pulper that combines it with hot water and detergents to turn it into a liquid slurry. The recycled pulp then goes through a series of screens and rinses to remove paper coatings and inks. The pulp is whitened somewhat and sanitized with oxygen-based products like peroxide. It then goes through steps 7 through 10 like virgin paper products, producing a cheaper, less-white paper. Quality Control Paper companies often maintain their own tree stands in order to ensure the quality of the paper they manufacture. The chemicals used in the pulping process are also carefully tested and monitored. Temperatures at which a slurry is cooked is ensured, too, by checking gauges, machinery, and processes. Completed paper may be tested for a variety of qualities, including stretch, opacity, moisture content, smoothness, and color. In addition, black liquor, the fluid removed from the pulp after cooking, is further evaporated to a thick combustible liquid that is also used to power the mill. This reduction process, in turn, yields a byproduct called tall oil that is widely used many household products. But other problems associated with the industry are less easily solved. The production of virgin toilet paper has spawned two current controversies: While virgin paper processing does necessitate the destruction of trees, they are a readily renewable resource and paper companies maintain large forests to feed their supply. Despite this, some activists have proposed that toilet paper be manufactured only from recycled products and suggest that consumers boycott toilet paper made of new materials. These activists object to new paper processing because it often uses chlorine bleaching, which produces dioxins, a family of chemicals considered environmental hazards, as a byproduct. Paper and pulp mills are the primary producers of dioxins, and manufacturers must carefully assess their effluvia to counteract the emission of dioxins. Increasingly, virgin paper makers use alternative bleaching methods that substitute oxygen, peroxide, and sodium hydroxide for chlorine. Some simply reduce the amount of chlorine used in the process. Others experiment with cooking the wood chips longer, removing more lignin earlier in the process, which requires less bleach. Better pulp washing also removes more lignin, and reduces the amount of bleach needed for whitening. The Comforts of Home. Stein and Day Publishers, Other Charmin Bathroom Tissue. Other articles you might like: Page 14