PAPER INDUSTRY

Table of Contents

I. Introduction
A. Background 1
B. Limitations 3

II. Manufacturing Process

A. Raw Materials 4
B. Processing 4
C. Product 9
D. Equipment Used 10
E. Quality Control 12

III. Health, Safety and Environment

A. Human Safety and Health 12
B. Environment Impact 13

IV. Industry Market Profile

A. Economics of Production 14
Local Market 14
Global Market 14
B. Future Market Outlook 15
C. Local Companies 17

V. Research and Development 18

VI. References 19
I. Introduction

A. Background

Paper is an incredibly versatile substance made from naturally occurring plant fibers
called cellulose. Originally derived from cloth rags and grasses, paper is now predominantly
made with wood.

From the finest quality paper through to the thickest, strongest corrugated carton,
the manufacturing process for this renewable resource is the same: the wood must first be
shredded and mixed with water to make pulp. The pulp is then refined, cleaned and agitated
before being pumped onto a moving screen or mesh. As the pulp travels along the screen,
excess water is drained away and recycled. A paper sheet made from interlocking cellulose
fibers begins to form. As it moves through the papermaking machine it is pressed between
huge rollers to extract water and subsequently through heated rollers to remove any
remaining water. Once the paper has been dried and pressed and depending upon its end use,
it may be finished with coatings or other additives which ensure uniform smoothness and
thickness.

Paper products have a vast range of useful applications - it can be made soft and delicate
as the lightest tissue or strong and tough enough to be used as a construction material. And
this ubiquitous substance continues to reveal new attributes: paper can be treated and made
fire-resistant and it can even be waterproofed and used in boat hulls.

History of Papermaking

Between 2500 and 2000 B.C.

- writing paper was first manufactured from a tall reed growing along the Nile called papyrus,
hence the word paper.

A.D. 105
- The birth of paper, as we know it today, took place under the Chinese Han Dynasty in AD
105. Ts'ai Lun, a court official, invented a papermaking process which primarily used rags
(textile waste) as the raw material with which to make paper.

A.D. 610
- Papermaking spreads across Asia, Middle East, and Europe.

1690
- Americas first paper mill was established.

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17th and 18th Century
- Papermaking technology improves demand for paper increases.
- 1799: a Frenchman, Robert, invented a process for forming a sheet on a moving wire screen.
This machine is known today as Fourdrinier machine.
- 1844: Keller of Saxony invented a mechanical process for making pulp from wood.
- 1851: soda process was developed by Watt and Burgess.
- 1867: American chemist Tilghman was granted the basic patent for sulfite process.
- 1884: sulfate, or kraft process was the result of basic experiments conducted by Dahl.

19th and 20th Century

- Emergence of wood based paper and increased mechanization and full-scale
industrialization.
- 1909: sulfate process was introduced into the United States.

Pulp
- is a cellulose fiber material, produced by chemical or mechanical means, from which
paper and paperboard are manufactured. Sources of cellulose fiber include wood, cotton,
straw, jute, bagasse, bamboo, hemp and reeds.

Types of Pulp

1. Hardwood
- Deciduous trees. Short fibers.
- Ex. beech, birch, poplar and eucalyptus

2. Softwood
- Coniferous trees. Long fibers.
- Ex. cedars, Douglas-firs, cypresses, firs, junipers, kauris, larches, pines, hemlocks,
redwoods, spruces, and yews

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Types of Pulping Process

1. Mechanical Process / Groundwood

- This process involves no chemical treatment of the pulp. The chief woods employed
are spruce and balsam, which are soft, coniferous species.

2. Chemical Process

Sulfate Process
- also called Kraft Process. It is an alkaline process and is responsible for the pulp
manufactured at the present time. Almost any kind of wood may be used, hard or
soft, although coniferous woods are mostly employed.

Soda Process
- manufactured similarly to sulfate process, both being alkaline process.

Sulfite Process
- utilizes a cooking acid consisting of a combination of free sulfur acid and sulfur acid
bound as magnesium bi-sulfite. Although spruce is the wood most commonly
employed, appreciable quantities of hemlock and balsam are also used.

B. Limitations
This report will focus on the production of paper in the pulp and paper industry from
wood cellulose and the pulping process used is the kraft pulping process. The
manufacturing process was adapted from SAPPI (South African Pulp and Paper
Industries).

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II. Manufacturing Process

A. Raw Materials
Raw materials in manufacturing paper:

Wood principal source of cellulose for paper making

Rags
Recycled paper
Other fibrous plants

B. Processing

Figure 1. Pulp and paper making flowchart

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Pulp Making

CHIPPING
When the logs arrive at the wood yard, they are fed into a rotating drum which removes the
bark. The logs are then chipped.
The largest source of wood chips for paper making is the recycled off-cuts from industrial
saw mills.

PULPING

Kraft Pulping Process

1. Impregnation
The cooking liquors consist of a mixture of white liquor containing essentially sodium
sulfide and caustic soda, water in chips, condensed steam and weak black liquor. In the
impregnation, cooking liquor penetrates into the capillary structure of the chips and low
temperature chemical reactions with the wood begin. A good impregnation is important
to get a homogeneous cook and low rejects. About 4060% of all alkali consumption in
the continuous process occurs in the impregnation zone.

2. Cooking
The wood chips are then cooked in pressurized vessels called digesters. The materials are
fed at a rate which allows the pulping reaction to be complete by the time the materials
exit the reactor. Typically, delignification requires several hours at 170 to 176 C (338 to
349 F). Under these conditions lignin and hemicellulose degrade to give fragments that
are soluble in the strongly basic liquid. The solid pulp (about 50% by weight of the dry
wood chips) is collected and washed. At this point the pulp is known as brown stock
because of its color. The combined liquids, known as black liquor (because of its color),
contain lignin fragments, carbohydrates from the breakdown of hemicellulose, sodium
carbonate, sodium sulfate and other inorganic salts.
We call the pulp obtained from this process wood-free because the lignin has been
dissolved.

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 3. Blowing
The finished cooked wood chips are blown to a collection tank called a blow tank that
operates at atmospheric pressure. This releases a lot of steam and volatiles. The volatiles
are condensed and collected; in the case of northern softwoods this consists mainly of
raw turpentine.

4. Screening
Screening of the pulp after pulping is a process whereby the pulp is separated from
large shives, knots, dirt and other debris. The accept is the pulp. The material separated
from the pulp is called reject. The screening section consists of different types
of sieves (screens) and centrifugal cleaning. The sieves are normally set up in a multistage
cascade operation because considerable amounts of good fibers can go to the reject
stream when trying to achieve maximum purity in the accept flow.

5. Washing
The brownstock from the blowing goes to the washing stages where the used cooking
liquors are separated from the cellulose fibers. Normally a pulp mill has 3-5 washing
stages in series. Washing stages are also placed after oxygen delignification and between
the bleaching stages as well. Pulp washers use counter current flow between the stages
such that the pulp moves in the opposite direction to the flow of washing waters. Several
processes are involved: thickening / dilution, displacement and diffusion. The dilution
factor is the measure of the amount of water used in washing compared with the
theoretical amount required to displace the liquor from the thickened pulp. Lower
dilution factor reduces energy consumption, while higher dilution factor normally gives
cleaner pulp. Thorough washing of the pulp reduces the chemical oxygen demand (COD).

BLEACHING
Before it can be used to make white paper, the pulp is bleached, and any residual lignin which
would cause the paper to yellow with age, is filtered out. To protect the environment, this
beaching is chlorine free, using oxygen and peroxide.
The yellow-brown wood chips that entered the pulp mill have now been turned into a soft
white pulp, the principal raw ingredient for making paper.

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 ADDITION OF SIZE, CLAY AND DYES
Wood fibers alone would produce rough textured and unevenly dense paper, and fillers such
as calcium carbonate and clay are mixed in to make the paper opaquer and give it a more
controlled density. Dyes, optical brighteners, and sizes may also be blended into the pulp to
improve the appearance of the paper.
The pulp solution is now a carefully controlled mix of fibers, fillers and coloring agents
suspended in water, ready to enter the paper machine.

Paper Making
Paper machine is the heart of paper mill.

Located at the beginning of the paper machine is the headbox.

The pulp solution is injected at high pressure directly into the space between two
continuously rotating wires.
Rotating wires carry the pulp into the gap former, which rapidly drains the excess water from
both sides. This immobilizes the pulp within millisecond of leaving the headbox turning it
into a continuous web of paper, still wet and fragile, but already exhibiting its most important
sheet properties.

WET PRESS SECTION

The delicate paper web is now carried into the press section by continuously looped wet
felts, which carry away most of the water, and stop sheet from tearing. The paper web is
forced between a soft rotating roller pressing against a hydraulically-actuated metal pad.
Water is squeezed out of the paper by this pressure, and this is absorbed and carried away
by the wet felts.

DRYER SECTION
The longest section of the paper machine contains the drying cylinders. These huge heated
rollers dry the paper, giving it the strength to become self-supporting, ready for the
processes which will determine its surface qualities.

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 CALENDER SECTION
The paper passes through a machine calender where two finely polished steel cylinders at a
precisely determined width apart ensure that the paper thickness is consistently even.

COATING & FINISHING

The paper then passes through a series of sizing and coating presses. Here, starch and coating
colors are applied to its surface using a film press process. The coating color is sprayed onto
an elastic roll which then transfers the coating film to the paper web. Film press coating
creates a uniformly thick coating layer which follows the surface of the paper. After each
coating process, the surface is dried by infrared heating panels and drying cylinders.
Setting the surface with sizing encourages printing inks to dry on the surface of the paper
rather than be absorbed into the paper, increasing the color intensity of the finished print
and improving the surface strength and water resistance of the paper.
The paper is then wound onto series of steel cores which press against a pope reel. This
makes sure that the paper is wound at the right tension on each core.
The final surface qualities of each batch of paper are controlled in the coating and finishing
lines. The coating compounds are mixed according to precise recipes in tanks in the coating
kitchen. The main color pigment is calcium carbonate, which makes the paper surface white,
but the coating solution may also include clay and talcum powder. Binders can be natural
starches, or purely synthetic compounds such as latex.
To create a smoother surface, up to two more coatings per side are applied using blade
coating process, excess solution is sprayed directly onto the paper and is then scraped off by
a steel blade.
Depending on the pressure of the doctor blade, a uniform paper surface is created as the
irregularities in the paper are smoothed out.

Each side is coated and dried in sequence to create the correct characteristics for each paper
grade. The paper passes through up to 10 rollers, which each apply pressure and
temperature. These rolls have different surfaces such as hard steel and soft rubber,
depending on the type of gloss and surface treatment required.

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 CUTTING
The jumbo reels are transported to a slitter winder. Rotary blades cut the reel into several
narrow reels which are rewound and sent forward to the finishing department.
Several reels are simultaneously fed into a sheet cutter, which cuts the paper into sheets and
stacks these onto pallets.
Several printing processes, like heat set web offset, cutstar and label presses use paper in
reel form. These reels remain uncut and are moved forward on automated conveyor belts.

PACKAGING
Each reel of paper is wrapped in kraft cardboard to avid damage in transport. Each pallet
load of sheets is either shrink wrapped, or wrapped in reams, ready for delivery to the
customer.
Every consignment, of both sheets and reels, is labeled with the brand name, a batch number
to identify its exact manufacturing history, and its destination. All that remains is to ship the
paper, now a branded, quality controlled product with precise characteristics and
performance, out to the customer.

C. Products
Newsprint and magazine papers
Printing and writing papers
Sanitary and household papers
Packaging material
Specialized papers

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D. Equipment Used

Paper Machine / Fourdrinier Machine

Drum Debarker

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 Calender Roll

Digester

Sheet Cutter

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 Rewinder

E. Quality Control
Weight
Thickness
Smoothness
Opacity

III. Health, Safety and Environment

A. Human Safety and Health

Pulp and paper manufacturing can also be very hazardous due to massive weights and falling,
rolling and/or sliding pulpwood loads. Workers may be struck or crushed by loads or suffer
lacerations from the misuse of equipment, particularly when machines are used improperly
or without safeguards.

Injuries
The most commonly encountered risk factors for serious and fatal accidents in the pulp
and paper industry are the papermaking equipment itself and the extreme size and
weight of pulp or paper bales and rolls.

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 Non-malignant diseases
- acute and chronic respiratory disorders
- skin problems
- exposure to microorganisms
- excessive heat exposure
- noise

B. Environment Impact

Air Pollution
Nitrogen dioxide (NO2) sulfur dioxide (SO2) and carbon dioxide (CO2) are all emitted
during paper manufacturing. Nitrogen dioxide and sulfur dioxide are major contributors
of acid rain, whereas CO2 is a greenhouse gas responsible for climate change.

Water Pollution
Wastewater discharges for a pulp and paper mill contains solids, nutrients and dissolved
organic matter such as lignin. It also contains alcohols, and chelating agents and inorganic
materials like chlorates and transition metal compounds. Nutrients such as nitrogen and
phosphorus can cause or exacerbate eutrophication of fresh water bodies such as lakes
and rivers. Organic matter dissolved in fresh water, measured by Biological Oxygen
Demand (BOD), changes ecological characteristics, and in worst-case scenarios leads to
death of all higher living organisms. Waste water may also be polluted
with organochlorine compounds. Some of these are naturally occurring in the wood, but
chlorine bleaching of the pulp produces far larger amounts.

Land Pollution
The composition of solids (sludge) removed from liquid effluent treatment systems varies,
depending on their source. Solids from primary treatment principally consist of cellulose
fibers. The major component of solids from secondary treatment is microbial cells. If the
mill uses chlorinated bleaching agents, both primary and secondary solids may also
contain chlorinated organic compounds, an important consideration in determining the
extent of treatment required.

Deforestation
Worldwide consumption of paper has risen by 400% in the past 40 years, with 35% of
harvested trees being used for paper manufacture. Plantation forest, from where the
majority of wood for pulping is obtained, is generally a monoculture and this raises
concerns over the ecological effects of the practice.

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IV. Industry and Market Profile

A. Economics of Production

1. Local Market

The Philippine paper industry seeks to attain the capability to serve all major pulp and
paper requirements of the country and develop high-value and quality pulp and paper
products in the long-term, in a manner that is internationally competitive and
environmentally sustainable.

Volume of Paper and Paperboard (000 MT)

2006 2007 2008 2009 2010 2011
Exports 176 168 135 132 165 130
Imports 620 419 339 326 400 823

Paper and Paperboard Production and Consumption (in 000 MT)

2006 2007 2008 2009 2010 2011
Production 524 1097 843 1019 1038 950
Consumption 968 1348 1468 1253 1834 1643

2. Global Market

Top 5 Paper and Paperboard Producing Countries (2013)

Country Production (in million MT)

China 105.1
USA 74.3
Japan 26.1
Germany 22.4
Korea Republic (South) 11.8

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 Top 5 Paper and Paperboard Importing Countries (2013)

Country Imports (in million MT)

Germany 10.6
USA 9.7
UK 5.9
France 5.0
China 4.8

Top 5 Paper and Paperboard Exporting Countries (2013)

Country Exports (in million MT))

Germany 13.1
USA 12.1
Sweden 10.1
Finland 9.87
Canada 8.2

B. Future Market Outlook

The pulp and paper industry contributes about P30 billion per year in domestic sales value
to the economy, or saves the country $700 million per year in foreign exchange from
imported paper and board. As of 2012, the local paper industry directly employs about
6,000 personnel, mostly skilled workers and technical professionals, and contribute value
to the economy by sustaining the livelihood opportunities of about 1.2 million workers in
the wastepaper collection, sorting, and hauling sub-sectors.

Current socio-economic conditions in the country are profitable for businesses in the pulp
and paper industry. While paper and paperboard consumption in the Philippines is still low
at 19 kg per capita, total annual demand is growing at 2.5% per year, with packaging and
tissue grades experiencing high growth rates. Moreover, total paper and board demand in
the Philippines is projected to surpass 2 million tons within five years, or an additional of
0.3 million tons per year at current consumption levels.

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The countrys recent strong economic performance has pushed a steady rise in demand
for packaging materials such as corrugating container boards and carton boards, which
can be traced to the increasing export sales of electronics, fresh fruits, garments,
handicrafts and furniture. Strong growth is also seen in the domestic market, coming from
the demand for packaging processed foods, appliances and other consumer goods, as well
as consumption of tissue, publishing and printing paper. This strong demand is driven by
improved standards of living, higher disposable income, rise in education, tourism, and
increased manufacturing activities in the Philippines.

Furthermore, the shift towards environmentally-friendly policies and lifestyles drives

demand further, thereby providing promising opportunities to invest in the industry. For
instance, sales of paper bags and wrappings in retail stores are expanding in large volumes
for the next 3 to 5 years, as a result of new laws regulating the use of plastic and
polystyrene in packaging consumer and industrial products.

At present, the Philippines has twenty-four (24) non-integrated paper mills with a total
production capacity of 1.3 million tons of paper and paperboard per year, as well as four
(4) abaca pulp mills exporting 25,000 tons of specialty non-wood pulp per year. Major
grades of manufactured papers in the country are mostly derived from recycled
wastepaper, and these products come in the form of newsprint, printing and writing
paper, tissue, container board, and other packaging paper and boards.

In the last five years, almost all grades produced in the Philippines have a recycled fiber
content of 95-100%, compared to the minimum recycled content of 25-35% implemented
in developed countries. By being a market of about 1 million tons of wastepaper per year,
the paper industry provides strong support to the countrys solid waste management
efforts. Consequently, it provides thousands of indirect jobs for garbage collectors, junk
recyclers, sorters, haulers, and other workers in the countrys marginalized sectors.

Aside from recycling paper for its fiber requirements, the Philippines has unutilized
volumes of agricultural waste and abaca (Manila hemp) that farmers in Bicol, the Visayas,
and Mindanao can supply to the paper industry. Other fibers from agricultural waste (such
as rice straw, banana and sugarcane bagasse), as well as plants like kenaf and bamboo,
can be supplemental sources of pulp in the industry. Such production technique facilitates

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 not only environmental sustainability and resourcefulness, but also inclusiveness in
generating jobs for marginalized sectors.

Finally, the Philippines has suitable areas for fast-growing and sustainably-managed
commercial forests. For instance, in the eastern half of Mindanao, pulp production can be
established based on privately-owned tree farms, industrial tree plantations, and
community-based forestry. The forest products sector has also identified various species
excellent for reforestation, such as Acacia mangium, Eucalyptus spp hybrids, Gmelina
arborea, and Albizzia falcata. Virgin kraft and chemi-mechanical pulps (used in high-grade
and international standards-compliant paper and paperboard products) can be locally
manufactured from these wood species.

Since there is sufficient domestic market paper production in the Philippines, the countrys
pulp requirements are enough to support the establishment of an economic-sized pulp
mill. The industry presently operates without the presence of a local pulp mill, which is
necessary for the production of specialty and high-value paper products. Domestic and
foreign investments on this significant component will make the paper and pulp supply
chain more productive and cost-competitive.

C. Local Companies

1. Trust International Paper Corporation (TIPCO)

The TIPCO mill is located in a 37-hectare lot at the TECO Industrial park in
Bundagul, Mabalacat, Pampanga. TIPCO started the construction and installation of
the first paper machine (PM1) in July 1987 and formally inaugurated the mill site and
PM1 on December 13, 1988. Full commercial operations began in August 1989.
In 1993, the Company constructed a second paper machine (PM2) purchased from
Quebec Canada and built with the capacity of 350 metric tons per day. Full commercial
operations of PM2 started in May 1995.
In 1995, with the vision of achieving global competitiveness, TIPCO ventured into
a third paper machine (PM3) acquiring a J-Former machine from Avenor, Canada with
a capacity to 350 metric tons per day. The J-Former, a twin-wire paper machine, was
the first of its kind installed in the country. Compared to the usual less efficient
conventional fourdrinier type, the machine has advanced J-formation and sheet
stability, the qualities required for copy paper, 4-color printing and high-speed
printing. PM3 was officially declared on commercial operations in January 1998.

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 2. United Pulp and Paper Co., Inc. (UPPC)

UPPC is the Philippines leading manufacturer of high quality industrial grade

paper, including corrugated medium paper and liner board that are used in carton
packaging products. The company is located in Bulacan in the Philippines, has about
400 employees and has a rated annual production capacity of 200,000 tons. UPPC was
incorporated in December 1969 and started its operations in August 1975. UPPC is
practically fully owned by the Siam Cement Group of Thailand and is jointly managed
by Filipinos and Thais.

3. VECO Paper Corporation

Located in the City of Muntinlupa, VECO Paper has many modern printing and
converting equipment. VECO Paper's products are distributed by an extensive network
of dealers nationwide. It is also carried by major bookstores and department stores
nationwide. These had given our customers easy access to our products.

V. Research and Development

A ground-breaking discovery: Deep Eutectic Solvents (DES) produced by plants, opens the
way to produce pulp at low temperatures and at atmospheric pressure. Using DES, any
type of biomass could be dissolved into lignin, cellulose and hemicellulose with minimal
energy, emissions and residues. They could also be used to recover cellulose from waste
and dissolve ink residues in recovered paper. DES will ultimately lead to a 40% lower
energy cost level and a 20% less CO2 emission level.

Nanotechnology in the pulp and paper industry. This is drawn from the wood that is
synthesized naturally and composed of nanofibrils with less than 20 nm width. There are
benefits from the nanocellulose in TMP based and filed paper and here the strength was
improved much better. Because of the property of nanocellulose as greater absorption of
water and can drain in wet web of a paper machine, there is a limiting factor exist to use
nanocellulose in the scale of industry. When we observe the developments in
conventional paper and the nanopaper is look like as a keyword. In nanopaper there are
extreme number of high barrier properties and convention plastics on the basis of oil and
are conventional which is superior and comparable. Because of the strength involved
intrinsically, cellulose nanofibrils and their self-assemble capability and strong
nanobarriers, dense and nanocomposites can be produced. There are certain advances
happened to change the surface of cellulose of nanofibrils and films thus control the

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 surface hydrophobicity. This is the most significant aspect in considering the packaging
applications of food and beverages. There is an additional benefit that from change in
surface of cellulose nanofibrils also significant for the applications which are novel and
these are like emulsions stabilization that demonstrates diesel emulsion fuels to be
promised.

IV. References

Shreve, N.R., Brink Jr., J.A. Chemical processes industries (4th edition).

http://www.ilocis.org/documents/chpt72e.htm
http://individual.utoronto.ca/abdel_rahman/paper/history.html

https://en.wikipedia.org/wiki/Environmental_impact_of_paper

https://prezi.com/vjvw1onnhcnv/the-pulp-and-paper-industry-and-health-implications/

http://www.paperonline.org/paper-making/paper-uses

http://industry.gov.ph/industry/paper/#about-the-industry

http://www.paperonweb.com/World.htm

http://www.cepi.org/topic/innovation/pressrelease/twoteamproject

http://www.pulpandpaper-technology.com/articles/id/Nanotechnology

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