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Over the centuries, paper has been made from a wide variety of materials such as cotton, wheat straw, sugar cane waste, flax, bamboo, wood, linen rags, and hemp. Regardless of the source, you need fiber to make paper. Today fiber comes mainly from two sources — wood and recycled paper products.
Paper mills differ in their processes based on the source of fiber used and the end product produced. There are three basic types of mills:
Pulp mills
Recycled paper processing mills
Mills that use both recycled and virgin fiber
Pulp Mills
Pulp mills make pulp, a mixture of cellulose fibers and water used as the basis of all paper products. Pulp is made in several ways, depending on the type of paper being produced. Wood chips, which come from logs or from residues from sawmills, furniture manufacturers and other sources, can be chemically or mechanically separated into individual wood fibers in a process called pulping.
In chemical pulping, the most common pulping process , the wood chips are “cooked” in a digester at an elevated pressure with an appropriate solution of chemicals to dissolve the lignin (the “glue” that binds the fibers in the wood) and allow the cellulose fiber bundles in the wood to separate into individual cellulose fibers. Since chemical processing is gentle on the cellulose fiber, chemical pulps tend to have longer fibers and make strong paper such as printing and writing papers and paperboard.
In mechanical pulping, chemicals are not used to remove the lignin in the wood chips. Instead, wood chips are pressed against a grinder that physically separates the fibers. Mechanical pulps have shorter fiber lengths and produce papers which do not require as much strength — such as newsprint.
After the fibers have been separated, the mill washes and decontaminates the pulp. To produce a white paper product, the mill must bleach the pulp to remove color associated with remaining residual lignin. Typically, the bleaching chemicals (such as chlorine dioxide, oxygen, or hydrogen peroxide) are injected into the pulp and the resulting mixture is washed with water.
The bleached or unbleached wood pulp — which at this point is in a very dilute slurry — is then pumped onto rolling wire screen mats that vibrate slightly to allow water to drain out of the pulp and to help the fibers interlock into sheets. By varying the amount of pulp pumped onto the rolling mats, the speed of the mat, and the speed of the vibrations, paper with different qualities and properties can be achieved. The sheets then pass through a long series of rollers that press out any remaining moisture, followed by steam-heated drums that dry the paper. Finally, a process called calendaring polishes the sheets and smoothes out wrinkles. Large sheets of paper are wound onto rolls and can then be cut to produce a variety of paper products.
The Paper Recycling Process
The paper recycling process basically involves the generic recycling process of collecting the recyclables, sorting them by their types, processing them into raw materials and manufacturing new products using these recycled raw materials.
Nevertheless, there are some variations from the process of recycling other materials.
Three categories of paper can be used as feedstocks for making recycled paper – mill broke, pre-consumer waste, and post-consumer waste.
Mill broke refers to paper trimmings and other paper scrap from the manufacture of paper. Pre-consumer waste paper refers to paper that is discarded (eg. packaging) before the product of interest is ready for consumer use. Post-consumer waste paper refers to paper discarded after use (eg. waste paper, old newspaper).
Below are more facts about the paper recycling process after the waste paper is collected.
Sorting
To start the paper recycling process, the waste paper needs to be sorted, such as by newsprint, computer paper, magazine paper etc, as different types of paper are treated differently during the paper recycling process to make different types of recycled paper products.
For example, finer paper with multi-colored ink would require additional processing.
Effort is taken to ensure that the waste paper is free of any pins, clips, staples etc.
Processing: Pulping
During this stage of the paper recycling process, the sorted paper is usually soaked in huge pulpers, which contain water and chemicals.
The pulper shreds the paper up into smaller pieces. The heating of the paper mixture also breaks the paper down more quickly into the paper fibers. The paper mixtures turns into a mushy mix, known as a pulp.
Processing: Pulp screening and cleaning
The third stage of the paper recycling process is known as screening and cleaning.
The pulp is forced through screens with holes of various shapes and sizes to remove small contaminants such as bits of plastic and globs of glue.
In addition, the pulp may also be spun around in large cone-shaped cylinders. Heavy contaminants (eg. staples) are thrown out of the cone via centripetal forces, while lighter contaminants collect in the center of the cone and are removed.
Processing: Deinking
The next stage in the paper recycling process involves deinking – removing the ink from the paper fibers of the waste paper. Sticky materials (referred to as “stickies”) like glue residue and adhesives are also removed at this stage.
Deinking is achieved by a combination of mechanical action (eg. shredding) as well as chemical means (eg. additional of chemicals). Small particles of ink are rinsed from the pulp with water, while larger particles and “stickies” are removed with air bubbles in a process known as flotation.
With flotation, the paper pulp is fed into a flotation cell, where air and soap-like chemicals called surfactants are injected into the pulp. The surfactants cause the ink and “stickies” to dislodge from the pulp and stick to the air bubbles as they float to the surface of the mixture. The inky air bubbles create froth which is then removed, leaving the clean pulp behind.
Processing: Refining, Color Stripping and Bleaching
During refining, the pulp is beaten to make the recycled fibers swell, as well as to separate the individual fibers to facilitate paper making.
If the recovered paper is colored (eg. color printed paper), color stripping chemicals are added to remove the dyes from the paper. From this processing, brown paper is obtained.
If white recycled paper is to be produced, the pulp would need to be bleached with hydrogen peroxide, chlorine dioxide, or oxygen to make it whiter and brighter.
Processing: Papermaking
In the last stage of the recycling process, the cleaned up pulp is ready to be made into recycled paper.
The recycled fiber can be used alone, or blended with new wood fibers (ie. virgin fibers) to give it extra strength or smoothness.
The pulp is mixed with water and chemicals, such that the pulp is 99.5% water. This watery pulp mixture then enters the headbox of a paper making machine, and is sprayed in a continuous jet onto a huge wire mesh-like screen moving very quickly through the paper machine.
On the screen, water starts to drain from the pulp, and the recycled fibers begin to bond together to form a watery sheet. The sheet then moves rapidly through a series of felt-covered press rollers which squeeze out more water from the pulp.
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