The Paper Savages Mill Report Elizabeth, Keelin, Kelsey, Hans and Chris

Introduction Main Objective: correctly proportion four pulp stocks to create a high quality, general purpose copy grade paper. Awarded $30,000 research contract to develop and test product on PM2 Formed handsheets from a test stock of 35% NBSK, 54% BHK, 4% TMP, 7% ONP and 10% filler. Paper samples tested in TAPPI standard lab Evaluated for Grammage, Caliper, Opacity, Brightness, Tensile and Burst Strength

Introduction Test results showed that the filler impacted percent error, but couldn’t change filler percentage. Amounts added changed from: 7% ONP 35% NBSK 4%TMP 54% BHK to: 5% ONP 35% NBSK 3.25% TMP 56.75% BHK

Introduction : Conditions After the initial testing we moved onto the Pilot Plant Run Five total Runs were done, to collect 5 samples of Paper Condition Filler Calendar Nips Additional Pressure A no — B yes C 2 D 4 E

Ours Goals Produce a copy grade paper out of a stock blend of: Bleached Hardwood Kraft Fiber (BHK) Northern Bleached Softwood Kraft (NBSK) Thermomechanical Pulp (TMP) Recycled ONP/OMG Calcium Carbonate Filler Cost per air dried metric ton ($/ADMT): $599.41 Specification: Target Value (+/- 5%) Freeness 450 ml Grammage 75 gsm Thickness 115 µm Opacity 90% Brightness 72% Tensile Index (machine direction) 35 N-m/g Tensile Index (cross direction) 15 N-m/g Burst Index 1.7 kPA-m^2/g

How we did it: Procedure -Determined our target freeness value and new stock component percentages -Moved operations to the pilot machine where we were assisted by Mr. Appleby -Started operations and creating paper from our custom stock

How we did it: Procedure -Stock pumped from stock chest by the fan pump into the flow spreader in the headbox. -The headbox then produced a uniform jet of fibers which were evenly distributed across the forming wire -The recently formed paper web was conveyed along the forming wire through a dandy roll -The paper was then circulated through section of press nips and into the steam heated drying cylinders

How we did it: Procedure - Our paper was winded on a roll which would later be measured by performing a series of TAPPI standard method tests - Our team produced five grades of paper under conditions A, B, C, D and E - Conditions A used no filler and B used filler - Conditions C, D and E added a new process into the paper manufacturing line known as calendering

How we did it: Procedure - Physical tests performed on the handsheets included grammage, thickness, brightness and opacity - The destructive tests performed where tensile strength and burst strength - These tests were all calculated following TAPPI Standards including TAPPI 220, T411, 452 and 403 respectively

Our Results: Caliper (Thickness)

Our Results: Smoothness

Our Results: Apparent Density

Our Results: Print Quality In order to truly test the quality of our paper, we found it necessary to print on our product from condition E so you can see the print quality in front of you

Our Results: Overall Specification: Target Value (+/- 5%) Condition E Percent Error Freeness 450 ml Grammage 75 gsm 75.33 gsm 0.4% Thickness 115 µm 126.48 µm 9.08% Opacity 90% 96.27% 7.0% Brightness 72% 72.91% 1.3% Tensile Index (machine direction) 35 N-m/g 33.84 N-m/g 3.3% Tensile Index (cross direction) 15 N-m/g 16.96 N-m/g 13.1% Burst Index 1.7 kPA*m^2/g 1.68 kPA*m^2/g 1.1%

Our Results: Overall Sample E had the best results, this graph shows the % error from our product, and the desired product properties. Error Grammage: 0.44% Burst Index: 1.09% Tensile MD: 3.32% Brightness: 1.26% Opacity: 6.97% Tensile CD: 13.08% Thickness: 9.08%

Why The Paper Savages are the right pick for you! Capable of producing a paper product that was close to the required specifications of our target furnish. Have the ability to consistently produce a paper grade that meets most specifications of physical properties Ability to analyze different portions of the paper manufacturing process We understand that we are in constant need of improvement, and will not not stop working towards a better grade of paper

Summary Gained the Skills needed to produce paper in the Pilot Plant After comparing all 5 samples, E was by fair the Best choice 4/7 Of target specs were made, with the other 3 being a few Percent away Ability to analyze the process and make alterations has been gained We have grown as a group and improved our engineering ability