Recycled Kraft Paper from Waste Cartons or Old Kraft Papers Industry Project

Report

There are approximately 600 paper mills in India

1. Different Grades of Paper – Board:

Card Board
Mill Board
Grey Board
Duplex Board
Box Board
Coated Board
Art Board
Chromo Board
Coated Box Board
Clay-Coated Blanks
Blanks

A. UNBLEACHED KRAFT PAPERS

Virgin Natural Kraft Paper

Virgin natural kraft paper is clean, durable and affordable. This type of paper is most often used for
heavy-duty applications where high tear resistance and superior bursting strength are critical. It can be
printed on as well, making it perfect for branding, protective layering and other instances where it needs
to be strong and bear certain markings or logos. Virgin kraft can contain up to 5% recycled materials.

Virgin natural kraft paper can be used for wrapping, book covers, paint masking, carrier sheets,
stationery products, floor protection liners, and pallet interleaving, to name a few applications.
Layers of the paper are used to make corrugated boxes.

Recycled Kraft Paper

Recycled kraft paper is not as strong as natural virgin kraft, but it is a very eco-friendly option and costs
less than its non-recycled counterpart. Compared to natural Kraft, recycled Kraft has a lower tear and
bursting strength and breaks down more easily when exposed to friction or moisture. It is more
economical and offers many beneficial qualities.

This type of paper is used for bundling and stuffing, including as newspaper bottom wrap, garment
underlay paper, textile wrappers, interleave, internal carton packaging, void filler or dunnage, dust
covers, floor protection liners, carrier sheets, paint masking, and box/tray liners.
Black Kraft Paper

With its deep color, black kraft is one of the most popular papers. You’ve seen black kraft paper used as
backing for photo frames, and it's a very popular choice for a variety of craft applications.

Colored Kraft Paper

Also, a favorite among crafters, colored kraft paper is seen in everything from elementary school supplies
to scrapbooks, to bulletin boards. This is more often recognized as “crafter’s construction” paper.

Printed Kraft Paper

Because it is so versatile, custom printed kraft paper is used in many industries for branded wrapping,
packaging, and in-store displays. Delis use this paper for wrapping sandwiches in paper bearing their
logo, while many fashion manufacturers ship their garments with printed kraft paper sleeves or sheets
between individual articles.

Steel Interleaving Kraft Paper

Part of the stainless-steel milling process involved cold-rolling on interleaving kraft paper. This gives the
steel its signature shine.

Absorbent Kraft Paper

Absorbent kraft paper is used in a wide variety of applications where exposure to moisture is present.
You’ll find this type of kraft paper in building construction and furniture. Absorbent kraft paper features
high wet strength, high porosity, and can be used as filter media and laboratory filter paper. Other
application includes special bags for plantation of saplings.

Spinning Kraft Paper

Some papers can be made flexible enough for use in weaving. Spun kraft paper can be used in wicker
furniture, cloth making, rugs, and even yarn. When waxed, spun kraft paper can even be used in matches!

Electrotechnical Kraft Paper

With our love of electronics, we wouldn't get far without electrotechnical kraft paper. Designed to be non-
conductive by unique cleaning process for removal of impurities and charged ions from the pulp,
electrotechnical kraft is used for insulating cables and electrical components.

Super Calendared Kraft Paper / Release Base Paper

This dense paper is designed to hold up to silicone coatings where a label-release is also required. It can
also be cut very precisely using a die.

Sack Kraft paper

A sack paper is a porous paper made in kraft paper plants from any combination of fibers. This paper
features high elasticity and high tear resistance and is designed for packaging products that need strength
and durability.

Sack kraft paper strikes the perfect balance between strength and porosity, making it ideal for valve sacks
for commodities like cement and other powdered materials. To impart sack kraft with barrier properties, it
is provided PE coating.

Foaming Kraft paper

Foaming kraft is designed to release smoothly and easily from the object it covers and is used in
applications with polyester and polyether foams. MG foaming kraft paper is mainly used in the
polyurethane industry for excellent performance in leading foam lines where the glossy surface of MG
kraft paper offers excellent chemical resistance. The density of the foaming kraft paper is high and the
porosity low which prevents penetration of the chemicals. The glazed side prevents too much chemical
penetration and makes it easier to remove the paper from the dry foam.

B. BLEACHED KRAFT PAPERS

The bleaching process renders the paper weaker than unbleached kraft, and it also has a higher price tag.
This type of paper is more common for wrapping packages that demand a higher “value look” than
packages wrapped in dark, non-bleached, or recycled paper.

What are the Paper Grades for Bleached Kraft Paper?

Bleached kraft paper comes in four distinct grades. They are listed below.

Machine Glazed (MG)

Glazed paper has a high gloss on one side for added opacity, printability and runnability.

Smooth Finished (SF)

This provides a softer finish which is needed for print applications have a better print quality,
convertibility, and printability.

Machine Finished (MF)

This is a highly refined type of kraft and it is most commonly seen in commercial applications, such as
carrier bags, product wrapping, laminated products, and protective paper coverings.

Clay Coated Kraft (CCK)

A bleached sheet coated with clay coating to improve opacity and increase smoothness and printability.
Clay coated kraft paper, because of its dimensional stability and lay-flat benefits, is used in the graphic art
industry. CCK is frequently coated with silicone on one side and used as a release liner.

Here are some of bleached kraft paper applications:

Shopping/Retail Bags & Carrier Kraft Paper

Retail shopping bags offer one of the best strength-to-weight ratios available in paper packaging, and they
can come in white, printed, machine glazed, grease resistant, or even ribbed. These bags are often PE
coated for moisture protection.

Folding Boxes

Solid bleached kraft paper is used in clay-coated folding boxes for frozen foods, butter, ice cream,
cosmetics and cartons for milk, juices and other liquid and oily foods. You can also find it used for plates,
dishes, trays and cups.

Laminated Kraft Paper

Laminated kraft papers offer high strength and excellent consistency. This paper features high
dimensional stability, high stiffness, and runnability.

Hygiene Release Liners & Release Base Papers

This type of kraft paper is used in feminine care and light adult incontinence markets. You’ll also find it
in baby products such as diapers.

Medical Grade Bleached Kraft Paper

Medical-grade bleached kraft paper must adhere to FDA standards for sterilization. That’s because these
papers are used in wound covers and medical adhesives.

Paper Sacks

Sack kraft paper features high elasticity and high tear resistance and is designed for packaging that need
strength and durability. The several different types of kraft papers are used for sacks, including natural,
wet-strength, bleached, and extensible.

Sack kraft paper is ideal for commodities like cement and other powdered materials. If you need an extra
moisture barrier, sack paper can have a PE coating. Sack kraft paper can also be used for packing
commodities, including food products such as rice, sugar and potatoes.

2. GSM:
Gram / m2 - paper density

3. The burst index means the bursting strength in kilopascals, divided by grammage:

Bursting Factor Formula & Bursting Index Formula

Bursting factor is the property of the material that decides its strength, quality and endurance. The
bursting factor is expressed in terms of the bursting strength per unit Grammage force applied on the
surface of material
 Burst factor = Burst strength (gf/cm2) / Grammage (grams/m2)
Burst Index = Burst strength (kPa) / Grammage (Kg/m2)

In this formula, kPa is kilopascal (pressure applied on the specimen)

Kgf is kilogram force (the force applied on the specimen)
Gf is Gram Force (the force applied on the specimen)
Grammage GSM of the material or the Grams per meter square weight of the material.

4. Basic Process steps:

Deinking conditions in the pulper are typically 6%–15% consistency, 40–70°C, pH 9–11 (generally
below 10 for groundwood pulps to limit yellowing), for 1 h.

Recycled paper can either be manufactured ‘in-line’ (pulp and paper produced in one process) or recycled
pulp can be produced and transported to a paper mill for paper production. For this example we have
shown the ‘in-line’ process:

 Raw Materials
 Pulping
 Screening
 De-inking
 Whitening
 Pulp Preparation
 Wet Section
 Pulp Transformation
 Drying
 Coating
 Drying
 Jumbo Reel
 Final Coating

Raw materials
The main raw material used to manufacture recycled paper is waste paper. We use post-consumer waste
paper which means it has been used by the customer for its final use. It takes approximately 1.2 tonnes of
waste paper to produce 1 tonne of recycled paper. It would take around 2.5 tonnes of wood to produce the
equivalent virgin fibre paper.

*based on Cocoon

Pulping
Sorted waste paper is dispersed in water in the pulper to separate fibres, ink and other components.
 *based on Greenfield

Screening
Cyclonic purification allows for complete elimination of all contaminants and non fibrous materials such
as:

 Minerals
 Plastics
 Staples
 Dirts

In addition, 99% of ink and glue is removed from the pulp during this process whilst preserving cellulose
fibre quality.

De-inking
Ink is extracted from the pulp mix through flotation. Air is blown into the bottom of the tank with soap
which creates bubbles; the ‘hydrophobic’ ink particles stick to bubbles that float to the surface, the ink is
then skimmed from the surface. 90% of the residue produced by this process is put to agricultural use
(composting and spreading), or used as a raw material to produce cement and bricks.

Whitening
Our recycled pulp is producedwithout the use of chlorine; a Process Chlorine Free (PCF) method.

The whitening process uses bio degradable cleaners. Colour is removed from the fibres using sodium
hydrosulphate, a reductive bleach. Hydrogen peroxide is used to brighten the fibres and when disposed of
it breaks down into water and oxygen.

Pulp Preparation
If the pulp and paper manufacturing process are split – it is at this stage that the pulp will need to be
transported to the paper mill – in this case, pulp is dried and cut into bales. For an ‘in-line’ process, the
pulp is cleaned, refined and purified in a 97% water mix containing both long and short cellulose fibres.

Wet section
The pulp mix is poured from  the ‘head box’ onto a wire mesh - usually made from nylon - called 'the
wire'. The fibres mesh together on the wire whilst water is drained to form the sheet. Water is collected,
recycled and ultimately treated prior to being returned to the environment often cleaner than when
extracted.

Pulp transformation
As the water drains, the pulp mesh becomes a wet paper base. The paper base is fed into the press section
where it is pressed between two absorbent cylinders to extract more water.
Drying (first stage)
Most of the remaining moisture in the paper is evaporated in the drying section as it goes through a set of
heated cylinders. The now dry paper web is called the base paper.

Coating
To improve the surface of the base paper, it receives a coating of ‘size’. The sizing material is fed onto
rollers from a vat, the sizing is to reduce the papers moisture absorbency.

Drying (second stage)

Having been 'wetted', the base paper goes through another drying stage to eliminate moisture added by
the coating.

The Jumbo Reel

At the end of the paper machine, paper is wound onto jumbo reels. By using a flying splice arrangement
between reels, the machine speed remains constant. Depending on the product and substance, this reel can
weigh 15-20 tonnes.

Final coating
After quality checks and depending on the required finish, the coating(s) are applied on the coating
machine. The coating contains a mixture of mineral pigments, binders (synthetic latex etc.) and colour
additives.

This reel is then cut down into smaller reels which can be packaged or further cut down and packaged as
sheets.

5. Important parameters used to determine quality of Kraft paper. Strength of paper depends
largely on the quality of the raw material used.

Bursting Strength - bursting strength tester digital (Presto)

GSM - grammage checking kit

Moisture - Moisture analyzer

Tensile strength – tensile testing machine

Cobb Value – cobb sizing teste

Stiffness - Stiffness tester

1. Drum Pulper

Range of important parameters

Import data

List of raw material and utilities

Old kraft paper, water, fuel for boiler (wood, animal waste, municipal solid waste), steam, electricity,
chemicals,

Qualities of waste paper

Composition of wastb epaper

Grades of waste paper and collection

Manufacturing process: making kraft paper, cooking composition of with water, preparation of the mix or
pulping, paper making,

Chemical required

Machinery

Pfd

Water and energy : raw water treatment, process water treatment, boiler feed water, energy consumption,
effluent,

Environmental effect

Raw material: waste carton, sodium hydroxide, alum, rosin, starch, soda ash, sodium borate,

Rosin and Alum: rosin sizing, that is commonly added to the papermaking furnish during refining in a
process called internal sizing. Rosin is added to paper pulp to increase resistance to water and other
liquids. Alum (short for aluminum sulfate) is added to help the rosin adhere to the paper fibers.

Starch: Starch is used as an adhesive in corrugated board, laminated grades, and other products. Starch-
based adhesives for corrugated boxes have used as corrugated adhesives since the beginning of the
industry. The adhesion base is on a hydrogen bond between starch molecules of the glue and cellulose
molecule of the paper. A corrugated board is a construction whose strength depends on its "bonding
points."