PAPER AND

PULP
INDUSTRY
I. INTRODUCTION
• 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.
• The pulp and paper industry can be divided into
four main segments: pulp, recovered paper, graphic
paper, and packaging.
• In addition to these four segments, paper products
also include paper plates, napkins, paper towels,
bath and toilet tissue, and similar products.
 A Brief history
Papermaking Spreads Further Improvements
to Middle East of Papermaking

105 A.D. 11th Century

8th Century 17-19th

Century

Invention of Paper Introduction of

Papermaking in Europe
 A Brief history
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.
105 A.D.

Invention of Paper
 A Brief history
Chinese papermaking spread to the Islamic world
Papermaking Spreads
to Middle East

8th Century
 A Brief history
Papermaking was brought to medieval Europe

11th Century

Introduction of
Papermaking in Europe
 A Brief history
17th – 18th century
• Papermaking technology improved thus
Further Improvements demand for paper increased
of Papermaking
• Invention of the Fourdrinier machine
19th century
• Emergence of wood-based paper and
increased mechanization and full-scale
industrialization
18-19th
Century
 Importance of the industry
C o mnewspapers,
Books, mercial
PPackaging
a c k a g iand
ng
P r i n t imanuals,
magazines, ng shipping
catalogs, I n d ucontainers
stry
I n d u s tetc.
ry

Packaging for
Record keeping,
O tfoods,
prepared h e r soap
B u s i n e s sand
communication,
products,
billing I n d u scosmetics,
tries
and similar products
II. Industries in the Philippines
II. Industries in the Philippines
 Trust International Paper Co.
(TIPCO)
• The company is a major player in the paper manufacturing industry in the
Philippines that is equipped with technologically advanced paper
machines, de-inking plants and environmental management facilities.

• TIPCO specializes in the production of quality newsprint, printing and

writing paper and packaging, utilizing 100% recycled paper.

• Primary users of TIPCO products can be grouped into two (2) sectors: the
publisher and the converters.
Trust International Paper Co.
(TIPCO)
Tipco: a brief history
 TIPCO: A Brief History
• 1987: TIPCO started the construction and
installation of the first paper machine.

• 1988: Inauguration of the mill site and the PM1.

• 1989: Full commercial operations of the PM1
began.

• 1993: The company constructed a second paper

machine (PM2) purchased from Quebec, Canada.
 TIPCO: A Brief History
• 1995: Full commercial operations of PM2.
TIPCO ventured into a third paper machine
(PM3) acquiring a J-Former machine from Avenor,
Canada.

• 1998: Full commercial operations of PM3.

III. Production Process
 Raw Materials
 Process Flowchart
 Products
Raw Materials
Raw Materials
 Pulping

PROCESS
FLOWCHART
Mechanical pulping
De-inking

Coating
Paper for Recycling

Chemical pulping

De-barking Headbox Wire

and chipping Section

Finishing
Cleaning
Calendering

Paper Making
Press
Wood Section
Drying
 Pulping of wood

Mechanical Pulping Chemical Pulping

 Pulping of wood
• Mechanical Pulping
For mechanical pulping wood is ground
against a water lubricated rotating stone. The
heat generated by grinding softens the lignin
binding the fibers and the mechanized forces
separate the fibers to form groundwood. After
grinding, the pulp is sorted by screening to
suitable grades. It can then be bleached with
peroxide for use in higher value-added
Mechanical Pulping products.
 Pulping of wood
• Chemical Pulping
For chemical pulp, logs are first chopped
into wood chips which are then cooked with
chemicals under high pressure. Cooking removes
lignin and separates the wood into cellulose
fibers. The resulting slurry contains loose but
intact fibers which maintain their strength. During
the process, approximately half of the wood
dissolves into what is called black liquor. The
cooked pulp is then washed and screened to
Chemical Pulping achieve a more uniform quality.
Pulping of Recycled Paper

De-inking
Pulping of Recycled paper
• De-inking
Before printed paper, such as office
waste and newspapers, can be processed into
graphical paper grades, the ink needs to be
removed. There are two main processes for de-
inking waste paper - washing and flotation.

De-inking
Pulping of Recycled paper
oWashing
In the washing process the waste paper is
placed in a pulper - a huge tank that liberates the
paper fibers from the paperweb by agitation with
large quantities of water - and broken down to slurry.
Staples and other undesirable material are removed
by using centrifugal screens, thereby diminishing the
risk of damage in the processes that follow. Most of
the water containing the dispersed ink is drained
through slots or screens that allow ink particles
De-inking through. Adhesive particles, known as ‘stickies', are
removed by fine screening.
Pulping of Recycled paper
oFlotation
In the flotation process the waste is made
into slurry and contaminants are removed. Special
surfactant chemicals are added to the slurry,
which produces froth on the top of the pulp. Air is
then blown into the slurry. The ink adheres to the
bubbles of air and rises to the surface. As the
bubbles reach the top, a foam layer is formed that
traps the ink. The foam is removed before the
bubbles break so the ink does not go back into the
De-inking pulp.
Papermaking

Paper Machine
 Papermaking
• Paper Machine
oWire Section
The water is then removed on a wire
section by a mixture of gravity and suction in a
process known as sheet formation where the
fibres start to spread and consolidate into a thin
mat, which is almost recognizable as a layer of
paper on top of the wire mesh.

Wire Section
 Papermaking
oPress Section and Drying Section
Then this web of wet paper is then lifted
from the wire mesh and squeezed between a
series of presses where its water content is
lowered to about 50%. It then passes around a
series of cast-iron cylinders, heated to
temperatures in excess of 100ºC, where drying
takes place. Here the water content is lowered
to between 5% and 8%, its final level.
Press Section and
Drying Section
Finishing

Coating and/or Calendering

 Finishing
• Coating
Coating improves the opacity, lightness,
surface smoothness, lustre and colour-absorption
ability of paper. It meets exacting quality demands
regarding surface smoothness. Coating means
that a layer is applied to the paper, either directly
in the papermaking machine or separately.
Varieties of coated paper range from pigmented
to cast-coated. The coat consists of a mix of
pigments, extenders such as china clay and chalk,
Coating and binders such as starch or latex.
 Finishing
• Calendering
For even smoother paper surface, super-
calendering is required. This is done primarily
for magazines and coated papers. The paper
passes through rollers, which are alternately
hard and soft. Through a combination of heat,
pressure and friction, the paper acquires a high
luster surface. The paper becomes somewhat
compressed during the process and is therefore
Calendering
thinner than its matt finished equivalent.
 Process flowchart: tipco

Raw Mat’ls Paper

De-inking Logistics
Warehouse Machine
Department Plant Department
Department
 Process flowchart: tipco
• Raw Materials Warehouse
Department
This dept. processes
imported and locally sourced
recovered paper by sorting,
conveying them into pulpers
and converting them into
fibrous cellulose mass
Process flowchart: tipco

• De-inking Plant
It takes over to clean,
screen, de-ink and wash out
all contaminants from the
paper stock
 Process flowchart: tipco
• Paper Machine Department
The dept. that converts
cleaned pulp into finished sheets
through forming, pressing, drying,
calendering and winding
processes in which the end result
is a high quality finished paper
that is prepared for wrapping and
shipping out customers
Process flowchart: tipco

• Logistics Department
It handles all finished
goods for careful piling,
storage and loading into
trucks for delivery to local
and offshore clients
Products
Products
IV. Environmental & Social
Programs
• TIPCO takes to heart its corporate social
responsibility by initiating various programs
geared toward preserving the environment
and touching base with the people in the
neighboring barangays and other localities.
Employee volunteers take part in CSR
programs such as tree planting, river
clean-ups, ‘Adopt a River’ drives, nutrition
and feeding campaigns, school painting
activities, donation drives, medical
missions, and livelihood teaching sessions
to promote the Company’s goal of
strengthening and sustaining partnerships
with the local communities.
IV. Environmental & Social
Programs
• Its ISO 14001 Certified Environmental
Management System guides all efforts toward
the transformation of process by-products into
treated, recycled, safe and reusable forms.
• TIPCO is also hailed as the first Philippine
company found compliant to manufacture
products that are FSC and PEFC certified. The
certifications from Forest Stewardship Council
(FSC) and Program for the Endorsement of
Forest Certification (PEFC) assure clients that a
company’s products are environment-friendly
and are produced in ways that conserve the
Earth’s resources so that future generations can
continue to enjoy the bounty of our forests.
Safety Procedures
• TIPCO considers people as its most valuable assets. As such, the
Company upholds the highest standards in occupational health and
safety through trainings and implementation of corporate wellness
programs designed to promote industrial hygiene, personal safety,
observance of safe work procedures and accident prevention.
• TIPCO is a proud holder of OHSAS 18001 Certification in
Occupational Health and Safety Management System.
Examples of Machine
Hazards
• Pinch Points / Nips
• Sharp Surfaces
• Hot Surfaces
• Water and Air Hoses
• Slips, Trips, and Falls
• Airborne Particles
• Noise
• Chemicals
Examples of Machine
Hazards
• Pinch Points / Nips
Pinch points are places where a person
or a body part can be caught or crushed by
equipment movement. Nips are a type of pinch
point usually associated with adjacent rotating
rolls, a rotating roll and a moving rope or web
(like a fabric or sheet of paper) or moving ropes
and rope sheaves.
• Sharp Surfaces
Sharp surfaces are objects or machine
parts that can scratch, puncture, or lacerate
the skin.
5
Examples of Machine
Hazards
• Hot Surfaces
Machine surfaces can be hot because they are designed to
produce or transfer heat, or because the friction created by
machine movement has caused them to become hot.
• Water and Air Hoses
Water and air hoses are located throughout papermaking
and paper converting facilities and pose unique hazards. For
example, hoses can get caught in machine nips. If a hose gets
caught in an ingoing nip and it is wrapped around a person, that
person could be pulled into the machine. To prevent this, always
position the hose so that it is not behind you or going around any
part of your body.
• Slips, Trips, and Falls
Injuries ranging from cuts and bruises to broken bones,
paralysis, and even death can result from falls at ground-level or
from only a few feet.
Examples of Machine
Hazards
• Airborne Particles
The papermaking and converting processes
produce paper fiber dust that accumulates on the
machinery and ground.
• Noise
Prolonged exposure to the intense and high-pitched
sounds of machinery can have damaging and lasting
effects on the human ear.
• Chemicals
Papermaking facilities use a wide range of
chemicals, including some that are quite hazardous. You
should have an understanding of the hazards associated
with each chemical, and the necessary precautions to
take when working with or near them.
Health and Safety Tips
• Personal Protective Equipment (PPE)
• Lockout/Tagout
• E-Stops
• Housekeeping
Health and Safety
Tips
• Personal Protective Equipment (PPE)
is another name for equipment or
clothing designed to keep you safe. All
facilities have requirements for the
necessary PPE when working in specific
areas or doing specific jobs.
• Lockout/Tagout refers to a set of
procedures designed to protect workers
from the unexpected startup of
machinery and equipment or the release
of hazardous energy during service or
maintenance activities.
Health and Safety
Tips
• E-Stops
Emergency stops, called E-stops for short,
are large red buttons that, when pressed, bring a
machine or system to an immediate stop to
protect personnel and equipment.
• Housekeeping
Housekeeping includes two basic activities:
cleaning and organizing. A clean, organized
facility will provide a more efficient and safer
work environment for its employees. Poor
housekeeping practices lead to messy,
disorganized work areas, and also increase the
number of workplace hazards.
 Economics
SOUTHEAST ASIA EXPORTERS IN PAPER GVC IN 2014
7,000

6,000
Export Value (US$, millions)

5,000

4,000

3,000

2,000

1,000

0
China Indonesia Thailand Vietnam Malaysia Philippines Cambodia
 Economics
Mills with Largest Production Capabilities in the Philippines

Bataan 2020

UPPC

TIPCO

0 50,000 100,000 150,000 200,000 250,000

Capacity(MetricTons/year)
 Economics
Domestic Sales Volume and Value of Newsprint
Year *Sales Volume % Increase/ *Sales Value % Increase/
(in MT) (Decrease) (P million) (Decrease)
2007 100 --- 100 ---
2008 126 26.45 134 34.29
2009 102 19.73 98 26.91
2010 87 13.91 88 9.88
2011 82 6.23 92 3.63
2012 (Jan – Aug) 52 --- 65 ---
 Economics
Export Sales Volume and Value of Newsprint
Year *Sales Volume % Increase/ *Sales Value % Increase/
(in MT) (Decrease) (PhP) (Decrease)
2007 100 --- 100 ---
2008 82 18.36 102 1.88
2009 78 4.20 79 22.85
2010 97 24.05 100.14 27.40
2011 76 21.11 87.78 12.34
2012 (Jan – Aug) 14 --- 15.88 ---
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.
Research and Development
• 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. 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-assembling 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 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.