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The Two main processes in “Hand made paper” manufacturing are :
A)
Preparation of pulp and
B)
The lifting of paper.
 The raw material
(cotton rags) is sorted by hand to remove foreign particles and unwanted
variations in color.
Preparation of pulp is done by Hollander type Beater directly for the raw
material other than the Agro-waste. For the Paper to be made from cotton
linters, the raw material is first digested in suitable Digesters & then useful
digested material is converted into pulp by Hollander type Beater. Pulp should
be free from knots & lumps.
Raw material:
“Hand made Paper” Industry uses different types of raw materials like
new & old cotton Rags, Hosiery & Tailor cuttings, jute waste, paper waste &
Agro-waste fibers like Bagasse, Banana, Mulberry, Hemp & Remi etc. Many more
different grades of “Hand Made Paper” can be manufactured from these Raw
materials.
Now following different
processes are outlined apart from beating raw material to convert the same in
pulp.
Rags/ Tailor cuttings
sorting:
Rags/ Tailor cuttings are sorted carefully & thoroughly screened and dusted
before Beating to remove the non cotton fibers like metallic pieces, Buttons &
elastics etc.
Rags cutting:
The sorted rags then well cut into small pieces to the size of 1inch to 1.5
inch by means of Rag chopper machine.
Beating (Pulping):
In Hollander type Beater machine the sorted Rags or digested Agro-waste are
beaten to knot free & lump free pulp or described above. Different mild
chemicals such as Rosin (Abetic Acid), Alum, Dicol, coloring Azo group free dyes
etc. are added for getting different quality of papers to be lifted on Vats.
Paper lifting:
Paper is prepared with the help of vat machine – The water content of
pulp gets drained from wire mesh & sheet of desired weight (GSM) is formed on
the surface of wire mesh of mould of vat machine.
 Couching:
The wet sheet is transferred to woolen or cotton felt of different
surface finishes spread on couching table. By applying pressure by hand on wire
mesh of mould paper sheet is transferred to felt. Pile of sheet is formed
thereby. Hence same mould is used again & again for lifting other paper Sheets.
Pressing:
The pile of wet sheets & felts together are pressed in screw press or
hydraulic press to remove excess water from the pile of paper sheets & felts to
maximum.
Separation:
The pressed sheets of paper are then separated manually from felts & the
same felts can be reused again.
 Drying:
Separated pressed sheets of paper are then dried under the shed by
clamping or on wooden stands like clothes. Fans, Heaters may be used in closed
sheds for quick drying of paper sheets.
Sorting & Cleaning:
The dried paper sheets with & without defects are separated carefully &
then are cleaned by means of wire brush and sharp blades etc.
Glue sizing / Tub
sizing:
The defectless sheets of paper as per requirement or demand are then
dipped in Animal glue solution to make paper sheet more durable for painting &
writing. This is also called external sizing.
 Calendering:
In this machine sheets of paper
are sandwiched in between galvanized iron sheets or zinc metal sheets by passing
through heavy rollers to impart desired finish such as: Rough, Medium, Smooth
Burlap, Mat etc.
Cutting:
The calendered sheets are then cut in to desired sizes using Guillotine
cutting Machine.
Storage:
Cut paper sheets are counted & packed
properly in suitable quantity and labeled accordingly to make them ready for
sale in the market.
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