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

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. Our Results: Caliper (Thickness)

11. Our Results: Smoothness

12. Our Results: Apparent Density

13. 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

14. 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 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%

15. 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%

16. 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

17. 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