Toilet paper mftg.

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Start a Toilet Paper Manufacturing Unit

(324). Start a Toilet Paper Manufacturing Unit

Most of us can't imagine living without toilet paper. The average American
uses over 100 single rollsabout 21,000 sheetseach year. It's used not only
for bathroom hygiene, but for nose care, wiping up spills, removing makeup,
and small bathroom cleaning chores. Manufacturers estimate that an average
single roll lasts five days.
Toilet paper, paper towels, napkins, and facial tissues are sanitary papers,
personal products that need to be clean and hygenic. They're made from
various proportions of bleached kraft pulps with relatively little refining of the
stock, rendering them soft, bulky, and absorbent. Sanitary papers are further
distinguished from other papers in that they are creped, a process in which the
paper is dried on a cylinder then scraped off with a metal blade, slightly
crimping it. This softens the paper but makes it fairly weak, allowing it to
disintegrate in water.
Toilet paper can be one-or two-ply, meaning that it's either a single sheet or
two sheets placed back-to-back to make it builder and more absorbent. Color,
scents, and embossing may also be added, but fragrances sometimes cause
problems for consumers who are allergic to perfumes. The biggest difference
between toilet papers is the distinction between virgin paper products, which

are formed directly from chipped wood, and those made from recycled paper.
Most toilet paper, however, whether virgin or recycled, is wrapped around
recycled cardboard cylinders.

History
Before paper was widely available, a variety of materials were employed. The
Romans used an L-shaped stick (like a hockey stick) made of wood or precious
metal; at public toilets people used sponges on sticks that were kept in
saltwater between uses. In arid climates, sand, powdered brick, or earth was
used. Until the late nineteenth century, Muslims were advised to use three
stones to clean up. One favorite tool was a mussel shell, used for centuries.
Until the early twentieth century, corn cobs were used.
In the late fifteenth century, when paper became widely available, it began to
replace other traditional materials. Sometimes old correspondence was
pressed into service, as were pages from old books, magazines, newspapers,
and catalogs. People also used old paper bags, envelopes, and other bits of
scrap paper, which were cut into pieces and threaded onto a string that was
kept in the privy.
Toilet paper is a fairly modern invention, making its debut around 1880 when
it was developed by the British Perforated Paper Company. Made of a coarser
paper than its modern incarnation, it was sold in boxes of individual squares.
In America, the Scott Paper Company made its Waldorf brand toilet paper in
rolls as early as 1890. The first rolls were not perforated, and lavatory
dispensers had serrated teeth to cut the paper as needed. It was a nearly
"unmentionable" product for years, and consumers were often embarrassed to
ask for it by name or even be seen buying it. Timid shoppers simply asked for
"Two, please," and the clerk presumably knew what they wanted. To keep
things discreet, toilet paper was packaged and sold in brown paper wrappers.

During the 120 years since its introduction, toilet paper has changed little,
although it's

A diagram of toilet paper manufacturing process.

now perforated, and may be scented, embossed, or colored. Recently, toilet
paper manufacturers increased the number of sheets on a roll, allowing
consumers to replace the roll less frequently.

Raw Materials
Toilet paper is generally made from new or "virgin" paper, using a
combination of softwood and hardwood trees. Softwood trees such as
Southern pines and Douglas firs have long fibers that wrap around each other;
this gives paper strength. Hardwood trees like gum, maple and oak have

shorter fibers that make a softer paper. Toilet paper is generally a combination
of approximately 70% hardwood and 30% softwood.
Other materials used in manufacture include water, chemicals for breaking
down the trees into usable fiber, and bleaches. Companies that make paper
from recycled products use oxygen, ozone, sodium hydroxide, or peroxide to
whiten the paper. Virgin-paper manufacturers, however, often use chlorinebased bleaches (chlorine dioxide), which have been identified as a threat to the
environment.

The Manufacturing Process

1.

Trees arive at the mill and are debarked, a process that removes the
tree's outer layer while leaving as much wood on the tree as possible.

2.

The debarked logs are chipped into a uniform size approximately 1 in x

1/4 in. These small pieces make it easier to pulp the wood.

3.

The batch of wood chipsabout 50 tonsis then mixed with 10,000

gallons of cooking chemicals; the resultant slurry is sent to a 60-ft (18.3-m)tall pressure cooker called a digester.

4.

During the cooking, which can last up to three hours, much of the
moisture in the wood is evaporated (wood chips contain about 50% moisture).
The mixture is reduced to about 25 tons of cellulose fibers, lignin (which binds
the wood fibers together) and other substances. Out of this, about 15 tons of
usable fiber, called pulp, result from each cooked batch.

5.

The pulp goes through a multistage washer system that removes most of
the lignin and the cooking chemicals. This fluid, called black liquor, is
separated from the pulp, which goes on to the next stage of production.

6.

The washed pulp is sent to the bleach plant where a multistage chemical
process removes color from the fiber. Residual lignin, the adhesive that binds
fibers together, will yellow paper over time and must be bleached to make
paper white.

7.

The pulp is mixed with water again to produce paper stock, a mixture
that is 99.5% water and 0.5% fiber. The paper stock is sprayed between
moving mesh screens, which allow much of the water to drain. This produces
an 18-ft (5.5-m) wide sheet of matted fiber at a rate of up to 6,500 ft (1981 m)
per minute.

8.

The mat is then transferred to a huge heated cylinder called a Yankee

Dryer that presses and dries the paper to a final moisture content of about 5%.

9.

Next, the paper is creped, a process that makes it very soft and gives it a
slightly wrinkled look. During creping, the paper is scraped off the Yankee
Dryer with a metal blade. This makes the sheets somewhat flexible but lowers
their strength and thickness so that they virtually disintegrate when wet. The
paper, which is produced at speeds over a mile a minute, is then wound on
jumbo reels that can weigh as much as five tons.

10.

The paper is then loaded onto converting machines that unwind, slit,
and rewind it onto long thin cardboard tubing, making a paper log. The paper
logs are then cut into rolls and wrapped packages.
Toi l e t P a p e r M a n u f a c t u r i n g

Introduction
The toilet paper manufacturing business has been reported as being one of the fastest
growing manufacturing industries in South Africa today. The local tissue paper
manufacturing plants (jumbo rolls) are doubling and trebling their production to keep up with
demand. An exceptional winner time and time again. We have had the privilege of setting
up many successful rewinding operations throughout Africa. Most of the entrepreneurs
purchase their second and third machines a few months into running their operations.
B e n e f i t s / Ad va n t a g e s
- Cash business (depending on market sector, this can be up to 100%).
- Ability of producing SABS approved toilet rolls.
- Simple manufacturing process.
- Easy administration (very few product lines and variations).
- High demand for product.
- Easy to market.

R e l a t e d Ava i l a b l e Ma c h i n e s : - C o r e Ma n u f a c t u r i n g
- Garage Wipes
- Kitchen Towels
- Facial Tissues
- Rest Room Towels
- Paper Serviettes
- Many more, please enquire

Recycled toilet paper

Toilet tissue made from recycled paper is made from both colored and white
stock, with staples and pins removed. The paper goes into a huge vat called a
pulper that combines it with hot water and detergents to turn it into a liquid
slurry. The recycled pulp then goes through a series of screens and rinses to
remove paper coatings and inks. The pulp is whitened somewhat and sanitized
with oxygen-based products like peroxide. It then goes through steps 7
through 10 like virgin paper products, producing a cheaper, less-white paper.

Quality Control
Paper companies often maintain their own tree stands in order to ensure the
quality of the paper they manufacture. The chemicals used in the pulping
process are also carefully tested and monitored. Temperatures at which a
slurry is cooked is ensured, too, by checking gauges, machinery, and
processes. Completed paper may be tested for a variety of qualities, including
stretch, opacity, moisture content, smoothness, and color.

Byproducts/Waste
The first waste product produced in the papermaking process, the bark
removed from tree trunks, burns easily and is used to help power the paper
mills. In addition, black liquor, the fluid removed from the pulp after cooking,

is further evaporated to a thick combustible liquid that is also used to power

the mill. This reduction process, in turn, yields a byproduct called tall oil that
is widely used many household products. About 95% of the cooking chemicals
are recovered and reused.
But other problems associated with the industry are less easily solved. The
production of virgin toilet paper has spawned two current controversies: the
destruction of trees, and the use of chlorine dioxide to bleach the paper. While
virgin paper processing does necessitate the destruction of trees, they are a
readily renewable resource and paper companies maintain large forests to feed
their supply. Despite this, some activists have proposed that toilet paper be
manufactured only from recycled products and suggest that consumers
boycott toilet paper made of new materials.
These activists object to new paper processing because it often uses chlorine
bleaching, which produces dioxins, a family of chemicals considered
environmental hazards, as a byproduct. Paper and pulp mills are the primary
producers of dioxins, and manufacturers must carefully assess their effluvia to
counteract the emission of dioxins. Increasingly, virgin paper makers use
alternative bleaching methods that substitute oxygen, peroxide, and sodium
hydroxide for chlorine. Some simply reduce the amount of chlorine used in the
process. Others experiment with cooking the wood chips longer, removing
more lignin earlier in the process, which requires less bleach. Better pulp
washing also removes more lignin, and reduces the amount of bleach needed
for whitening.