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Chapter 21 Substrates 383 This sample chapter is for review purposes only. Copyright © The Goodheart-Willcox Co., Inc. All rights reserved. 382 Graphic Communications Chapter 21 Substrates 383 Important Terms Some historical highlights of papermaking are: • basic size postconsumer paper 105 A.D.—Ts’ai Lun, a Chinese offi cial, mixed bleaching waste the bark of the mulberry tree with linen and calendering preconsumer paper hemp to make a crude form of paper. cellulose waste • 500 A.D.—The Mayans produced paper using Chapter chain of custody print strength fi g tree bark. chipper printability • 751 A.D.—Papermaking spread to Europe coated paper pulpers as a result of the Crusades and the Moorish de-inking ream conquest of northern Africa and Spain. elemental chlorine recycled paper • 1400 A.D.—Papermaking by hand fl ourished. equivalent weight show-through • fi l l e r s sizing 1690 A.D.—The fi rst paper mill in America fourdrinier machine substance weight was established near Philadelphia by William furnish substrate Rittenhouse and William Bradford. grades supercalendering • 1798 A.D.—Nicholas Louis Robert of France 21 grain tensile strength invented a machine with an endless wire grain long thermoformed screen to produce paper in rolls. The machine grain short totally chlorine free was fi nanced by two English merchants, the lignin (TCF) Fourdrinier brothers, and was named the opacity trim American fourdrinier machine. paper fl atness uncoated paper Most of the paper manufactured in the United petrochemicals watermark States today is made on the fourdrinier machine. Substrates It can produce continuous sheets of paper up to 33′ (10 m) wide at speeds faster than 3000′ (900 m) per Substrates include any material with a surface minute. Some fourdrinier machines are more than that can be printed or coated. Although the most 350′ (110 m) long. The mechanical principles of the Learning Objectives common printing substrate is paper, substances original machine have remained nearly unchanged. After studying this chapter, you will be able to: such as plastic, metal, and wood are also classifi ed Other inventions have occurred, but many are simply refi nements. • Explain how paper is manufactured. as substrates. Matching the substrate to the job is critical. A Signifi cant improvements in papermaking in • Identify the basic characteristics of various high-quality layout, plate, ink, and printing technique recent years include thermomechanical pulping, types of paper. will be wasted if a low-quality substrate is used. On synthetic wires and felts, twin-wire machines, and the • Describe the applications of coated and the other hand, expensive stock should not be used use of computers to control pulping and papermaking uncoated papers. to print low-quality products such as newspapers operations. Paper manufacturers have also worked to improve pollution control and energy conservation • Explain the basic size and basis weight of or sales fl yers. Salespeople, designers, strippers, in the industry. paper. press operators, and fi nishing and binding personnel must have knowledge of the characteristics of paper • Determine various paper weights. and its applications. Its misuse can be very costly. • Summarize the characteristics of plastic More than one thousand different grades of paper Making Paper substrates. are listed in paper merchant’s catalogs. For centuries, the principle raw materials used in • Explain the changes occurring with substrates papermaking were cotton and linen fi bers obtained based on environmental issues. Papermaking from rags. Some cotton and linen fi bers are still used for high-quality writing papers, business letterhead History papers, art papers, and documents that will be kept for years. However, cellulose is the raw material Most paper is manufactured using machine used to make most paper today. technology, although some paper is still handmade. The use of handmade papers is usually limited to substrate: Any material with a surface that can be printed special applications, such as fi ne art reproductions, or coated. or limited editions of books printed and bound by fourdrinier machine: A paper machine that forms a craft workers using hand methods. continuous web of paper on a moving, endless wire belt. cellulose: The raw material used to make paper. 384 Graphic Communications Chapter 21 Substrates 385 Pine, fi r, spruce, aspen, beech, birch, maple, and chipper cuts the logs into 3/8″ to 3/4″ chips. The chips oak are typical species harvested for papermaking. The are sized so the digester is able to separate the cellulose length of the tree fi bers varies and determines, among fi bers. After the chips are screened for size, they are put other characteristics, the strength of the paper. in a huge cooking kettle called a digester. Papermaking is a complex manufacturing process. It uses both chemical and mechanical means to reduce Making Pulp wood fi bers to pulp, which is the material used to ultimately produce paper in sheet form. See Figure 21-1. In the chemical pulpmaking process, chemicals in the sealed, pressurized digester break down the lignin present in the cellulose fi bers. The cellulose Chipping fi bers, which once resembled soda straws, become Harvested logs are cut to uniform length, debarked, pulp, a mass of soft, spongy matter. The pulp is blown Figure 21-2, and sent to a chipper or grinder. The into a pit where the chemicals are washed away. Figure 21-2. This huge machine rotates logs inside a toothed chamber to remove the bark. (Southern Forest Products Assn.) Chipper The mechanical pulpmaking process (groundwood Raw materials process) uses grinding wheels to reduce the logs to Barker Chip pile fi ber. The by-product is pulp with high opacity but relatively low strength. Sizing and Fillers Pulp wood Grinder Digester Sizing is added to the pulp slurry to make the Groundwood pulp paper more resistant to moisture. Rosin is a common Knotter screen sizing material. Alum is added as a binding agent. Figure 21-3. The fourdrinier wire section of the Washer Chemical pulp Binding is a part of the sizing process. papermaking process. Wet paper fi bers ride on an Bleaching Fillers are needed to improve a paper’s opacity, endless wire screen. This is known as the “wet end” cell brightness, smoothness, and ink receptivity. Two of the machine. Water drains off as the fi bers move common fi llers are clay and titanium dioxide. toward the dryers. (Mead Publishing Paper Division) Steam Dyes, Pigments, and Bleach Some papers are given a watermark, a translucent identifying design impressed in the Cooking liquid Dyes and pigments are added to produce colored Blow pit paper while it is still wet. The symbols or images are substrates, while bleach makes the pulp white. Coloring created by rearranging the fi bers with a tool known or bleaching additives are mixed in vats called pulpers. as a dandy roll. See Figure 21-4. Thickener Screens The pulp goes through a fi nal beating and refi ning stage Centrifugal cleaners Washer before it is pumped to a stock chest. Disc refiner Removing Water chipper: A machine that cuts logs into chips. A jordan machine is a beater or refi ner of the lignin: A glue-like substance that bonds wood fi bers fi bers. A jordan machine refi nes the fi ber slurry together. Stock blender until it is about 99% water and 1% fi ber and other sizing: Material, such as rosin, that is added to pulp slurry Calender stack Headbox Drying rolls solids. At this point, the paper is known as furnish. to make the paper stronger and more moisture-resistant. Paper Fourdrinier The solution is pumped into the headbox of the fi llers: Inorganic materials, such as clay or titanium dioxide, papermaking machine. added to the papermaking furnish to improve opacity, Pulp The pulp furnish is evenly dispersed on the brightness, smoothness, and ink receptivity. fourdrinier wire, Figure 21-3. The wire screen vibrates pulpers: Vats in which coloring or bleaching additives are as it travels along an endless belt, aligning the fi bers added to pulp. Press section Tub size in the direction of travel. A continuous web of paper furnish: The slurry of fi llers, sizing, and colorants in a water Figure 21-1. Major steps in the manufacture of paper. A modern papermaking operation requires a large is formed in the process. Gravity and suction remove suspension from which paper is made. investment in equipment and raw materials. about 35% of the water. watermark: A translucent design impressed in paper. 386 Graphic Communications Chapter 21 Substrates 387 gloss might be used to convey a bright and exciting image. No. 1 paper produces very bright color through the use of transparent inks. Printed material, such as catalogs or posters, is typically printed on No. 2 or No. 3. Groundwood-processed sheets are of lower-grade stock, often No. 4 or No. 5. Uncoated paper does not have a layer applied over the surface and tends to have a textured feel. Uncoated paper textures include laid, woven, and linen. These textures are suited to printed pieces that will be written on, such as stationery. Uncoated papers also enhance legibility, making them good choices for text-intensive printed material, such as A textbooks or novels. Wire Adhesive-Coated Paper Watermarks mesh Adhesive-coated stock is coated with an adhesive material that is permanently tacky or activated by MARK water or heat. Labels are a common product that use MARK MARK MARK Figure 21-5. Many of the papers used today for this type of substrate. The heat-seal type of paper magazine and book publishing are coated for better uses heat to melt the coating so it will stick to another MARK MARK reproduction of color and fi ne-screened halftones.
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