Mohawk Fine Papers is a non-integrated paper mill, which means that we do not manufacture our own pulp. When we buy pulp, it has already been purified and formed into thick sheets. We buy a variety of hardwood and softwood pulps and postconsumer fiber, because each of our papers requires its own special mix of fiber.
Stock Preparation
One of the most important aspects of papermaking takes place in large beaters before the paper machine. Each paper requires its own special mix of fibers and fillers to achieve its unique characteristics. The furnish, which consists of the finest available wood pulps, fillers, and internal sizing, is mixed with water in large beaters until the mixture (a slurry called stock or stuff) resembles oatmeal.
Wet End
The slurry is about 99% water and 1% fiber. It moves from the headbox, which evenly distributes the mixture onto a fine wire mesh (wire). At Mohawk, the wire travels at speeds of up to 1,800 feet per minute. A gentle shaking motion on the wire mats the fibers together. Water drains off as the wire moves forward.
Dandy Roll
Rides on top of a moving web of paper. Its functions are to help remove water from the web and to lay down and compact the fibers. May also be used for watermarking via designs in wire sewn to its surface, or for reproducing the surface of laid paper by a laid watermark.
Stock Preparation
One of the most important aspects of papermaking takes place in large beaters before the paper machine. Each paper requires its own special mix of fibers and fillers to achieve its unique characteristics. The furnish, which consists of the finest available wood pulps, fillers, and internal sizing, is mixed with water in large beaters until the mixture (a slurry called stock or stuff) resembles oatmeal.
Wet End
The slurry is about 99% water and 1% fiber. It moves from the headbox, which evenly distributes the mixture onto a fine wire mesh (wire). At Mohawk, the wire travels at speeds of up to 1,800 feet per minute. A gentle shaking motion on the wire mats the fibers together. Water drains off as the wire moves forward.
Dandy Roll
Rides on top of a moving web of paper. Its functions are to help remove water from the web and to lay down and compact the fibers. May also be used for watermarking via designs in wire sewn to its surface, or for reproducing the surface of laid paper by a laid watermark.
The partially dry web of paper leaves the wet end of the paper machine here. It is now strong enough to support itself.
Press Section
The paper at this point is still about 50% water. For genuine felt marks, the paper web is run against special textured marking felts, which impart their finish to the paper.
Dryer Section
Most of the remaining moisture is removed from the paper by steam-heated drums.
Size Press
In this section, surface sizing is added to uncoated paper to provide surface strength and to prevent feathering and picking when ink is laid down in the offset printing process.
Coater
The coating process can be performed either while the paper moves through the papermaking machine, or when it comes off of the machine. Coating improves ink holdout, reducing dot gain, for creating sharper, brighter printed images.
Calendering
The calender stack controls the caliper, smoothness, and gloss of paper.
Paper is wound up into rolls and taken off the paper machine.
Embosser
Embossing takes place off the paper machine as a separate operation. The embosser uses a patterned steel roll and pressure to produce an embossed (raised) pattern on a web of paper.
Paster
The paster is an off-line process that pastes, or laminates, two finished rolls of paper together to make a duplex sheet, often called a Double-Thick Cover or a Cover Bristol. Pasting two equal-weight papers together adds bulk, strength and stiffness.
Finishing
Paper is cut into smaller web rolls, precision-sheeted, and packed in cartons or on skids.