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Manufacturing

Manufacturing

The reincarnation of paper

Rolland’s innovative manufacturing processes mine the “urban forest” with the least amount of impact to the environment and its natural resources. From biogas energy to closed-loop water and hydrogen peroxide bleaching processes, our recycled paper is one of the most environmentally sustainable in North America.

Manufacturing stages of Rolland's fine papers

 

Environmental cycle

Closing the loop means reducing our environmental footprint.

Rolland collects waste paper in Quebec, Ontario and in North Eastern United States. Moving the waste paper towards Levis deinking plant, located near Quebec City, we then transform the waste paper into pulp bales and are sent to the St. Jerome plant to produce our high quality fine papers. 

Recycled de-inked pulp manufacturing


  • 1. Pulping
    Preparation of coarse pulp by mixing old papers with water and breaking them up using the pulper’s powerful agitator

  • 2. Screening
    The pulp is pushed through the screen to remove solid impurities such as staples and glue

  • 3. Washing
    Visible dirt and glue residue in the water are removed

  • 4. Dispersion
    Ink particles are removed by rubbing fibers together

  • 5. Flotation
    Fine soapy bubbles are added to the pulp to bring ink particles to the surface

  • 6. 2nd washing
    Removal of small water impurities that were set apart from pulp in previous stages

  • 7. 2nd dispersion
    Release of remaining dye particles with fiber-on-fiber friction wear

  • 8. Bleaching
    The pulp is bleached using hydrogen peroxide, a non-chlorinated component that is environmentally friendly

  • 9. 2nd flotation
    Fine soapy bubbles are added to the pulp to bring residual ink particles to the surface

  • 10. Cleaning
    The pulp is put through cleaners, which use centrifugal force to separate the impurities from the pulp

  • 11. Bleaching
    In this second phase of chlorine-free bleaching, the degree of whiteness of the pulp increases and any remaining coloring is removed

  • 12. 2nd screening
    The pulp is pushed through the screen to remove residual sticky particles

  • 13. Baling
    Thickening the pulp by dewatering, sheeting, cutting and baling

The pulp is then ready to be sent to the Rolland facility to be converted into quality recycled fine paper.

 

Paper manufacturing


  • Pulp preparation

    1 - Disintegration
    The pulp is mixed with water to a consistency of approximately 8% fiber and 92% water. Additives are then added to define the opacity, brightness and color of the paper.

    2 - Refining
    To avoid build-up accumulation, refining separates fibers from each other, which are mixed and stirred in a large vat in order to obtain a completely uniform pulp.

    3 - Screening and Treatment
    The screening and treatment phase removes all debris and agglomerations from the pulp to improve fiber dispersion.

  • Paper machine

    1 - Head Box
    A contstant amount of pulp is pumped evenly, across the machine’s width, from the head box onto the wire.

    2 - Wire
    A woven mesh made from synthetic filaments, permits water drainage from the pulp through gravitational pull, thereby allowing the fibers to settle properly to form a wet sheet.

    3 - Forming or Dandy Roll
    A mesh covered roll that pierces air bubbles that may have formed and improves the sheet formation. The forming roll can be replaced by a dandy roll with a pattern used to make a watermark on the paper.

    4 - Suction Roll and Felt
    The paper passes through a suction roll in order to remove as much water as possible before arriving at felt section to start the drying stage. At that time, the sheet contains approximately 50 to 60% humidity/moisture.

  • Drying

    1 - Size Press
    The size press applies a light film and continuous starch on both sides of the sheet. This treatment hardens the paper’s surface and fixes the fibers so that the sheet is able to resists penetration of liquid inks.

    2 - Dryers
    The paper passes through a series of steam-heated cylinders shaped like an accordion. The evaporation rate is constant and increases rapidly from one cylinder to another.

    3 - Calenders
    Calendering determines the finished of the paper. The sheet passes through two adjacent rollers which rotate to smooth and compress in the same way on both sides.

    4 - Winder
    The paper is wrapped on a wide metal mandrel to create a master roll, which is then transferred to a jumbo roll using a crane for the winding step. The master roll is held and then cut into strips according to the needed width, to then be finally wound onto cardboard cores.

The rolls are then ready to be sent to customers or to the conversion center to be cut into sheets.

Paper conversion


  • 1 - Cutting

    Once delivered to the processing center, the rolls are cut into sheets.

  • 2 - Packing

    The sheets can be packaged in several ways depending on the format or the customer’s needs. Smaller sizes are packed as reams which are the placed in cardboard boxes while larger sizes are put directly into cardboard boxes or on press ready skids.

  • 3 - Labeling

    All products are labeled. The label includes the trade business name, format, environmental certifications and paper specifications.