Common Browns.—The raw material used in the manufacture of common brown papers is chiefly jute and waste fibres of every description, such as waste cuttings from boxboard factories, old papers, wood pulp refuse, and other substances of a like nature. The jute, in the form of sacking or old gunny bags, and the hemp refuse, in the shape of old rope and string, are subjected to a slight chemical treatment just sufficient to isolate the fibres to a condition in which it is possible to work them up into paper. The bagging and string are cut up in a rag chopper and boiled in revolving boilers with lime or caustic soda for several hours at a pressure of 20-30 lbs., the lime being used when it is desired to manufacture a harsh paper, and the caustic soda being employed for the production of paper having a softer feel. The pulp is not always washed very completely after the process of digestion, as is the case with white papers, and it is often possible to extract from brown papers of this class a considerable proportion of the alkaline matter which has not been thoroughly removed from the boiled pulp. The presence of this alkaline residue does not affect the quality of ordinary brown paper, but is frequently a serious defect in the case of middles or straw boards, which are afterwards utilised for boxes and covered with coloured papers. The colour of the paper pasted on to such incompletely washed boards is frequently spoilt by the action of the alkali when moistened with the paste used, many aniline dyes being susceptible to the small proportion of alkali present.

The stronger materials, such as jute or old rope and string, are either used by themselves or blended with inferior raw material according to the quality of the paper being made. The jute and hemp fibres are generally beaten by themselves in the engine before the other materials are added. The pulp is mixed with the required amount of loading, while the sizing and colouring operations are carried out in the usual way.

The common brown papers are known by a variety of trade names which at one time indicated the nature of the fibrous constituent, but at the present day the name is no guide or indication of the material used for the manufacture of the paper. The common heavy brown used for wrapping sugar and sundry groceries made in heavy grey and blue shades is a coarse paper made from cheap materials and containing a large proportion of mineral matter. It is usually supplied under the trade name of royal.

A somewhat lighter and stronger wrapping paper of a white or buff colour, used for wrapping groceries, tea, and cotton goods, is that known as casings, a name probably derived from the application of this paper originally to the lining of cases.

Manila papers so called were originally made from rope, but the term is now applied to papers which may be made entirely of wood pulp.

Rope browns are common papers made of fairly strong material of a miscellaneous character, this name having been derived from the fact that rope and similar fibre were at one time used exclusively.

Wood Pulp Wrappers.—Most of the papers of the present day are made from wood pulp, this material giving a thin, light, tough paper, which is pleasant to handle and forms a great contrast to the dense, opaque, heavily loaded, and inartistic specimens produced some years ago. Paper of this kind, though apparently more expensive than common browns, is really more economical in use. The paper is not only stronger, but it is possible to obtain a larger number of sheets for a given weight. The great advantage in the improvement of brown papers dates from the introduction of the now well-known kraft papers, which are of comparatively recent origin.

Kraft Paper.—The term Kraft, meaning “strength,” is applied to a remarkably strong cellulose paper prepared from spruce and other coniferous woods by the soda treatment, the special feature of the process being an incomplete digestion of the wood.

The wood previously chipped into pieces 1 inch to 1½ inches in length, is boiled with caustic soda, the digestion being stopped before the wood pulp has been quite softened, and while the pulp is still too hard to be broken up into isolated fibres by simple agitation in water. The pulp after thorough washing is disintegrated by means of an edge-runner, or some form of breaking engine, the first mentioned probably giving the most satisfactory results, and converted into paper by the usual methods.

The wood can also be reduced by the sulphate process, in which case the chipped wood is boiled in a liquor to which about 25 per cent. of spent lye from a previous cooking is added.

The best results are obtained by attention to the cooking process to ensure an under-cooked pulp, by careful isolation of the fibres in a kollergang, or edge-runner, which machine is capable of separating the fibres without shortening them, and by proper manipulation on the paper machine.

The paper produced under favourable conditions in this direction is wonderfully tough and strong and may be quoted as the most recent example of the fact that the latent possibilities of wood pulp have by no means been exhausted or even thoroughly investigated.

Imitation Kraft Paper.—If wood is boiled in water at high temperatures the fibre is softened and much of the resinous matter is removed. Such wood, if ground in the same way and by the same methods as ordinary mechanical wood pulp, is readily disintegrated, and a long-fibred pulp may be obtained. The process of boiling short 2 feet logs of wood in a digester under a pressure of 20-50 lbs. has long been known. The wood after boiling is partly washed and then worked up into pulp by the usual mechanical process. The wood is easily ground and yields pulp containing long fibres which in their physical properties closely resemble those of pure wood cellulose, but the original constituents of the wood are present almost unchanged, just as in mechanical pulp. The product obtained by grinding is a very tough flexible material of a brownish yellow colour, and the paper is known as Nature brown. It is chiefly used for the preparation of tough packing papers, for the covers of cheap pocket-books, and other miscellaneous purposes. When this brown mechanical wood pulp paper is glazed on both sides it is then known as ochre glazed, the word ochre referring to the colour. When made up into light weight papers it is sold as imitation kraft paper.

A great variety of wrapping papers are now made from wood pulp, such as sealings, sulphite browns, manilas, sulphite caps, but the distinctions between these papers relate chiefly to the amount of finish, the colour and size of the sheet. The methods of manufacture only differ in small details as indicated by these distinctions.

Fine Wrappings.—The papers used for packing small goods such as silver ware and other delicate articles are generally tissues, the better qualities of which are made from rag, and the cheaper qualities from wood pulp. These papers are known as tissue, crÊpe, crinkled tissue, manila tissue, and by a variety of trade terms.

Many of the fine wrappings of the tissue class and the somewhat heavier papers known as M. G. Caps are manufactured on the single cylinder machine, which produces a paper having a highly polished surface on one side and a rough unglazed surface on the other side.

In the single cylinder machine the beaten pulp passes from the stuff-chest on to the wire of the ordinary Fourdrinier machine and through the press rolls, but instead of being dried over a number of cylinders the paper is led over one single cylinder of very large diameter which is heated internally with steam. The paper is usually pressed against the surface of the cylinder by means of a heavy felt, which is, however, sometimes omitted. The side of the paper coming into contact with the cylinder becomes highly polished, the surface in contact with the felt remaining in an unfinished rough condition. This paper is said to be machine glazed and is known as an M. G. paper.

Boards.—Cards, millboards, middles, boxboards, carriage panels, and similar paper products are manufactured either on a single board machine, by means of which single sheets of any required thickness can be obtained, or on a continuous board machine, which is capable of producing cards and plain or duplex boards of moderate thickness.

The raw material used consists, as in the case of browns and wrappers, of every conceivable fibrous substance mixed with mineral matter and then suitably coloured. The preliminary processes for the treatment of the pulp are exactly the same as those employed in the case of brown papers up to the point at which the beating has been effected.

Single Board Machine.

The beaten pulp, diluted with large quantities of water, is pumped continuously into a large wooden vat of rectangular shape. Inside this vat revolves slowly a hollow cylindrical drum, the circumference of which is covered with wire gauze of fine mesh. The drum is not completely immersed in the mixture of pulp and water, so that as it revolves the water passes through the wire, while the pulp adheres to the surface. The water flows regularly into the interior of the drum and runs away through pipes fitted at each side of the vat near the axis of the drum, and the pulp is brought up out of the water until it comes into contact with a travelling felt. The thin moist sheet of pulp adheres to this felt, passes through squeezing rolls which remove part of the water, and is finally carried between two wooden or iron rollers of large diameter. The pulp adheres to, and is wound up on the upper roller, the felt being carried back by the lower roller to the vat. When the sheet on the upper roller has attained the desired thickness, it is immediately cut off and transferred to a pile of similar sheets, a piece of coarse sacking or canvas being interposed between every wet board. The dimensions of the full-sized board are determined by the diameter of the upper roller and its length. A roll 74 inches wide and 14 inches diameter will give a board 74 inches by 44 inches.

As soon as a sufficient number of wet boards has been obtained they are submitted to pressure in order to remove the excess of water and at the same time compress the material into dense heavy boards. The pieces of sacking are then taken out and the boards dried by exposure to air at the ordinary temperature or in a heated chamber.

The dried boards are finished off by glazing rolls. These rolls compress the boards still further and impart a polished surface. The amount of “finish” may be varied by the pressure, number of rollings, temperature of the rolls, and by damping the surface of the dry boards just before they are glazed. The boards are cut to standard sizes before or after glazing.

Duplex Boards.—If the single board machine is fitted with two vats instead of one, it is possible to manufacture a board with different coloured surfaces. A board coloured red on one side and white on the other is manufactured by having one vat full of pulp coloured red and the second vat full of white pulp. The thin moist sheets from the two vats are brought together and passed through the glazing rolls, which cause the moist sheets to adhere closely to one another, the double sheet of pulp so formed being wound up on the rollers at the end of the machine. The board is then dried, glazed, and finished in the usual way.

The same principle is occasionally adopted on the Fourdrinier machine for duplex wrappers. Thus a common brown pulp is worked up in conjunction with a dyed pulp to produce a brown paper having one surface of good paper suitably coloured. The brown pulp flows on to the wire of the paper machine, and after it has been deprived of part of the water at the suction boxes, a thin stream of coloured pulp, diluted to a proper consistency, flows from a shallow trough, placed across and above the wire, on to the wet brown web of paper in such a manner as to completely cover it as a thin even sheet of coloured pulp. The adhesion of the latter to the surface of the brown paper is practically perfect, and the weight of the couch and press rolls ensures uniform felting of the fibres.

Middles.—This term is applied to a thin or thick cardboard made of common material, the colour and appearance of which is of little importance for inferior goods. Boards of this kind are covered subsequently with papers of all colours and qualities, and the origin of the word “middle” is easily seen. The manufacture of a board consisting of two outside papers of good material and a middle produced from common stuff is effected by the continuous boxboard machine, unless the board is too thick to be passed over drying cylinders, calendered, and reeled, in which case the boards are produced on an ordinary wet machine and the paper pasted on the surface of the dry board.

The term is, however, now also applied to a common paper made of mechanical wood pulp with perhaps a little chemical pulp, used for tram tickets, cheap advertising circulars, common calendar cards, and similar purposes, to which no outer surface of a special character is added.

Continuous Board Machine.

This machine differs from the single board machine in that the finished board can be produced from the pulp at one operation. It is used principally for cards and boards of moderate thickness which can be wound up in the form of a reel at the end of the machine.

The mixture of pulp and water is pumped into two or more vats and formed into a number of thin sheets, which are all brought together between squeezing rolls and passed through heavy press rolls which compress the several layers into a compact mass. The thick sheet obtained is dried over steam-heated cylinders which are placed at the end of the press rolls, and calendered. The whole process, indeed, resembles that of ordinary paper-making, the main difference being the method of producing the wet sheet or card.

Some machines are constructed with six or seven vats and forty to fifty drying cylinders, and are capable of turning out a large quantity of finished material.

The board can be made of uniform quality and texture throughout, or be finished off with high-grade paper on one or both sides. In the latter case the constituents of the “middle” part are waste papers and raw material of inferior quality, the outer surface of wood pulp, white or coloured according to circumstances. The variety of papers and boards which can be produced is due to the fact that the several vats of pulp are independent of one another and can be filled with any kind of paper stock. The combined sheets forming the ultimate board are dried on the ordinary cylinders, calendered, and reeled up at the end of the machine.