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welcome to pixel specialty solutions a
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leading supplier of specialty papers
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with over a century of experience here
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at pixel our people are passionate about
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crafting the finest paper products and
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take pride an unparalleled customer
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service whether it's our diverse
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portfolio of specialty products or
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highly customized solutions pixel has
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the experience and technical
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capabilities to meet your growing
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demands and it all happens at our fully
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integrated pulp and paper mills in
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Spring Grove Pennsylvania and
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Chillicothe Ohio I invite you to explore
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our paper making process as we combine
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paper and print with interactive
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technology to deliver a truly unique
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experience your journey will take you
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through our Woodyard into our pulp mill
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and across a paper machine that
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stretches more than four football fields
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in length throughout the tour you'll see
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how our commitment to continuous
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improvement has helped minimize our
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environmental footprint and position the
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company for long-term success we hope
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you enjoy your tour and we thank you for
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your time welcome to pixel
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the paper making process begins with
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trees in our long-standing commitment to
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sustainable forestry as the first to
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develop sustainably managed forests in
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Pennsylvania and Maryland are
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established policies and procedures
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ensure that we conduct business in a
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manner that protects the environment and
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reduces energy consumption natural
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resource consumption and waste in
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support of this commitment we have
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invested over 100 million dollars to
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transition mill operations from coal to
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clean burning natural gas to reduce
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carbon emissions and further minimize
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our environmental footprint in the
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forests our certified foresters assist
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with individual tree selection and
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thinning and work closely with private
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landowners and developers to ensure the
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responsible harvesting of timber they
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also provide expertise to help minimize
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impacts on the surrounding environment
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when harvesting trees timber is
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classified into soft woods and hardwoods
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a simple way to identify the difference
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is to remember that hardwoods have
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leaves while soft woods have needles
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when inspecting a hardwood tree such as
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oak maple and ash the tree is divided
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into three sections or grades based on
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diameter the first grade is referred to
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as Vanir Vanir is obtained from the
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widest section of the tree and used to
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produce furniture flooring and cabinetry
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the second grade called low grade spans
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the midsection of the tree and is used
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to produce shipping pallets railroad
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ties and rough cut timber frames for
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barns
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the third and final grade spans the
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upper section of the tree diameters
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between 4 inches and 12 inches this
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grade is called tough wood and it's used
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to make paper soft woods on the other
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hand such as pine and spruce are divided
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into two sections for grades the first
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grade is called construction lumber and
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is used for decking boards two-by-fours
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for homes and treated lumber the second
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grade is classified as both wood and is
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used to make paper for those requiring
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forestry certification our pennsylvania
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mill was one of the first to achieve
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triple chain of custody forestry
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certification in the u.s. from the
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Forest Stewardship Council the
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sustainable forestry initiative and the
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program for the endorsement of forest
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certification today both mills offer
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forestry certifications across our broad
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portfolio of products for more
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information or to obtain copies of our
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forestry certificates please visit pick
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Cellcom
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[Music]
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in an integrated pulp and paper mill the
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process of making paper begins in the
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wood yard here
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what is unloaded debark chipped and
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screen wood is delivered to the mill in
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two forms as logs known as round wood
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and as pre-cut chips during unloading
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all round wood is separated and stacked
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into softwood and hardwood piles so that
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wood fibres can be isolated later in the
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pulping process trees with needles such
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as pine and spruce are stacked in the
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softwood pile while trees with leaves
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such as oak maple and ash are stacked in
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the hardwood section round wood begins
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its journey on a long conveyor belt and
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it makes its way towards the debarking
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drum as it drops in the drum logs
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tumbled together until the bark is
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stripped holes in the drum allow the bar
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to fall and be reclaimed for use as an
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environmentally friendly biofuel logs
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continue their journey as they are fed
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into an industrial chipper where they're
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converted into 1 inch by 1 inch square
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chips in a matter of seconds chips are
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then sent through a screening process to
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remove any irregularly sized chips a
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uniform chip size is important later in
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the pulping process because it increases
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the yield and quality of wood fiber
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produced during screening undersized
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chips and sawdust are removed and sent
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to a power boiler along with bark from
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the debarking drum where they are used
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as biofuel to generate clean burning
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electricity to power the mill as well as
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residential houses in fact 40% of the
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mills electricity comes from this
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biofuel to help supplement the demand
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for wood pre-cut chips are delivered in
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trucks
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these chips bypass the Woodyard
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operation as they are unloaded and sent
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directly to screening here trucks are
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tilted on a steep 60 degree angle to
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expedite the unloading process once
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screen chips remain separated and are
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transferred into hardwood and softwood
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piles where they wait to enter the
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pulping process now that round wood has
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been chipped and screen chips can enter
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the pulping operation so that cellulose
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fibers can be separated from the lignin
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or gluey substance that hold the fibers
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together
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[Music]
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the pulping process begins in the
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digester where wood chips are
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transported on a conveyor belt to either
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a batch or continuous digester chips
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along with white liquor are fed into the
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top of the digester as the mixture makes
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its journey downwards liquor is heated
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to 170 degrees Celsius to begin the
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cooking process under pressure and heat
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the white liquor dissolves or digests
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the lignin that holds the individual
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cellulose fibers together several hours
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later this process is complete the
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result is a massive fibers called pulp
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pulp from the digesters along with spent
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cooking chemicals now called
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black liquor are sent to the washing and
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screening area so the black liquor and
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undigested wood such as knots can be
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washed away from the pulp
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at this stage an additional process
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known as oxygen delignification occurs
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this process uses oxygen and white
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liquor along with steam to remove any
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remaining lignin and extract some color
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from the pulp so that less chemicals are
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needed during bleaching next pulp enters
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the bleaching area to be brightened
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bleaching occurs in multiple stages as
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it takes the fibers from their natural
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brown color called brown stocks to white
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today most US Mills use elemental
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chlorine free or ECF chemicals for
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bleaching a more environmentally
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friendly process without bleaching all
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printing and writing papers would look
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like a brown grocery shopping bag and
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would not be suitable for use in books
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business forms envelopes and other
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printing papers the fibers are now ready
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to make paper until now everything is
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focused on producing the pulp needed to
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make paper now we're ready to refine the
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pulp blend in the fillers and dyes and
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send the mixture or furnish through the
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paper machine in its simplest form a
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paper machine is like a giant oversized
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dryer extracting water from the furnish
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to produce a dry sheet of paper paper
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machines can be as small as a bowling
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alley or as long as four football fields
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paper traveling at speeds up more than
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5,000 feet per minute
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for nearly 60 miles per hour shown here
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is the chief located in Chillicothe Ohio
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the first step in our paper making
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process is to refine the pulp in
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refining pulp fibers are shortened and
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frayed to create additional contact
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points with the fibers to more easily
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connect and intertwine because softwood
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fibers are long they will naturally have
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more contact area thereby imparting
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strength to the finished sheep hardwood
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fibres however are short allowing them
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to pack closer together creating bulk
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smoothness and opacity blending these
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fibers together in specific proportions
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provides the ability to produce papers
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with a wide range of physical
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characteristics it is for this reason
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that soft woods and hardwoods have been
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isolated throughout the entire process
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for the first time hardwood and softwood
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fibers are pumped into a blend chest
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where they are finally mixed together
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along with fillers such as clay calcium
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carbonate and titanium dioxide to
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improve surface and optical properties
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other chemicals may also be added
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including sizing agents to control the
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penetration of liquids and optical
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brighteners and dyes to enhance visual
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properties this blended mixture of fiber
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and additives is called the furnish
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the furnish flows from the blend chest
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into the head box and been onto a moving
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wire mesh called the foreign ear section
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when the furnish hits the wire mesh it
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is approximately ninety nine and a half
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percent water and one-half percent fiber
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filler and additives as this mixture
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travels across the rotating mesh water
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drains under simple gravity to help
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remove additional water improve fiber
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formation and avoid to sidedness a top
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wire former is used to suction water
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from above the mesh as the intertwined
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fibers reach the end of the ford Rainier
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they hit one more dewatering device
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called the couch roll before lifting for
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the first time as a solid sheet of paper
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at this point the newly formed paper is
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85% water the wet paper passes through a
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series of rollers and felts called the
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press section reducing moisture levels
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to roughly 65 percent it Ben travels
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through a series of dryer cans each
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filled with steam heat from the steam
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drives off additional water resulting in
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a final moisture profile of about four
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to five percent water along the way
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starch can be applied as paper passes
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the Desai's press starch helps fill
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microscopic ridges in the paper and
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provides a smoother surface for enhanced
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credibility in fine printing and writing
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papers as paper reaches the end of the
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machine it passes through high-tech
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scanners that look for variations in
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faces weight moisture caliper opacity
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brightness and physical defects like in
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the scanning system on the chip is so
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exact that it can spot a single hole the
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size of a pin across a 300 inch width
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web of paper traveling 40 miles per hour
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and it can tell you where in the
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finished role that is located so it can
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be removed as paper reaches the end of
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the Machine it is wound onto a large
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steel spool capable holding over 15 tons
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when the spool reaches capacity the
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resulting roll of paper called a log
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roll or jumbo roll is slit into smaller
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sections and rewound unto thick
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cardboard cores so it can be transported
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more easily to the wrapping station or
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to other locations in the mill for
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further processing
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[Applause]
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[Music]
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in the finishing area paper is prepared
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according to customer specifications
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packaged and shipped as finished rolls
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leave the paper machine they are
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transported to a packing station where
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they receive a watertight poly wrap or a
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moisture resistant craft wrap at the
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craft wrapping station rollers spin the
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paper and apply the wrap fluted
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cardboard covers are placed against each
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side of the roll while spinning the
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edges are folded and glue is applied
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thin cardboard caps called end caps are
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carefully pressed onto both sides using
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heated steel plates the roll receives a
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finished label and is ready for
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transport to the customer for customers
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requiring sheeted product we have the
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ability to convert rolls into a wide
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variety of sizes shown here are white
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canary and pink carbonless rolls as all
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three unwind the paper enters the
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sheeter where a rotating blade cuts the
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paper and stacks them into reams the
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reams take a journey across conveyor
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belts where they receive a moisture
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resistant wrap and product label finish
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dreams are then packaged into cartons
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and shipped to the customer
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in the shipping department rolls are
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carefully loaded onto trailers using a
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specialized clamp truck capable of
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grabbing lifting and if necessary
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rotating rolls without damaging the
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paper to help improve visibility and
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increase safety all clamp trucks are
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affixed with blue lights that can easily
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be seen around corners and in
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high-traffic areas to help improve on
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time delivery and enhance customer
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communications excel has invested in
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four kites the largest supply chain
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visibility platform with over 4 million
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GPS electronic logging devices across
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all modes of transportation with four
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kites customers can easily track their
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shipments 24 hours a day seven days a
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week with information updates every 15
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minutes the platform can even provide
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alerts when unexpected delays occur in
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transit
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in addition Excel has a nationwide reach
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with warehouses across the country able
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to ship over 90% of the US with next day
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service on stock items all this is
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backed by one of the broadest product
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portfolios and experienced customer
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service teams located on-site
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at each mill
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at pixel we have a proud heritage of
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papermaking that spans more than 150
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years our continued investments in the
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business that positioned us for long
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term success that could strive to be
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your supplier of choice thank you for
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taking the time to tour our facilities
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we hope you enjoy the tour and we look
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forward to your continued support
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[Music]
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you
