Making paper from straw with your own hands. “Launching an innovative production of cardboard from straw. interesting and surprising facts about paper production

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The production of paper from wood is a relatively recent invention. For example, in North America, paper was made almost exclusively from recycled linen and rags until 1850.

For example, banknotes, dollars, were made from flax (25 percent) and cotton (75 percent). It turns out paper - rough and velvety, elastic and durable, neutral color, interspersed with the smallest synthetic fibers (red and blue hairs). Rumor has it that hemp fibers are also used for the production of this paper - which is why the dollar is so resilient and wrinkle-free. However, the official .

A powerful twist of laws in the era of industrialization introduced tax breaks and lucrative freight rates in the late 1800s - a development that firmly established timber as the primary material for paper. These incentives remain valid to this day and are most of our dependence on endangered forests for our paper needs.

During World War II and up until 1960, there were 25 mills in the United States that still produced paper from wheat straw.

More than 20% of the paper produced in India and China is made from wheat and rice straw and cane pulp. (The stalks of the residual sugarcane are crushed to extract their juice, and then the fibers are used).

Globally, 8% of all paper products are produced from agricultural waste.

Each year, millions of tons of agricultural residues of wheat and flax straw remain unused, while paper production continues to accelerate. According to various estimates, this leads to the felling of about 830 million trees in the United States alone every year.

6 interesting and surprising facts about paper production

What paper is made of

One such company is Nature's Paper, which uses wheat straw left over from harvesting to make office paper, which is usually fed to livestock or left in the fields with no use other than fertilizer.

Nature's Paper collects straw and converts it into pulp, but not only the end product is provided by the straw, but the heating of the water for production is also done with fossil fuels made from straw.

Office paper made of this material has a yellowish color, therefore sodium and chlorine salts are used to whiten it. The quality of bleached paper does not differ at all from wood. If you think about it, how much waste paper is constantly thrown away with food

The company shows an example of an exceptionally respectful attitude to nature and maximalism in the use of agricultural products. This idea is for thinking and developing similar thoughts in the minds of future entrepreneurs and inventors.

Another company, New Leaf Paper, makes paper from banana and palm fibers. All paper produced at this enterprise has nothing to do with trees. She is ordered for printing books.

Ecopaper makes paper from anything but wood. Banana, mango, coffee plantation paper. It is made from the leaves and stems of these plants that remain after harvest. Previously, they were simply thrown away, now they make excellent paper. Chlorine is not used in the production of such paper. The production of paper from hemp has also been mastered there. Sugarcane cake paper - ideal white, suitable for use in office equipment.

Poopoopaper has mastered the technology of paper production from ... elephant dung!

The manure is first dried, then boiled, washed thoroughly and used for papermaking. No, the paper does not smell and does not look different from ordinary paper!
Production is put on stream, paper is sold in 16 countries around the world.
Taken

A tree appears. For this, conifers are used. 10% of the volume of industrial wood production is spent on paper needs. The development of computer technology and the Internet reduces the need for it. But the need for such material is gradually increasing. The developed glades will be renewed in 50 years. When felling, the forest border moves further and further from transport routes.

The destruction of the forest will cause irreparable harm to humanity. Exists alternative way production. For this, use ordinary straw. After the harvest of wheat is harvested, a lot of it remains in the fields.

Material consumption:

• for the production of one ton of paper, one and a half tons of straw are needed;
• for the manufacture of cardboard - two tons.

Sometimes a small amount of recycled waste paper is added during the production process. Nowadays, Woody Harrelson actively promotes the type of paper based on wheat straw.

Paper is made not only from wood. In China, this material has been made from reed or rice straw for hundreds of years. In Russia, the first attempts to produce such paper date back to 1715.

Actor Woody Harrelson founded a paper company made from wheat straw. He promotes the production and use of this eco-friendly, high quality wheat straw paper. Woody Harrelson believes that using straw to make paper helps protect nature more effectively.

Woody Harrelson with Straw Paper Making Book

Production

Reed technology is a complex process. First, straw is poured into the box. Straw cannot be used right away, long stems will damage the processing.

First stage

First you need to grind the material. A special device is used, which is a rotating drum. The straw is fed into a pipe where it is sucked in. After processing, the straw becomes suitable for further processing. 1,300 kilograms will be processed into 1 ton of paper. Loading occurs approximately every 15 or 20 minutes. The chopped straw will need to be transferred to the brewhouse where further stages of the process will be carried out.

Cooking processing

The crushed material is transferred to the vats, which contain alkali - caustic soda.

1. To prepare high-quality paper, it is necessary to soak the straw well with the specified solution. This is done by digestion in it. An essential role is played by the ability to easily absorb and release moisture. This eliminates the use of powerful presses and an intensive brewing process.
2. The processed material is discharged through holes that are prepared near the end of the brewing hose. The straw at this stage is saturated with moisture and alkali to the degree of 20 - 25 percent.
3. It is fed into the next cooking chamber. In this case, the processing takes place with the help of a hot steam with a temperature of one hundred degrees.

The operator monitors the filling of the tank. For this purpose, there are openings in the tank shell, as well as various sensors are installed here, which allow the operator to quickly respond to the degree of loading of the cooking chamber. There is a special discharge hose at the bottom. Through it, the finished mass is discharged from the container.

Flushing

The mass of processed straw is fed to the pulper.

1. It is saturated with liquid to a concentration of three percent. In this chamber, the material is washed and prepared for further processing stages.
2. The washed and diluted solution is pumped into the buffer tank, which is considered as an intermediate tank. It is specially equipped to ensure constant mixing and to prevent possible compaction of the top layer of the mortar.

For this, there is an elevation in the center of the pool, and direct mixing is carried out using special fans.

The last stage of preparation

The next step is to grind the material.

1. The device to which the mixture is fed is a primary grinding mill. The material is additionally straightened and crushed.
2. At this stage, the pre-processing ends and, after drying, it is sent directly to the paper shop. There it is mixed with a small proportion of waste paper and is directly used in the paper-making process.

Paper making

After the final grinding and dilution with water, the solution is sent to the table of the paper machine, where the vibrating screens are located. There, with the help of vacuum boxes, excess moisture is sucked out and still wet sheets are cut to the desired size. The presses bring the mixture to a fifty percent state, after which the drying machines produce the final drying of the paper. The moisture content of the sheets of paper does not exceed ten percent.

Conclusion

The stocks of straw are enormous. Paper and cardboard made in this way are of high quality and environmentally friendly. They can be produced not only from straw, but also on the basis of similar materials:

• reed;
• reeds;
• cattail.

The need for cardboard packaging is gradually increasing.
Now our team is able to produce cardboard without harming our planet, since the stocks of straw are endless. Paper and cardboard made in this way are of high quality and environmentally friendly. Within 5-10 years, in Russia, this production method will be the main focus in pulp and paper industry. No deforestation, no chemical pollution of rivers, all this will be a thing of the past!

Current state

Pre-investment stage. There is a site for the project. In 2017, the innovative technology was tested by our team on the basis of OOO Karton-Yug, Novocherkassk.

Market

Within the framework of the project, it is planned to manufacture products that use
consistently high demand not only in a particular region or federal district, but in general in Russia. The company adequately evaluates its products in terms of
consumer qualities and prices for these products. The balance of these parameters ensures stable demand and successful competition. The planned price difference with competitors is at least 10-12%, which is a significant indicator for wholesale buyers. The main counterparties of the planned plant will be corrugated cardboard enterprises producing corrugated cardboard, enterprises producing roofing materials based on roofing cardboard.

Problem or Opportunity

Demand for corrugated packaging for Russian market is influenced like
consumer market and industry sectors. Magnification
consumer spending due to growth in real disposable income
of the population, of course, has a positive effect on retail trade, while
an increase in the volume of goods turnover requires more and more packaging along the entire chain
supplies. Increase in retail trade in the country over the past seven years
explains the outstripping dynamics of growth in the production of corrugated packaging by
in relation to the volume of production of manufactured products.
Imposition of restrictions on the import of agricultural products from Europe and
North America plays into the hands of Russian food manufacturers
food, beverage and tobacco, which have benefited from reduced competition from
import side. Some of the local industries were focused on
import substitution, which contributed to an increase in workload
industrial enterprises (mainly food companies) and the creation
additional domestic demand for corrugated packaging in 2018.

Solution (Product or Service)

The production plan envisages the production of two main types of cardboard: packaging and roofing. The versatility of production is one of the advantages of this project. Chipboard for smooth layers of corrugated packaging is a raw material
the purchaser of which is the manufacturer of packaging products. So
Thus, by launching a cardboard production project, the Company enters the b2b sector,
understanding and taking into account all the features of work in this market.
The target for cardboard sales is 21,000 tons per year. These are very significant volumes, and even despite the gradual withdrawal of production to this volume, it is necessary to be ready for competition.
Technical cardboard is a raw material for which consumers have two main
Requirements:
 Price
 Consistency of quality corresponding to the price.
It is the price that will be the main tool for promoting products.
Since the business idea of ​​cardboard production is based on the desire to reduce the cost of finished products as much as possible, using energy resources and secondary raw materials optimally, the Company has the opportunity to enter the market with an unprecedentedly low price and at the same time maintain a relatively high sales margin.

Competitors

The company - the initiator of the project thoroughly analyzed the main trends in the market for cardboard consumers. A possible summary as a result of this analysis could be based on the following statements:
1. Domestic market of cardboard consumers in last years despite the crisis, it shows a steady and significant growth.
2. The increase in demand for cardboard is due to an increase in demand from manufacturers of corrugated packaging, and these enterprises are potential partners of the project - buyers of finished products planned for production - cardboard for smooth layers of corrugated packaging.
3. The constant increase in the cost of secondary raw materials, namely waste paper, also indicates the presence of demand for cardboard and, in part, a certain shortage of waste cardboard.
4. Using only waste paper as a raw material for the production of cardboard can be a very risky decision, since a high proportion of waste paper in the cost price and its price can significantly affect the marginality of the cardboard, its selling prices and the planned, very high and ambitious dynamics of reaching the planned targets. production and sales volumes.
Competitors:
Nicole-Pak, Novoulyanovsk ", Ulyanovsk region... The factory is focused on the production of cardboard cores for winding roll materials. The factory was commissioned in October 2011. The design capacity is 3,000 tons of products per year with an increase in productivity up to 6,000 tons. The volume of production and sales of the factory is steadily growing: the territorial location allowed us to expand the geography of sales and reduce the costs of our customers for the transportation of products.
"Nikol-Pak, Nizhny Novgorod", Nizhny Novgorod region
Founded on the basis of the cardboard-roofing plant, "Nikol-Pak g.
Nizhny Novgorod ”after the reconstruction of the KDM, which began in December 2011, began production of box and core cardboard in May 2012. Designed production capacity - 20,000 tons per year; in 2016 it was planned to reach an increase in indicators up to 24,000 tons of finished products per year.
Limited Liability Company "KARTONPRO", Nizhny
Novgorod. LLC "KartonPro" is engaged in wholesale supplies and complex supply of paper products and packaging enterprises different spheres activities: printing, pharmaceutical, industrial, furniture, food, etc. The range of main products includes paper, cardboard,
corrugated cardboard, roofing material. There are no competitors in the Tyumen Region (where the plant is planned to be located and operate).

Benefits or Differentiators

The main material for obtaining cellulose is wood. For this, conifers are used. 30% of the volume of industrial wood production is spent on the production of cardboard packaging. The demand for this material is gradually increasing. The developed forest clearings will be renewed in 50 years at best. When felling, the forest border moves further and further from the transport routes.
The destruction of forests causes irreparable harm to humanity. For the production of 1 ton of cardboard, on average, 7 trees are processed. These are terrifying statistics. However, there is an alternative method of production, which has been actively popularized in the west since 2015 (for example, Actor Woody Harrelson, an ardent defender of the forests of the USA and Canada, invested in organizing the production of office paper from straw). To do this, use ordinary straw (cereal straw). After the wheat is harvested, a lot of straw remains in the fields; many agricultural enterprises completely dispose of it by burning it.
for the production of one ton of paper, 1.2 tons of straw is sufficient;
for the manufacture of cardboard 1.3 tons.
Our organization, having studied a huge amount of literature, having consulted with foreign technologists of this type of production, in 2017 conducted pilot closed tests by producing 1 ton of straw cardboard on the basis of the Novocherkassk Cardboard Plant (Karton-Yug), the indicators are simply staggering (considering that the cost price straw cardboard will not exceed 6-6.5 thousand rubles per ton). Now we are able to produce cardboard without harming our planet, since the stocks of straw are endless. Paper and cardboard made in this way are of high quality and environmentally friendly. We are sure that within 5-10 years, in Russia this method of production will be the main direction in the pulp and paper industry. No deforestation, no chemical pollution of rivers, all this will be a thing of the past! This technology is not yet used anywhere in Russia.

Finance

Planned revenue per month 52,500,000 rubles
Planned gross profit per month 39,013,539 rubles
Planned net profit per month 27,250,000 rubles
Discount rate 10.00%
Payback period 8.6 months
Project profitability 22%
Net present value per year 327,000,000 rubles

Purpose of investment

Equipment for the production of paper (stock preparation, paper machine, baboon cutter)
44 000 000
Generator (with cogeneration system)
18 000 000
Circulating water purification system
12 000 000
Fire extinguishing system
2 000 000
Ventilation systems with catalytic converters
1 200 000
Equipment for packaging finished products
380 000
Laboratory equipment for quality control of raw materials and products (QC)
600 000
Well drilling and water disposal
200 000
Purchase and installation of crane girders in the production area
450 000
Acquisition and configuration of automated control systems
700 000
Truck tractor KamAZ
2 800 000
Semitrailer
700 000
Forklift
800 000
Purchase of construction tools for installation works and production process
500 000
Other expenses of the investment stage (costs of obtaining permits, unforeseen expenses)
500 000
Total:
84 830 000
Also 8 170 000 rub. to replenish working capital.

Offer to the investor

We will announce the proposal for interested investors at the meeting during the negotiation process.

Risks

The equipment provided for by the project should, at the request of the Project Initiator, be capable of producing a wide range of cardboard at a relatively high productivity: in a wide range of grammage (i.e. density and, accordingly, weight) using pulp prepared from different raw materials. This unification makes it possible to significantly eliminate the risks associated with a drop in demand and prices for a particular type of cardboard. The possibility of using straw and sawdust together or as a substitute for waste paper is a step in the same direction: reducing the cost of cardboard and roofing material. Successful implementation of this plan will reduce the risks associated with rising prices or lack of raw materials for production.
In general, the future production looks balanced, the main items of expenses have been taken into account, and the estimated cost of production allows us to look with optimism at the sales plan and planned revenue and gross profit.