This invention relates to manufacturing of print base paper or decorative or decor base paper for printing with combination of virgin and recycled pulp using a unique chemical composition.
BACKGROUND OF THE INVENTION
Print base paper is a very technical paper manufactured by pulp and a combination of certain chemicals on a paper machine. This paper is then used in the lamination industry by converters who supply the same as mica for furniture and doors etc. Currently this paper is being manufactured by only few other mills in India with virgin pulp but there is no company that uses paper with a combination of recycled fiber and pulp. It is important to use recycled fiber as a combination in the entire pulp process to help the environment. The other limitation is the limited use of virgin which is not available in India. Furthermore, most of the virgin pulp is imported into India whereas recycled fiber can be obtained from local market.
In other words, the making of print base paper is very research oriented and pain staking development. There few mills in India find it difficult to make this grade of paper and to achieve the exact color and shade required for the customer in each run. Moreover, once it is made on the machine there should be no shade variation between any materials made and hence it makes this grade of paper more technically challenging. There are other parameters in this kind of paper that are not easy to maintain, such as, opacity, density, porosity, wet strength and water absorption. This calls for months of research and development and many trials on the machine.
Therefore, there is a need for a method to manufacture print base paper or decorative or decor base paper for printing with combination of virgin and recycled pulp with a unique chemical composition.
SUMMARY OF THE INVENTION
The following presents a simplified summary of the subject matter in order to provide a basic understanding of some of the aspects of subject matter embodiments. This summary is not an

extensive overview of the subject matter. It is not intended to identify key/critical elements of the embodiments or to delineate the scope of the subject matter. Its sole purpose to present some concepts of the subject matter in a simplified form as a prelude to the more detailed description that is presented later.
A method disclosed here addresses the need for a technique to manufacture print base paper or decorative or decor base paper for printing with combination of virgin and recycled pulp with a unique chemical composition. A method of manufacturing of print base paper comprises 4 different steps. First, a mixture of virgin pulp and recycled pulp is conveyed to a pulper via a conveyor to produce pulp from cellulose fibers present in the pulp mixture. Secondly, the pulp mixture via a poir is received from the pulper for removing high density particles from the pulp mixture, passing the pulp mixture through screens and pulp thickeners, which is fed to a discharge pump that discharges the pulp mixture to a bleaching tower. Thirdly, the bleached pulp mixture is mixed and recirculated at the stock chest to reduce magnitude of consistency fluctuations in production of the pulp, which is transferred to a refining chest. Fourthly, fibers of the pulp mixture are treated via the refining chest to obtain desired paper property, wherein a critical degree of Schopper-Riegler (SR) is maintained in the refining process as intended parameters of the required print base paper are achieved in the refining chest. The mixture of the virgin pulp and the recycled pulp is in proportion, for example, 50% of the virgin pulp and 50% of the recycled pulp, or 70% of the virgin pulp and 30% of the recycled pulp.
The method further comprising removing heavy, light, coarse particles, and contaminants from the pulp mixture via a coarse screen having a 0.35 slot or 2.5 mm hole screen, to protect subsequent process equipment from damage. The method further comprising secondary cleaning of the pulp mixture via one or more centricleaners to remove any sand and residues from the coarse screen and to reduce loss of the pulp mixture in initial phase. The method further comprising conveying concentrated form of the pulp mixture from each centri cleaner to a disc filter or pulp thickener having consistency of 3-5% to further wash the pulp mixture and open the fibers present in the pulp mixture. The method further comprising dewatering of suspensions in the pulp mixture received via the screw conveyor using the screw press. The method further comprising a kneader conveyor that receives the dewatered pulp mixture from the screw press

and transfers to a kneader, wherein the kneader disperses the stickies, grease, wax, plastic, rubber, ink particles, and hot melt impurities from the pulp mixture.
The method further comprising mixing the pulp mixture with fillers and additives together, in a specified formula via a mixing chest and a machine chest that receives the dispersed pulp mixture from the kneader conveyor. The mixture of the pulp mixture with fillers and additives is a critical component in making this print base paper as the color matching and percentage of ash of print base paper is dependent on the pulp mixture with fillers and additives. The method further comprising a headbox that receives the pulp mixture from the machine chest and delivers a uniform pulp slurry on a wire part, at substantially similar velocity as that of the wire part. In an embodiment, the intended parameters of the required print base paper comprise one or more of density, formation, water claim, and thickness, which are achieved in refining chest. The method further comprises a press part, a dryer part, and a pop reel section. The press part presses the pulp mixture, and the dryer part dries the pressed pulp mixture transferred from the press part using a dryer part. The pop reel section winds continuous sheet of paper produced from the pulp mixture, via a pop reel section connected after the dryer part, where the paper is to be rolled on to a spool to produce paper rolls for further processing.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The following drawings are illustrative of particular examples for enabling systems and methods of the present disclosure, are descriptive of some of the methods and mechanism, and are not intended to limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description.
Figure 1A shows a block diagram associated with prior art system of manufacturing of print-based paper.
Figure IB shows a block diagram associated with manufacturing of print-based paper related to the present invention, as an example embodiment.

Figures 2A and 2B show a detailed block diagram associated with manufacturing of print-based paper related to the present invention, as an example embodiment.
Figures 3A and 3B show auxiliary block diagrams associated with the manufacturing of print-based paper related to the present invention as described in Figures 2A-2B, as an example embodiment.
Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may represent both hardware components of the system. Further, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION
Exemplary embodiments now will be described. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. The terminology used in the detailed description of the particular exemplary embodiments illustrated in the accompanying drawings is not intended to be limiting. In the drawings, like numbers refer to like elements.
It is to be noted, however, that the reference numerals used herein illustrate only typical embodiments of the present subject matter, and are therefore, not to be considered for limiting of its scope, for the subject matter may admit to other equally effective embodiments.
The specification may refer to "an", "one" or "some" embodiments) in several lo cations. This does not necessarily imply that each such reference is to the same embodiments), or that the feature only applies to a single embodiment. Single features of different embodiments may also be combined to provide other embodiments.

As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms "includes", "comprises", "including" and/or "comprising" when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Furthermore, "connected" or "coupled" as used herein may include operatively connected or coupled. As used herein, the term "and/or" includes any and all combinations and arrangements of one or more of the associated listed items.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
The present invention relates to a method of manufacturing of print base paper that describes the use of raw material and chemicals in detail. The ratio of oxide and other chemicals used, wherein the parameters are kept differently at each different equipment such as pulp degree SR, pulp temperature, Pulp pH, consistency.
Figure 1A shows a block diagram associated with prior art system of manufacturing of print-based paper. Figure IB shows a block diagram associated with manufacturing of print-based paper related to the present invention, as an example embodiment. Figures 2A and 2B show a detailed block diagram associated with manufacturing of print-based paper related to the present disclosure, as an example embodiment. A method of manufacturing of print base paper comprises different steps. First, a mixture of virgin pulp and recycled pulp is conveyed to a pulper 104, which is a high density pulper 104, via a conveyor 102 to produce pulp mixture from

cellulose fibers present in the pulp mixture. Secondly, the mixture is received via a poir 106 from the pulper 104 for removing high density particles from the pulp mixture, passing the pulp mixture through screens and pulp thickeners 118, which is fed to a discharge pump 128 that discharges the pulp mixture to a bleaching tower 108. Thirdly, the bleached pulp mixture is mixed and recirculated at the stock chest 110 to reduce magnitude of consistency fluctuations in production of the pulp mixture, which is transferred to a refining chest 112 (or refiners 112). Fourthly, fibers of the pulp mixture are treated via the refining chest 112 to obtain desired paper property, wherein a critical degree of Schopper-Riegler (SR) is maintained in the refining process as intended parameters of the required print base paper are achieved in the refining chest 112
In an example, raw materials used by other mills comprises 100% virgin pulp. However, in an
embodiment, raw material used in the method of manufacturing of print base paper in the present
disclosure comprises a blend of virgin and recycled pulp in ratio of 50%-70% virgin pulp and
remaining 50%-30% recycled pulp. Or in other words, 50% of the virgin pulp and 50% of the
recycled pulp, and 70% of the virgin pulp and 30% of the recycled pulp.
Chemicals blended in the method of manufacturing of print base paper in the present disclosure
is as listed below:
Clay (Fine or Dull) = 450-500 kilogram (kg) per batch
Red Oxide = 25-35 kg per batch
Black Oxide = 7-15 kg per batch
Yellow Oxide = 50-60 kg per batch
Titanium Dioxide = 25 - 35 kg per batch
Pigment Dye = 20-30 kg per batch
Per batch = Per Tonnes of Paper.
The above chemicals are mixed in the above ratio into a clay disperser which has a high RPM agitator that agitates the chemicals before it is sent to the stock chest 110 for mixing with primary raw material.

After receiving the pulp mixture in the poir 106, a dump tower 136 that acts as a storage unit where the pulp mixture gets adequate holding time for chemical reaction, along with the chemicals added, which is followed by a high-density cleaner 138. The high-density cleaner 138 provides improved pulp consistency. In an example, the high-density cleaner 138 has a rotor that has a centrifugal rotation to remove the impurities from the pulp mixture with high specific gravity. The method further comprising removing heavy, light, coarse particles, and contaminants from the pulp mixture via a coarse screen 114a having a 0.35 slot or 2.4 mm hole screen, to protect subsequent process equipment from damage. The method further comprising secondary cleaning of the pulp mixture via one or more centricleaners 116a and 116b to remove any sand and residues from the coarse screen 114 and to reduce loss of the pulp mixture in initial phase. The centricleaners 116a and 116b are positioned after the controller level box (CLB) 130 after accepting the pulp mixture from the coarse screens 114a and 114b, and the auto discharge screen 132. The rejected portion is transferred from the auto discharge screen 132 to a reject sorter 134, which is configured for processing the reject of screening at pulp mixture preparation stage and to work with wastepaper in the virgin pulp portion. The method further comprising conveying concentrated form of the pulp mixture from each centricleaner 116a and 116b to a disc filter or pulp thickener 118 having consistency of 3%-5% to further wash the pulp mixture and open the fibers present in the pulp mixture. The method further comprising dewatering of suspensions in the pulp mixture received via the screw conveyor 120 using the screw press 122.
Figures 3A and 3B show auxiliary block diagrams associated with the manufacturing of print-based paper related to the present invention as described in Figures 2A-2B, as an example embodiment. Another screw conveyor 120b transfers the dewatered mixture to the discharge pump 128. The method further comprising a kneader conveyor 302a that receives the dewatered pulp mixture from the screw press 122 and transfers to a kneader 302b, wherein the kneader 302b disperses the stickies, grease, wax, plastic, rubber, ink particles, and hot melt impurities from the pulp mixture. Further, as shown in Figures 2A and 2B, the method further comprising mixing the pulp mixture with fillers and additives together, in a specified formula via a mixing and machine chest 124 that receives the dispersed pulp mixture from the kneader conveyor 302b. The pulp mixture with fillers and additives is a critical component in making this print base paper as the color matching and percentage of ash of print base paper is dependent on the pulp

mixture with the fillers and additives. The method further comprises a headbox 126 that receives the pulp mixture from the mixing and machine chest 124 and delivers a uniform pulp slurry on a wire part, at substantially similar velocity as that of the wire part. In an embodiment, the intended parameters of the required print base paper comprise one or more of density, formation, water claim, and thickness, which are achieved in the refining chest 112. The method further comprises a press part 304, a dryer part 306, and a pop reel section 308. The press part 304 presses the pulp mixture and the dryer part 306 dries the pressed pulp mixture transferred from the press part 304 using the dryer part 306. The pop reel section 308 winds continuous sheet of paper produced from the pulp mixture, where the pop reel section 308 is connected after the dryer part 306, and the paper is to be rolled on to a spool to produce paper rolls for further processing.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore, contemplated that such modifications can be made without departing from the spirit or scope of the present invention as defined.

We Claim:

1. A method of manufacturing of print base paper comprising:
conveying a mixture of virgin pulp and recycled pulp to a pulper via a conveyor to produce pulp mixture from cellulose fibers present in the mixture;
receiving the pulp mixture via a poir from the pulper for removing high density particles from the pulp mixture, and passing the pulp mixture through screens and pulp thickeners, which is fed to a discharge pump that discharges the pulp mixture to a bleaching tower;
mixing and recirculating the bleached pulp mixture at the stock chest to reduce magnitude of consistency fluctuations in production of pulp, which is transferred to a refining chest; and
treating fibers of the pulp mixture via the refining chest to obtain desired paper property, wherein a critical degree of Schopper-Riegler (SR) is maintained in refining process as intended parameters of the required print base paper are achieved in the refining chest.
2. The method as claimed in claim 1, further comprising removing heavy, light, coarse particles, and contaminants from the pulp mixture via a coarse screen having a 0.35 slot or 2.4mm hole screen, to protect subsequent process equipment from damage.
3. The method as claimed in claim 1, further comprising secondary cleaning of the pulp mixture via one or more centricleaners to remove any sand and residues from the coarse screen and to reduce loss of the pulp mixture in initial phase.
4. The method as claimed in claim 3, further comprising conveying concentrated form of the pulp mixture from each centricleaner to one of a disc filter and a pulp thickener having consistency of 3%-5% to further wash the pulp mixture and open fibres present in the pulp mixture.
5. The method as claimed in claim 4, further comprising dewatering of suspensions in the pulp mixture received via a screw conveyor using a screw press.

6. The method as claimed in claim 5, further comprising a kneader conveyor that receives the dewatered pulp mixture from the screw press and transfers to a kneader, wherein the kneader disperses the stickies, grease, wax, plastic, rubber, ink particles, and hot melt impurities from the pulp mixture.
7. The method as claimed in claim 6, further comprising mixing the pulp mixture with fillers and additives together, in a specified formula via a machine chest that receives the dispersed pulp from the kneader conveyor, wherein the pulp mixture with the fillers and the additives forms the print base paper as colour matching and percentage of ash of output print base paper is dependent on the pulp mixture with the fillers and the additives.
8. The method as claimed in claim 7, further comprising a headbox that receives the pulp mixture from the machine chest and delivers a uniform pulp slurry on a wire part, at substantially similar velocity as that of the wire part.
9. The method as claimed in claim 1, wherein the intended parameters of the required print base paper comprise one or more of density, formation, water claim, and thickness, which are achieved in the refining chest.
10. The method as claimed in claim 1, further comprising:
pressing the pulp mixture via a press part;
drying the pressed pulp mixture transferred from the press part using a dryer part; and
winding continuous sheet of paper produced from the pulp mixture, via a pop reel section connected after the dryer part, wherein the paper is to be rolled on to a spool to produce paper rolls for further processing.
11. The method as claimed in claim 1, wherein the mixture of the virgin pulp and the recycled
pulp is in proportion of one of:
50% of the virgin pulp and 50% of the recycled pulp, and

70%) of the virgin pulp and 30% of the recycled pulp.