Tour the Paper-Making Process at Pixelle Specialty Solutions™

Summary

Pixel Specialty Solutions, with a century of expertise, offers a diverse range of specialty papers and customized solutions. Their integrated mills in Pennsylvania and Ohio combine sustainable forestry practices with innovative papermaking processes, utilizing both hardwoods and softwoods to produce high-quality paper products. The company's commitment to environmental responsibility is evident through their transition to natural gas, minimizing carbon emissions and reducing their environmental impact. A tour of their facilities showcases the papermaking process, from sustainable forestry to the production of paper, highlighting their dedication to continuous improvement and customer service excellence.

Takeaways

• 🌲 Pixel Specialty Solutions is a leading supplier of specialty papers with over a century of experience.
• 🏭 The company operates fully integrated pulp and paper mills in Spring Grove, Pennsylvania, and Chillicothe, Ohio.
• 🌳 Pixel is committed to sustainable forestry and has invested over 100 million dollars in transitioning from coal to clean burning natural gas to reduce carbon emissions.
• 🔍 Certified foresters at Pixel work closely with landowners to ensure responsible timber harvesting and minimal environmental impact.
• 🪵 Timber is classified into softwoods and hardwoods, with different grades used for various applications such as furniture, pallets, and paper.
• 🌿 The Pennsylvania mill was one of the first to achieve triple chain of custody forestry certification from the Forest Stewardship Council, Sustainable Forestry Initiative, and the Programme for the Endorsement of Forest Certification.
• 🔄 In the wood yard, logs are debarked, chipped, and screened to isolate wood fibers for the pulping process.
• 🔧 The pulping process involves separating cellulose fibers from lignin using heat and chemicals in a digester.
• 📜 The paper-making process refines the pulp, blends in fillers and dyes, and then the mixture is spread onto a moving wire mesh to form a sheet of paper.
• 🔄 The paper is then pressed, dried, and undergoes quality checks with high-tech scanners that can detect minute defects.
• 📦 Finished paper is prepared according to customer specifications, packaged, and shipped, with capabilities to convert rolls into various sheet sizes.

Q & A

What is the core business of Pixel Specialty Solutions?

Pixel Specialty Solutions is a leading supplier of specialty papers, with over a century of experience in crafting high-quality paper products and providing exceptional customer service.

Where are Pixel's fully integrated pulp and paper mills located?

Pixel's fully integrated pulp and paper mills are located in Spring Grove, Pennsylvania, and Chillicothe, Ohio.

What is the significance of Pixel's tour through the papermaking process?

The tour is designed to showcase Pixel's commitment to continuous improvement, environmental sustainability, and the innovative use of technology in their papermaking process.

How does Pixel Specialty Solutions demonstrate its commitment to sustainable forestry?

Pixel has a long-standing commitment to sustainable forestry, being the first to develop sustainably managed forests in Pennsylvania and Maryland, and investing over 100 million dollars to transition mill operations from coal to clean burning natural gas.

What is the role of certified foresters in Pixel's forestry operations?

Certified foresters assist with individual tree selection and thinning, work closely with private landowners and developers for responsible timber harvesting, and provide expertise to minimize environmental impacts during harvesting.

How does Pixel differentiate between softwood and hardwood during the wood classification process?

Pixel differentiates between softwood and hardwood based on the type of tree leaves; hardwoods have leaves, while softwoods have needles.

What is the purpose of the pulping process in papermaking?

The pulping process is used to separate cellulose fibers from the lignin, which is the substance that holds the fibers together, in order to produce pulp for papermaking.

Why is a uniform chip size important in the pulping process?

A uniform chip size is important because it increases the yield and quality of wood fiber produced during the pulping process.

What is the purpose of bleaching in the papermaking process?

Bleaching is used to brighten the fibers, turning them from their natural brown color to white, which is necessary for the production of printing and writing papers.

How does Pixel Specialty Solutions ensure the quality of its paper products?

Pixel uses high-tech scanners to detect variations in face weight, moisture, caliper, opacity, brightness, and physical defects in the paper at high speeds and wide widths, ensuring a high-quality product.

What is the significance of the triple chain of custody forestry certification achieved by Pixel's Pennsylvania mill?

The triple chain of custody certification from the Forest Stewardship Council, the Sustainable Forestry Initiative, and the Program for the Endorsement of Forest Certification signifies that Pixel's Pennsylvania mill adheres to strict environmental and social standards in its forestry practices.

How does Pixel Specialty Solutions support its customers with logistics and supply chain visibility?

Pixel has invested in FourKites, a supply chain visibility platform, allowing customers to track their shipments in real-time with updates every 15 minutes and alerts for unexpected delays.

What is the final step in the papermaking process before the paper reaches the customer?

The final step in the papermaking process is the finishing area, where paper is prepared according to customer specifications, packaged, and shipped as finished rolls or sheets.

Outlines

00:00

🌲 Introduction to Pixel Specialty Solutions and Sustainable Forestry

Pixel Specialty Solutions is introduced as a leading supplier of specialty papers with over a century of experience. The company prides itself on crafting high-quality paper products and providing exceptional customer service. The script takes the viewer on a tour of the paper-making process, highlighting the company's commitment to sustainable forestry and environmental responsibility. Pixel's paper-making process begins with trees, emphasizing their dedication to sustainable forestry practices, being the first to develop sustainably managed forests in Pennsylvania and Maryland. They have invested over 100 million dollars to transition from coal to natural gas, reducing carbon emissions. The script also explains the difference between hardwoods and softwoods and their respective uses in paper production.

05:02

🏭 The Paper Making Process from Wood to Pulp

This paragraph delves into the paper-making process starting in the wood yard, where logs are unloaded, debarked, and chipped. The process differentiates between hardwoods and softwoods, which are handled separately to isolate wood fibers for the pulping process. The chips are screened for uniform size, with undersized chips and other waste used as biofuel. Pre-cut chips are also used, bypassing the wood yard operations. The pulping process begins in a digester, where wood chips are cooked with white liquor to dissolve lignin, separating cellulose fibers. The resulting pulp is washed and undergoes oxygen delignification and bleaching to achieve a white color suitable for paper products.

10:05

📄 Paper Production: From Pulp to Finished Sheet

The paper production process is detailed, starting with refining the pulp to create a blend of softwood and hardwood fibers, which are mixed with fillers and dyes to improve the paper's characteristics. The blend, known as furnish, is spread onto a moving wire mesh to begin forming the paper sheet. Water is drained off through gravity and vacuum, and the paper sheet is pressed and dried to reduce moisture levels. Additional treatments like starch application can be used for a smoother surface. High-tech scanners monitor the paper for quality, and the finished paper is wound onto large spools, then slit and rewound for easier transportation and further processing.

15:05

📦 Finishing and Shipping of Paper Products

The final paragraph covers the finishing area where paper is prepared according to customer specifications and shipped as finished rolls. The rolls are wrapped for protection and labeled before being transported to the customer. Excel has implemented a supply chain visibility platform, allowing customers to track their shipments in real-time. The company's nationwide reach and broad product portfolio, along with experienced customer service teams, ensure efficient delivery and satisfaction. The script concludes by emphasizing Pixel's long-standing heritage in papermaking and their commitment to being a supplier of choice for customers.

Keywords

💡Specialty Papers

Specialty papers refer to a category of paper products that possess unique properties or characteristics tailored for specific applications, differentiating them from standard paper types. In the video's context, Pixel Specialty Solutions prides itself on crafting these high-quality, specialized paper products, showcasing their expertise and the diverse range of applications their papers serve.

💡Customer Service

Customer service is the assistance and advice provided by a company to those people who buy or use its products. The script emphasizes Pixel's commitment to 'unparalleled customer service,' indicating that the company values a high level of support to maintain strong relationships with its clientele and ensure their satisfaction.

💡Sustainable Forestry

Sustainable forestry is the practice of managing forests in a way that meets the needs of the present without compromising the ability of future generations to meet their own needs. The video highlights Pixel's dedication to this principle as they were the first to develop sustainably managed forests in Pennsylvania and Maryland, ensuring responsible timber harvesting and minimizing environmental impact.

💡Pulp and Paper Mills

Pulp and paper mills are facilities that process wood into pulp and then into paper. The script mentions Pixel's fully integrated mills located in Spring Grove, Pennsylvania, and Chillicothe, Ohio, which are central to their operations, combining paper and print with interactive technology to deliver a unique customer experience.

💡Environmental Footprint

The environmental footprint refers to the impact that human activities have on the environment in terms of carbon emissions, waste, and resource consumption. The video script describes how Pixel has invested over 100 million dollars to transition from coal to natural gas, reducing their carbon emissions and overall environmental footprint, demonstrating a commitment to sustainability.

💡Forestry Certification

Forestry certification is a system that verifies that forests are managed in a sustainable way. The script notes that Pixel's Pennsylvania mill was one of the first to achieve 'triple chain of custody forestry certification,' from recognized organizations, which assures customers of the company's responsible forestry practices.

💡Pulping Process

The pulping process is the method by which wood is converted into pulp, the primary material used in papermaking. The script details this process, starting from the woodyard where wood is chipped and screened, to the digester where the lignin is removed, resulting in the production of pulp that is essential for making paper.

💡Bleaching

Bleaching is the process of brightening the natural brown color of the pulp to a white color suitable for various paper products. The video explains that most U.S. mills, including Pixel, use elemental chlorine-free (ECF) chemicals for bleaching, an environmentally friendly approach to achieve the desired color for printing and writing papers.

💡Paper Machine

A paper machine is the equipment used to form the pulp into a continuous sheet of paper, extracting water to produce a dry sheet. The script describes the paper machine as an oversized dryer, with examples of its size and speed, such as the one located in Chillicothe, Ohio, which is as long as four football fields and operates at over 5,000 feet per minute.

💡Finishing Area

The finishing area is where the paper is prepared according to customer specifications, packaged, and shipped as finished products. The script explains the various processes in this area, including the application of watertight wraps, the use of high-tech scanners to detect defects, and the conversion of rolls into sheets if required by the customer.

💡Supply Chain Visibility

Supply chain visibility refers to the ability to track and monitor products throughout the supply chain. The video mentions that Pixel has invested in FourKites, a supply chain visibility platform, allowing customers to track their shipments in real-time and receive updates, enhancing communication and ensuring timely delivery.

Highlights

Pixel Specialty Solutions is a leading supplier of specialty papers with over a century of experience.

The company is passionate about crafting high-quality paper products and providing exceptional customer service.

Pixel operates fully integrated pulp and paper mills in Spring Grove, Pennsylvania, and Chillicothe, Ohio.

They offer a diverse portfolio of specialty products and highly customized solutions.

Pixel combines paper and print with interactive technology for a unique customer experience.

The company has a long-standing commitment to sustainable forestry and environmental protection.

Invested over 100 million dollars in transitioning from coal to clean burning natural gas to reduce carbon emissions.

Certified foresters assist with individual tree selection and work closely with private landowners for responsible timber harvesting.

Pixel's Pennsylvania mill was one of the first to achieve triple chain of custody forestry certification.

The papermaking process begins with tree classification into softwoods and hardwoods based on leaf type.

Timber is graded into different sections for various applications such as furniture, pallets, and paper production.

The wood yard is where logs are debarked, chipped, and screened for uniform size, crucial for pulping.

Bark and other residues are used as biofuel, generating 40% of the mill's electricity.

The pulping process involves separating cellulose fibers from lignin using a digester and white liquor.

Oxygen delignification and bleaching are used to brighten fibers and minimize environmental impact.

Pulp refining shortens and frays fibers to create contact points for easier connection and intertwining.

Blending softwood and hardwood fibers with fillers and dyes produces papers with a range of physical characteristics.

The paper machine extracts water from the furnish to produce a dry sheet of paper, traveling at high speeds.

High-tech scanners monitor paper quality, detecting even the smallest defects at high speeds.

Finished paper rolls are slit, rewound, and prepared according to customer specifications for shipping.

Pixel has a nationwide reach with warehouses for next-day service on stock items and a broad product portfolio.

The company's heritage in papermaking spans over 150 years, with ongoing investments for long-term success.

Transcripts

welcome to pixel specialty solutions a

leading supplier of specialty papers

with over a century of experience here

at pixel our people are passionate about

crafting the finest paper products and

take pride an unparalleled customer

service whether it's our diverse

portfolio of specialty products or

highly customized solutions pixel has

the experience and technical

capabilities to meet your growing

demands and it all happens at our fully

integrated pulp and paper mills in

Spring Grove Pennsylvania and

Chillicothe Ohio I invite you to explore

our paper making process as we combine

paper and print with interactive

technology to deliver a truly unique

experience your journey will take you

through our Woodyard into our pulp mill

and across a paper machine that

stretches more than four football fields

in length throughout the tour you'll see

how our commitment to continuous

improvement has helped minimize our

environmental footprint and position the

company for long-term success we hope

you enjoy your tour and we thank you for

your time welcome to pixel

the paper making process begins with

trees in our long-standing commitment to

sustainable forestry as the first to

develop sustainably managed forests in

Pennsylvania and Maryland are

established policies and procedures

ensure that we conduct business in a

manner that protects the environment and

reduces energy consumption natural

resource consumption and waste in

support of this commitment we have

invested over 100 million dollars to

transition mill operations from coal to

clean burning natural gas to reduce

carbon emissions and further minimize

our environmental footprint in the

forests our certified foresters assist

with individual tree selection and

thinning and work closely with private

landowners and developers to ensure the

responsible harvesting of timber they

also provide expertise to help minimize

impacts on the surrounding environment

when harvesting trees timber is

classified into soft woods and hardwoods

a simple way to identify the difference

is to remember that hardwoods have

leaves while soft woods have needles

when inspecting a hardwood tree such as

oak maple and ash the tree is divided

into three sections or grades based on

diameter the first grade is referred to

as Vanir Vanir is obtained from the

widest section of the tree and used to

produce furniture flooring and cabinetry

the second grade called low grade spans

the midsection of the tree and is used

to produce shipping pallets railroad

ties and rough cut timber frames for

barns

the third and final grade spans the

upper section of the tree diameters

between 4 inches and 12 inches this

grade is called tough wood and it's used

to make paper soft woods on the other

hand such as pine and spruce are divided

into two sections for grades the first

grade is called construction lumber and

is used for decking boards two-by-fours

for homes and treated lumber the second

grade is classified as both wood and is

used to make paper for those requiring

forestry certification our pennsylvania

mill was one of the first to achieve

triple chain of custody forestry

certification in the u.s. from the

Forest Stewardship Council the

sustainable forestry initiative and the

program for the endorsement of forest

certification today both mills offer

forestry certifications across our broad

portfolio of products for more

information or to obtain copies of our

forestry certificates please visit pick

Cellcom

[Music]

in an integrated pulp and paper mill the

process of making paper begins in the

wood yard here

what is unloaded debark chipped and

screen wood is delivered to the mill in

two forms as logs known as round wood

and as pre-cut chips during unloading

all round wood is separated and stacked

into softwood and hardwood piles so that

wood fibres can be isolated later in the

pulping process trees with needles such

as pine and spruce are stacked in the

softwood pile while trees with leaves

such as oak maple and ash are stacked in

the hardwood section round wood begins

its journey on a long conveyor belt and

it makes its way towards the debarking

drum as it drops in the drum logs

tumbled together until the bark is

stripped holes in the drum allow the bar

to fall and be reclaimed for use as an

environmentally friendly biofuel logs

continue their journey as they are fed

into an industrial chipper where they're

converted into 1 inch by 1 inch square

chips in a matter of seconds chips are

then sent through a screening process to

remove any irregularly sized chips a

uniform chip size is important later in

the pulping process because it increases

the yield and quality of wood fiber

produced during screening undersized

chips and sawdust are removed and sent

to a power boiler along with bark from

the debarking drum where they are used

as biofuel to generate clean burning

electricity to power the mill as well as

residential houses in fact 40% of the

mills electricity comes from this

biofuel to help supplement the demand

for wood pre-cut chips are delivered in

trucks

these chips bypass the Woodyard

operation as they are unloaded and sent

directly to screening here trucks are

tilted on a steep 60 degree angle to

expedite the unloading process once

screen chips remain separated and are

transferred into hardwood and softwood

piles where they wait to enter the

pulping process now that round wood has

been chipped and screen chips can enter

the pulping operation so that cellulose

fibers can be separated from the lignin

or gluey substance that hold the fibers

together

[Music]

the pulping process begins in the

digester where wood chips are

transported on a conveyor belt to either

a batch or continuous digester chips

along with white liquor are fed into the

top of the digester as the mixture makes

its journey downwards liquor is heated

to 170 degrees Celsius to begin the

cooking process under pressure and heat

the white liquor dissolves or digests

the lignin that holds the individual

cellulose fibers together several hours

later this process is complete the

result is a massive fibers called pulp

pulp from the digesters along with spent

cooking chemicals now called

black liquor are sent to the washing and

screening area so the black liquor and

undigested wood such as knots can be

washed away from the pulp

at this stage an additional process

known as oxygen delignification occurs

this process uses oxygen and white

liquor along with steam to remove any

remaining lignin and extract some color

from the pulp so that less chemicals are

needed during bleaching next pulp enters

the bleaching area to be brightened

bleaching occurs in multiple stages as

it takes the fibers from their natural

brown color called brown stocks to white

today most US Mills use elemental

chlorine free or ECF chemicals for

bleaching a more environmentally

friendly process without bleaching all

printing and writing papers would look

like a brown grocery shopping bag and

would not be suitable for use in books

business forms envelopes and other

printing papers the fibers are now ready

to make paper until now everything is

focused on producing the pulp needed to

make paper now we're ready to refine the

pulp blend in the fillers and dyes and

send the mixture or furnish through the

paper machine in its simplest form a

paper machine is like a giant oversized

dryer extracting water from the furnish

to produce a dry sheet of paper paper

machines can be as small as a bowling

alley or as long as four football fields

paper traveling at speeds up more than

5,000 feet per minute

for nearly 60 miles per hour shown here

is the chief located in Chillicothe Ohio

the first step in our paper making

process is to refine the pulp in

refining pulp fibers are shortened and

frayed to create additional contact

points with the fibers to more easily

connect and intertwine because softwood

fibers are long they will naturally have

more contact area thereby imparting

strength to the finished sheep hardwood

fibres however are short allowing them

to pack closer together creating bulk

smoothness and opacity blending these

fibers together in specific proportions

provides the ability to produce papers

with a wide range of physical

characteristics it is for this reason

that soft woods and hardwoods have been

isolated throughout the entire process

for the first time hardwood and softwood

fibers are pumped into a blend chest

where they are finally mixed together

along with fillers such as clay calcium

carbonate and titanium dioxide to

improve surface and optical properties

other chemicals may also be added

including sizing agents to control the

penetration of liquids and optical

brighteners and dyes to enhance visual

properties this blended mixture of fiber

and additives is called the furnish

the furnish flows from the blend chest

into the head box and been onto a moving

wire mesh called the foreign ear section

when the furnish hits the wire mesh it

is approximately ninety nine and a half

percent water and one-half percent fiber

filler and additives as this mixture

travels across the rotating mesh water

drains under simple gravity to help

remove additional water improve fiber

formation and avoid to sidedness a top

wire former is used to suction water

from above the mesh as the intertwined

fibers reach the end of the ford Rainier

they hit one more dewatering device

called the couch roll before lifting for

the first time as a solid sheet of paper

at this point the newly formed paper is

85% water the wet paper passes through a

series of rollers and felts called the

press section reducing moisture levels

to roughly 65 percent it Ben travels

through a series of dryer cans each

filled with steam heat from the steam

drives off additional water resulting in

a final moisture profile of about four

to five percent water along the way

starch can be applied as paper passes

the Desai's press starch helps fill

microscopic ridges in the paper and

provides a smoother surface for enhanced

credibility in fine printing and writing

papers as paper reaches the end of the

machine it passes through high-tech

scanners that look for variations in

faces weight moisture caliper opacity

brightness and physical defects like in

the scanning system on the chip is so

exact that it can spot a single hole the

size of a pin across a 300 inch width

web of paper traveling 40 miles per hour

and it can tell you where in the

finished role that is located so it can

be removed as paper reaches the end of

the Machine it is wound onto a large

steel spool capable holding over 15 tons

when the spool reaches capacity the

resulting roll of paper called a log

roll or jumbo roll is slit into smaller

sections and rewound unto thick

cardboard cores so it can be transported

more easily to the wrapping station or

to other locations in the mill for

further processing

[Applause]

[Music]

in the finishing area paper is prepared

according to customer specifications

packaged and shipped as finished rolls

leave the paper machine they are

transported to a packing station where

they receive a watertight poly wrap or a

moisture resistant craft wrap at the

craft wrapping station rollers spin the

paper and apply the wrap fluted

cardboard covers are placed against each

side of the roll while spinning the

edges are folded and glue is applied

thin cardboard caps called end caps are

carefully pressed onto both sides using

heated steel plates the roll receives a

finished label and is ready for

transport to the customer for customers

requiring sheeted product we have the

ability to convert rolls into a wide

variety of sizes shown here are white

canary and pink carbonless rolls as all

three unwind the paper enters the

sheeter where a rotating blade cuts the

paper and stacks them into reams the

reams take a journey across conveyor

belts where they receive a moisture

resistant wrap and product label finish

dreams are then packaged into cartons

and shipped to the customer

in the shipping department rolls are

carefully loaded onto trailers using a

specialized clamp truck capable of

grabbing lifting and if necessary

rotating rolls without damaging the

paper to help improve visibility and

increase safety all clamp trucks are

affixed with blue lights that can easily

be seen around corners and in

high-traffic areas to help improve on

time delivery and enhance customer

communications excel has invested in

four kites the largest supply chain

visibility platform with over 4 million

GPS electronic logging devices across

all modes of transportation with four

kites customers can easily track their

shipments 24 hours a day seven days a

week with information updates every 15

minutes the platform can even provide

alerts when unexpected delays occur in

transit

in addition Excel has a nationwide reach

with warehouses across the country able

to ship over 90% of the US with next day

service on stock items all this is

backed by one of the broadest product

portfolios and experienced customer

service teams located on-site

at each mill

at pixel we have a proud heritage of

papermaking that spans more than 150

years our continued investments in the

business that positioned us for long

term success that could strive to be

your supplier of choice thank you for

taking the time to tour our facilities

we hope you enjoy the tour and we look

forward to your continued support

[Music]

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