COMMERCIAL PRINT

Paper Substrates

Mark CupachDirector, National Sales

BASICS OF PRINTING

1Todays session addresses an element of the printing process common to all printing and thats the paper we put ink on.For years, the selection of substrates was limited to different types of paper. Today, printers can now put ink on synthetic papers, vinyls, plastics and other surfaces.This session will address only paper.how it is made.how it is measured.paper types and the characteristics that make paper types differ.Paper QuizDoes most of the paper made in the U.S. come from whole trees?

2Lets take a quick POP quiz to see what you already know about paper.

Read QuestionPaper QuizDoes most of the paper made in the U.S. come from whole trees?

No. Over 50% comes from recovered paper and wood waste from lumber manufacturing

3Its a big misconception that the paper industry is chopping down all the trees in America to make paper. Over 50% of the materials to make paper today come from two sources, one is the recycled papers market and the other is from lumbar mill waste.Todays technology has maximized the use of our natural resources. Over 99% of every tree harvested is used in one form or another. Much of the bark taken off a tree before cutting the wood is used as fuel to fire the paper and lumbar mills.Paper QuizAre we running out of trees in the U.S.?

4Read question.

Paper QuizAre we running out of trees in the U.S.?

No. In fact, there are MORE trees in the U.S. today than there were 70 years ago.

5Again, if you believe the more radical conservationists, you would believe that there will be no more trees for our children and grandchildren to enjoy. Today, there are MORE trees than there were in 1936.Most of the damage being done in the world is in South America where the rainforests are being defoliated, not for paper making, but for the huge population increases happening there and the need for cleared land for housing and fuel.Paper QuizHow much paper is used by the average U.S. person in one year?450 pounds700 pounds900 pounds1200 pounds

6Read Question.Paper QuizHow much paper is used by the average U.S. person in one year?

700 pounds per person

Every year, printers publish 2 billion books, 350 million magazines and 24 billion newspapers.

7The answer is Beach person in the US, on average, uses about 700 pounds of paper.

2 billion books350 magazines, of which my wife and daughter get half of.And 24 billion newspapers.a lot of paperPAPER MANUFACTURINGOVERVIEWPulp + Water + Fillers + Bleaches + Heat + Compression = PAPERFollow the ReceipeOutput onto WEB rollsORCut to order for paper distributors or printers

8Paper is made of wood pulp, water, fillers and bleaches amoung other ingrediants. Heat and paper forming compression is applied to finish making paper.All papers are made by following a specific receipe. Just the right amount of pulp, water, bleaches and chemicals with coloring agents need to be exactly followed to get the intended final paper type.

Paper mill machines output finished paper onto huge Web rolls and those rolls are then cut to order.

Mill customers are generally Paper Distributors unless they are fully integrated companies like Weyerhauser or International Paper who sell paper directly to printers/distributors as well as trade paper distributors.

Paper Mill

9Here, we see an external image of a paper mill. Mills are huge factories where specific kinds of paper are produced.

There are uncoated paper mills

Coated paper mills

Carbonless paper mills

all making a specific kind of paper.

STARTING THE MIX

10This diagram shows the start of the paper making process. Wood pulp, either processed mechanically or chemically, is added to water and other specific ingrediants to create a slurry that is almost all water and looks a lot like the oatmeal your mom used to make you eat on cold winter mornings. The slurry is poured from the headbox where it is about 99% water onto a moving belt of fine wire mesh.From that point on, the paper-making process starts reducing the water content. The first roller it passes under is the dandy roller that can imbed a watermark into the paper if required.After the paper hits the couch roller, it is about 50% water and is capable of supporting itself. The second and smooth presses are where different finishes like felt can be applied to the surface.The paper now will enter the main drying section.

TAKING THE WATER OUT

11As the paper feeds thru heated drums in the main drying section, the overall water content reduces from 50% down to about 12% as it enters the size press section where surface sizing is applied to the surface of the paper to add strength and to prevent events paper related problems like feathering and surface picking when ink is applied. Feathering occurs when ink fans out on the sheet and picking occurs when the ink does not dry sufficiently and pulls the surface of the paper away from the body of the paper.If the paper is to be coated.it enters the coater section where a fine layer of clay is applied to either one or both surfaces.The paper then enters the afterdry and calendar sections.

12Here is a photo of the paper web running thru a section of the mill.

FINISH AND SIZING

13The paper enters the calendaring section of the paper-making process. Here, the calendar presses and rollers control the exact caliper, smoothness and gloss level of the paper.A quality sensor monitors all facets of the production to insure the exact specifications required.

At this point, as the paper enters the winding section to be rolled onto large cores, the papers water content has been reduced to about 5-6%.

The Large Web rolls are then either slit into smaller rolls, or taken to a sheeter to be cut to order.

14Here, workers roll large rolls of stock into position for storage and finishing.

PAPER CHARACTERISTICSOpacityThe See-Through factorWhitenessAffects the brilliance and contrast of inkFinishLaid / Wove / Linen / FeltBrightnessMeasured numerically

15Other characteristics include

Opacity.or the ability to see thru the paper to the printing on the other side.

Whitenessit affects the brilliance and contrast of ink. As you gain experience in dealing with paper, you will find that there are many many shades of white when it comes to paper whiteness. The perception of ink colors change based on the whiteness type of the stock it is printed on.

The finish of a paper can affect how an ink color is perceived. Some popular paper finishes include Laid, Wove, linen and felt finishes.

Brightness.measured numericallya 92 white is better than an 84 white.and so on..

PAPER WEIGHTSBASIC SIZES

OFFSET AND COATED TEXT--25X38COVER STOCKS--20X26BONDS--17X22TAG AND NEWSPRINT-- 24 X 36

16Paper is measured in weights and point sizes. To get to the proper weight or point size, it is necessary to know that there are basic sizes for paper in the manufacturing process

read to chart..

The specific weight designation of a paper is directly linked to the basic size. For example. Lets say we are making 20# white bond paper at the mill today. When it comes off the mill web, how do we verify that it actually is 20#? We cant do it by thickness of paper because that is not exactly relative to weight.What we do is cut 500 sheets of the paper off the roll at its basic size which in this case is 17 x 22We take the 500 sheets and put them on a scale

next slidePAPER WEIGHTSBASIS WEIGHT

EQUALS THE WEIGHT OF 500 SHEETS OF A PARTICULAR PAPER TYPE, SIZED AT ITS BASIC SIZE.

17We read the scale and determine that the 500 sheets we cut off the roll.at 17 x 22weighs 20#..

Now, we know that the guys who made the paper followed the reciepe correctly and the machine was set up the right way.

18Visually, you see here what we mean when we say a paper weighs a certain weight.If we were making 20# bond, if we followed the reciepe correctly in the mill, then when it comes off the paper mill process, when we cut it at 17 x 22 and put 500 sheets on a scale, it better come out at 20#.

Same with the 24#.UNCOATED STOCKSREGULAR OR OPAQUE GRADESTEXT WEIGHTS(AKA Book)50# 60# 70# 80# -- Most CommonCOVER WEIGHTS65# 80# 100# -- Most CommonWRITING PAPERS (Stationery)Text and Cover weightsFinishes and wide variety of colorsMatching envelopes

19Uncoated Stocks can be separated into two groupsregular offset papers and Opaque papers

Regular offset stocks come in various weights and sizes, on rolls, and in sheets. The first category is Text weights, also known as Book weight stocks.Heavier stocks are known as cover weights with the most commonly used weights of 65, 80 and 100 pound

Writing papers come in a variety of colors and wide array of finishes like wove, linen, felt. There are an endless number of type, weight and color/finish combinations to choose from.

most of the writing text papers come with matching envelops and are used in projects like stationery, invitations, report covers and presentation folders.COATED STOCKS3 COATED FINISHESGLOSS / DULL / MATTETEXT WEIGHTS60# 70# 80 # -- Most CommonCOVER WEIGHTS60# 80# 100# -- Most CommonBoard Weights8 Pt. 10 Pt. 12 Pt. 14Pt -- Most CommonCoated One Side (C1S)Coated Two Sides (C2S)BEST FOR PROCESS COLOR PRINTINGBEST FOR VARNISH/AQUEOUS/UV COAT

20Coated papers have a clay coating applied to one or both sides of the sheet. They come in 3 distinct finishes.gloss, which reflects light in straight lines,dull gloss that reflects light in a scattered fashion and matte finish that actually absorbs more light than it reflects..Each type of finish reflects light differently.giving each its own distinctive look.When cover weights get too heavy, they are referred to in Board thickness sizes. The most common used board stocks are 8, 10, 12 and 14 point. A point is one thousandth of an inch. These stocks are either coated on one side or both sides. Single coated stocks, or c1S as they are referred to, are used to produce presentation folders.

Coated Stocks are best for full color printing.Stationery Product ApplicationsBusiness CardsStandard StocksCustom Stocks

Letterhead and EnvelopesStandard vs CustomMatching stocks for ensemble

21In the Stationery business, we use a lot of different types of stocks. BSI alone carries well over 200 different types of stock on our shelves to accommodate the needs of our customers.When you talk about stationery stocks, pricing is differentiated between standard stocks that are relatively common and purchased in large quantities, and custom stocks that are premium priced.PAPER RECAPPaper RecipesPaper CharacteristicsBasic SizesBasic WeightsPaper Types

22To summarize,

Each paper, and there are literally hundreds of types and weight combinations, have a specific reciepe to follow during the paper-making process.Each type of paper has unique characteristics like Opacity, runnability, whiteness, brightness and finish that make it different. A customers perception of an ink color can change based on the type of paper it is laying on..Paper is measured using the basic size established by the type of paper.

500 sheet of paper.cut at its basic size.needs to weigh exactly what its weight designation specifies. If our reciepe called us to make 20# bond, then 500 sheets cut at 17x22 should weigh 20 pounds.

There are many paper types.most jobs will have the paper specified already for you to quote on..Business Stationery hopes you have gained some knowledge about paper and how it plays a critical part in delivering a quality job to your customers.