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to the mill, Disley Tissue are able to recycle over 55% of it – which equates to 50,000Te per year, the equivalent of 10 billion pieces of A4 paper!

The recycled paper is manufactured

It’s not often I have the opportunity to visit many facilities but, when I received an invite to tour the Disley Tissue paper mill, I jumped at the chance, having never visited a paper mill before.

A little history... Back in 1800, the mill was built on the current site, as a cotton mill for the area. By the mid 19th Century, it was developed into a coated paper manufacturing site. In 1993, it was then purchased by Kruger and, following a £25million investment, it was transformed into a tissue making and de-inking site.

In 2009, both Disley Tissue and its sister company, Connect Hygiene Products (formerly known as Kruger Tissue) were purchased by Northwood Paper, which leads us to today...

Manufacturing today The mill recycles office waste paper, from newspapers, pamphlets, magazines and certain parts of office waste, making it an FSC certified facility. Amongst the waste produce that is sent

both internally and externally, primarily as the parent reel production for Connect – with 60- 70% of the paper going to Connect for conversion.

As well as recycling paper produce, the mill also recycles water, through its onsite water treatment and effluent plant. The treated water is then returned to the River Goyt, in a better condition than it began! The dewatered sludge (the dried inks removed at the cleaning stage) is also sold on to the agricultural industry to be used as fertilisers.

How paper is made... •Waste paper is loaded onto a conveyor belt and taken to the pulper, where water is added to produce the pulp.

•The pulp is thoroughly mixed together, which takes approximately 30 minutes.

•This is then transferred to the pulper chest - a large tank, which holds the pulp until it can be cleaned.

•When the pulp has been cleaned it is

24 | TOMORROW’S CLEANING | The future of our cleaning industry FEATURE

transferred to the machine chest, where the fibres are modified using a disk refiner to give us the characteristics required in the finished tissue.

•It then goes through the final cleaning process to remove any small contaminants that may be left. This paper will have a speckled appearance, as it is completely bleach and chemical free.

•The pulp is then carried along to the paper machine where it is diluted with water before being formed between the wire and the felt.

•The water is then removed to enable the tissue to stick to the felt so it can be carried to the drying section.

•It is then pressed against a large rotating cylinder that is filled with steam to aid drying. As the cylinder rotates it passes through a gas fired, heated hood, which reaches temperatures of up to 500 degrees!

•When the tissue is dry, it’s removed from the cylinder using steel blades. The tissue is then transferred onto a rubber-coated bar to make one large reel.

•When the roll is big enough, it is transferred to a rewinder, where two or more rolls can be plied together. Here, it can also be cut to any size that the customer requires.

•Then they are shrink-wrapped to protect them from moisture and damage.

And that, dear readers, is all there is to it! Make sure you watch the video to see for yourself!

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