Paper360 - May/June 2017 - 14

The paper machine running red. On average, there are six to eight changes daily, although Schelling
has seen as many as 11.

The inline size press was a later modification to the 1930s-era machine.

The stock prep room has two washers (foreground), a breaker, and two Bertram beaters.

14

Paper360º

MAY/JUNE 2017

fiber and is looking at wheat, hemp, jute, and
banana fiber.
"With all the grades we make and the fiber
we use, we need to concentrate on fiber preparation-for example, refiner plate design. Are
we optimizing the properties of the fiber we
have?" Schelling explains.
The stock prep room has two washers
(although only one is needed at a time), a
breaker (for cotton rag), and two Bertram
beaters. There are DD refiners, although one is
dedicated to the production of cellulose nanofibers (CNF), part of the mill's research group.
As a custom papermaker, Turners Falls
must adapt to numerous grade and color
changes daily. It specializes in small runs, as
low as 3,000 lbs; for example, a facing paper
run is usually 3,000-5,000 lbs, and takes about
two hours of machine time. Basis weights
range from 40 to 550 g/m2.
As Schelling says, the biggest challenge with
small runs is minimizing unsalable paper and
maximizing machine uptime; "On a good
change, we can be on spec in 20 minutes." On
average, there are six to eight changes daily,
although Schelling has seen as many as 11.
The mill's operators' experience helps. "We
set up runs to minimize dramatic changes,"
Schelling adds. For example, in one day in
March 2017, the machine went from making
blue paper to red to pumpkin to gold.
The critical objective is to set the desired
color in the pulper-that is, doing the color
match work ahead of the paper machine. "We
don't want to 'chase' the color in the wet end,"
Schelling says. "Otherwise, you can change the
wet end chemistry."
Along with the colored paper, Turners Falls
makes a wide range of papers, as can be seen
by the basis weight range: artist paper, vellum,
museum boards, Bristol, vellum sheets (there
is an offline Maxson sheeter), watermarked
paper, and envelope (this is converted at an
off-site facility).
Annual tonnage depends on basis weight.
"Our niche is smaller runs, 3,000-5,000 lbs,"
Schelling adds. The ability to change rapidly
and produce such a diversity of grades came
about because "We were able to define the
capabilities of the paper machine."
Although the sheeter is available, about
70-80 percent of production is shipped as rolls.
Employment at the mill numbers about
60, with a good mix of experience and youth,
according to Schelling. Finding employees
can be a challenge, as unemployment in the
area is low.
www.tappi.org


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Table of Contents for the Digital Edition of Paper360 - May/June 2017

Setpoint
Over the Wire
Leadership for a Changing Industry
An Ode to Small
The Graying of the Paper Industry
Suppliers Reach Out to Mill Leaders
Making a Difference: 2017 TAPPI/PIMA Awards
RISI’s Asian CEO of the Year
TAPPISAFE Offers Solid Benefits for Mills, Contractors
Reinventing Varkaus
Failure Isn’t Just an Option—It’s Unavoidable
Blower Technology Proves Its Worth
TAPPI Journal Summaries
Global Study: Most People Highly Value Paper and Print
The Changing World of OCC
TAPPI News
ASPI News
Index of Advertisers
Paper360 - May/June 2017 - intro
Paper360 - May/June 2017 - ebelly1
Paper360 - May/June 2017 - ebelly2
Paper360 - May/June 2017 - cover1
Paper360 - May/June 2017 - cover2
Paper360 - May/June 2017 - 3
Paper360 - May/June 2017 - 4
Paper360 - May/June 2017 - 5
Paper360 - May/June 2017 - Setpoint
Paper360 - May/June 2017 - 7
Paper360 - May/June 2017 - Over the Wire
Paper360 - May/June 2017 - 9
Paper360 - May/June 2017 - 10
Paper360 - May/June 2017 - 11
Paper360 - May/June 2017 - An Ode to Small
Paper360 - May/June 2017 - 13
Paper360 - May/June 2017 - 14
Paper360 - May/June 2017 - 15
Paper360 - May/June 2017 - The Graying of the Paper Industry
Paper360 - May/June 2017 - 17
Paper360 - May/June 2017 - Suppliers Reach Out to Mill Leaders
Paper360 - May/June 2017 - 19
Paper360 - May/June 2017 - Making a Difference: 2017 TAPPI/PIMA Awards
Paper360 - May/June 2017 - 21
Paper360 - May/June 2017 - 22
Paper360 - May/June 2017 - 23
Paper360 - May/June 2017 - 24
Paper360 - May/June 2017 - 25
Paper360 - May/June 2017 - 26
Paper360 - May/June 2017 - 27
Paper360 - May/June 2017 - RISI’s Asian CEO of the Year
Paper360 - May/June 2017 - 29
Paper360 - May/June 2017 - 30
Paper360 - May/June 2017 - 31
Paper360 - May/June 2017 - TAPPISAFE Offers Solid Benefits for Mills, Contractors
Paper360 - May/June 2017 - 33
Paper360 - May/June 2017 - Reinventing Varkaus
Paper360 - May/June 2017 - 35
Paper360 - May/June 2017 - Failure Isn’t Just an Option—It’s Unavoidable
Paper360 - May/June 2017 - 37
Paper360 - May/June 2017 - Blower Technology Proves Its Worth
Paper360 - May/June 2017 - 39
Paper360 - May/June 2017 - TAPPI Journal Summaries
Paper360 - May/June 2017 - 41
Paper360 - May/June 2017 - Global Study: Most People Highly Value Paper and Print
Paper360 - May/June 2017 - 43
Paper360 - May/June 2017 - 44
Paper360 - May/June 2017 - 45
Paper360 - May/June 2017 - The Changing World of OCC
Paper360 - May/June 2017 - 47
Paper360 - May/June 2017 - TAPPI News
Paper360 - May/June 2017 - ASPI News
Paper360 - May/June 2017 - Index of Advertisers
Paper360 - May/June 2017 - cover3
Paper360 - May/June 2017 - cover4
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