Welcome to Disley Tissue

1
Welcome to Disley Tissue
2
A brief history

• 1800 - cotton mill built on current site
• Mid 19th century - developed into a coated paper
  manufacturer
• 1993 Kruger purchase
• 1996 25m investment in tissue making and
  de-inking with integrated effluent and utilities
• 2009 Northwood Paper purchase
• 2012/3 50m investment in site redevelopment
  and second paper machine

3
Disley Manufacturing Today

• Recycling of office waste paper
• Manufacture and sale of de-inked pulp
• Internal use on the paper machine
• External sales to other customers
• Tissue making
• Parent reel production for sales to sister
  company, Connect Hygiene Products Ltd
• Outside sales to UK and export market
• 30,000 tonne annual production
• Water recycling
• Return of water to the River Goyt
• FSC certified facility
• Helping with the responsible management of world
  forests

4
Waste Paper

• Collected from offices across the UK by waste
  paper merchants
• Use 50,000Te per year
• 10 billion pieces of A4 paper
• Sorted, baled, delivered to Disley Mill by the
  merchants
• Dyed paper and/or printed with ink
• With staples, plastic covers, grit, sellotape,
  book bindings and labels etc.
• Includes brown envelopes and other non-bleachables

5
How paper is made

• The waste paper is loaded onto a conveyor belt
  ready to be carried to the pulper.
• Water is then added to the pulper along with the
  waste paper where it is broken down to form a
  pulp.
• When the pulp has been thoroughly mixed together,
  which takes approximately 30 minutes we are then
  left with a consistency similar to that of
  porridge.

6
How paper is made

• The pulp is then transferred to the pulper chest.
  This is a large tank which holds the pulp until
  it can be cleaned to remove contaminants such as
  ink, grit staples etc.
• When the pulp has been cleaned it is then
  transferred to the machine chest. The fibres are
  then modified to give us the characteristics
  required in the finished tissue - strength,
  softness etc This is done by using a disc
  refiner.
• The disc refiner works by allowing the pulp to be
  passed between two steel discs, one of which is
  rotating. The effect of the fibres rubbing
  together promotes fibre fraying and splitting.

7
How paper is made

• When the fibre has been modified it then goes
  through the final cleaning process to remove any
  small contaminants that may be left.
• The pulp is then carried along to the paper
  machine were it is diluted with water before
  being formed between the wire and the felt.

8
How paper is made

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

9
How paper is made

• When the tissue is dry it needs to be removed
  from the cylinder this is done by using steel
  blades. The tissue, which has now been removed,
  is 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. At this stage we can also cut the roll
  to any size the customer requires.

10
How paper is made

• The rolls are then shrink-wrapped to protect them
  from moisture and damage.
• When the rolls have been wrapped they are then
  transported to the customer for conversion into
  finished products.

11
Water and waste by-products

• Disley Tissue has its own on-site water treatment
  and effluent plant, where water used in the paper
  making process is treated before being returned
  to the River Goyt, from where it originally came.
• Dewatered sludge (the dried inks and other dirt
  contaminants removed at the cleaning stage) are
  sold to the agricultural industry to be used as
  fertilisers. 40,000 Te per annum are removed from
  site.

12
Visit Safety

• Our objective is to have a safe and incident free
  visit
• Hazards include
• Fork Lift Trucks
• Activity around the paper machine including use
  of strobe lights
• Overhead working, for example cranes
• Slippery floors
• Noise
• For your safety we ask that you
• Stay with your tour guide
• Wear fluorescent jackets
• Use the hearing protection provided
• This is a no-smoking site
• The Fire Alarm is a continuous tone muster at
  the car park