Hand Paper Making

Hand Papermaking
VITA
1600 Wilson Boulevard, Suite 500
Arlington, Virginia 22209 USA
Tel: 703/276-1800 * Fax: 703/243-1865
Internet: pro-info@vita.org
In many areas of developing countries paper is scarce.

Rural schools may not have enough paper for their students
and market goods may be wrapped in old newspapers if at
all. Often this is because resources are not available to
invest in modern papermaking factories, which require large
amounts of energy and raw materials if they are to be
economical.
But paper can be made in small shops in small quantities.

Access to electricity makes some of the steps easier, but
is not absolutely necessary. (Indeed, paper was made this
way for many years before electricity was discovered.) In a
situation where paper is scarce and expensive, it may be
worthwhile to consider small-scale papermaking as a source
of school supplies or as a small business. Such a business
might produce heavy coarse paper for packaging or even
thick paper egg cartons, plant pots, and so on.
PAPERMAKING PROCESSES
Whether paper is made in a home or school workshop or a

small factory, the production processes for making paper by
hand are quite similar. The scale of the equipment changes
with the volume of production and the raw materials vary
with what is available and the quality of paper to be
produced.
Pre-processing
Cotton or other rags and waste paper to be recycled are

sorted thoroughly to remove all non-fibrous materials such
as staples, paper clips, cellophane, nails, buttons,
zippers, etc. Both rags and paper are cut or shredded into
small pieces.
Pulping
The cleaned and shredded raw materials are brought to the

boiling point and cooked for two to six hours. They are
rinsed thoroughly to remove impurities that might have
separated out during the cooking process.
The beater--this can range from a kitchen blender to a

specially made tank—is filled with the required quantity of
water, and the cooked, chopped rags or paper are added
gradually with high speed agitation. Bleaching powder or
liquid bleach (1 percent) is then added. The pulp is washed
thoroughly, a process that may take another six to eight
hours. Additives used may include titanium dioxide or other
fillers, dyes (for colored paper), or optical bleaching
agents (for white paper). Rosin soap and alum are added
later.
Lifting, Couching, and Stacking
When the pulp process is complete, the pulp is transferred

to storage containers or vats. Depending on the scale of
the operation, the pulp is then mixed with a sufficient
quantity of water to dilute it to form a uniform
suspension, free of lumps. In the home workshop, the pulp
is mixed in quantities to make one sheet at a time. In the
small factory, a larger quantity may be mixed at one time.
The diluted pulp is then lifted from the water on wire
screens, and the resulting sheets are covered by felt or
other absorbent cloth. With the cloth is place, the still
wet pulp layer is carefully lifted from the screen. This
process is called couching (pronounced cooching). The
couching cloth, paper side down, is placed on a felt
covered board and smoothed to remove wrinkles or air
bubbles. Each succeeding sheet is placed in a stack over
the first.
Pressing and Drying
When a sufficient number of sheets have been formed, they

are put under a press to remove the water. The sheets are
then separated and, to avoid shrinkage, placed under
absorbent boards and pressed again. The sheets are hung to
dry in bunches of three to six, according to thickness, or
dried in a warm oven.
Sizing
Sizing gives paper a harder finish so that water based

paints and inks will not bleed or run. Paper may be sized
internally, by adding the sizing agents to the pulp, or
2
externally, by painting or dipping the dried sheets. For
internal sizing, alum, rosin, gelatin, cornstarch, or
linseed oil may be added in very small quantities at the
end of the pulping stage. For external sizing, the dried
sheets are dipped in a dilute glue or starch solution,
pressed to remove the excess, and hung up to dry again. In
the home workshop, the individual sheets may be painted
with the dilute solution.
Blotting paper, filter paper, toilet tissue, grey board,

and some art papers may be require very little, if any,
sizing.
Calendering
The dried sheets are placed alternately between metal

plates into a stack or "post." The stack is passed between
calender rollers to obtain the desired smoothness. This can
be done in the home workshop by pressing the paper sheets
between sheets of aluminum foil with a hot iron.
Sorting and Cutting
After calendering, the sheets are carefully sorted and cut

to size for packing, storage, and/or shipment.
MAKING PAPER IN THE SMALL WORKSHOP
Papermaking at this scale can be done as hobby, for gifts,

or to supply schools. The necessary equipment may already
be available in some kitchens, but the markets should be
considered carefully before any investment is made.
This process assumes that waste paper or cotton cloth will

be used to make the paper. Approximately 50 sheets of
21.5cm x 28cm (8 1/2" x 11") paper can be made from a half
kilo (about a pound) of waste paper. Household bleach,
alum, gelatin, cornstarch, and animal glue may also be
needed. And ordinary fabric dyes can be used to produce
tinted or colored papers. As described here, the
availability of adequate water and electrical or other
power supplies is also assumed.
Equipment and Materials
The following equipment is needed:
3
Deckle box and mold, made of oiled wood (figure 1)
4
Power food mixer or blender
Stainless steel or enamel pot (not almuinum)
Steam iron
Stove with oven
Sink, tub or wash basin
Couching cloth (e.g., cotton sheeting), cut to size
Felt or absorbent terry cloth, cut to size
Thin metal sheet
Flat "receiving" board, 1cm (1/4") plywood or other board
Pulping
Choose paper with minimal printing. Old envelopes are good

for this reason; the glue on the flap won't matter. Colored
paper is acceptable; the dye usually comes out when it is
boiled. Avoid paper that has "wet strength" such as paper
towels. Be careful how many brown paper bags you use.
Unbleached kraft paper lowers the brightness or whiteness
of the pulp, but it is strong and will give your paper
toughness.
Newsprint alone makes a weak pulp, grey in color. It adds

little but bulk. Cotton or other cloth or yarns may also be
used. They must be cut or shredded into very small pieces
to avoid jamming the mixer.
Cut or tear the paper into small pieces, about 5cm x 5cm
(2" x 2"). Shred any cloth that may be used. Put the pieces
in the pot, cover with water, and add a few tablespoonfuls
of household bleach. Turn on the heat, cover the pot, and
bring to a gentle boil. Stir occasionally for a couple of
hours to ensure that the bleach is mixed and all the paper
is wetted down well, then cool.
After the batch has cooled, try to break up the lumps and
any remaining pieces of paper still holding together. The
smaller the pieces in the beginning, the easier this step
is now. (The pulp can then be drained and stored in plastic
bags in a refrigerator, if you have one, until you are
ready to make the sheets. It will keep for weeks without
any change.)
Making the Sheets
Take a lump of the semi-moist pulp you have prepared. Press

as much moisture out of it as possible to leave a ball
5
about the size of a pigeon egg (7g--1/4 oz--dry weight).
This is enough pulp to make one 21.5cm x 28cm sheet. Make
the sheets, one at a time, as follows:
1. Blend and mix pulp in blender 3/4 full of water. Add

additives.
2. Put mold in box, screen side up and immerse in sink. Rap

box to get rid of air bubbles.
3. Pour pulp into box.
4. Holding box down, agitate the water in the box with

fingers so that the pulp spreads evenly over the mesh.
5. Grasp box and mold firmly and lift quickly and evenly to
surface (feel suction).
6. Hold for 10 seconds or so to drain.
7. Lift up out of water and hold vertically to drain. If

sheet looks okay, proceed; if flawed, put box and mold back
into sink. Repeat steps 4 to 7.
8. Set box on flat surface and carefully remove box. Note:

Water drops on wet web will make marks!
9. Carefully lay cotton couching cloth over web and smooth

gently.
10. Place absorbent felt over couching cloth. Smooth and

press down from center out.
11. Remove felt and wring out water.
12. Repeat 10 and 11 until no more water comes out.
13. Couch off sheet, starting at corner and peeling back

quickly.
14. Place couched sheet, paper side up or down on flat

absorbent surface. Smooth and press down to remove trapped
air.
15. Repeat for each sheet until a neat stack is built up.
6
Pressing and Drying
The sheets can be dried quickly by pressing them with a hot

iron and an aluminum sheet or slowly (2-3 hours) by placing
them in a 120[degrees]C (280[degrees]F) oven, with the
couching sheets tacked down to the receiving board all
along the edges of the paper sheets. The first method gives
a smooth surface on one side, embossing with cloth marks on
the other; the second gives embossing on both sides.
A very slick surface can be obtained by smoothing the

couching cloth, paper side down, against an aluminum or
oiled galvanized sheet. A squeegee can be used to get rid
of all the air. Dry in air or in a 120[degrees]C
(280[degrees]F) degree oven.
Sizing and Coating
A simple method of internal sizing uses a combination of

pure gelatin and cornstarch (either laundry or cooking
type). The gelatin is dissolved in boiling water and
cornstarch is added to make a clear, thick mixture to add
to the pulp. Use about one teaspoon of this per 21.5cm x
28cm sheet.
Another simple internal sizing procedure is to add about

1/4 teaspoon of linseed and/or a teaspoon of cornstarch
solution while the pulp is being mixed at step 1. The oil
is dispersed in the water and precipitates on the fiber.
The starch will be caught on the fibers and during the
drying stage will set to give a stiffer sheet. External
sizing is done when the sheet is coated with a water based
solution after the paper has been dried. With an ordinary
4cm (1 1/2") paint brush, coat each sheet with a 7 percent
straight corn starch solution. one tablespoonful of
cornstarch added to a cup of water will be enough for 20 to
25 sheets (both sides). Animal glue can be added to the
starch to improve the water resistance. Modern glues can be
added also.
When the coated sheets are nearly dry to the touch, place
them in a neat stack. They should be somewhat limp but not
wet. Put a metal sheet or smooth board on top. Allow the
stack to dry overnight. The sheets can then be trimmed if
necessary and packaged for sale.
MAKING PAPER IN THE MICRO FACTORY
7
On a somewhat larger scale, but still in an essentially
hand process, paper can be made in a micro factory capable
of producing about 240kg (1/4 ton) of paper per day. Such
small factories are fairly common in India, and VITA has
assisted at least one such operation in Tanzania. This
process uses wastepaper or rags to make pulp, or pulp
purchased from a pulp mill. It can produce good quality
bond or drawing paper, card stock, school tablets, filter
paper, toilet tissue, grey board, and album or blotting
paper. It can also turn out such articles as egg cartons,
flower pots, seed flats, hospital trays, and so on.
In addition to an identified, reliable market, the small

factory requires a steady, reliable supply of raw
materials, water, and power. Suggested facilities include a
building of about 300 square meters for operations and a
shed of about 185 square meters for collecting and sorting
the materials. Six administrative staff and as many as 100
laborers working in two or three shifts are needed.
The U.N. Industrial Development Organization (UNIDO)

estimates an investment of approximately US$26,000 (1984)
for the total cost of installation. Production may be
increased by installing one or two more beaters and
operating the vats in three shifts. (Beyond this capacity,
however, economies of scale decline, and production moves
up to small-scale mechanized plants.)
Sources:
Vogler, Jon, and Sarjeant, Peter. Understanding Small-Scale

Papermaking. Arlington, Virginia: Volunteers in Technical
Assistance, 1986.
Appropriate Industrial Technology for Paper Products and

Small Pulp Mills. Vienna Austria: United Nations Industrial
Development Organization (UNIDO), 1979
Sheriff Dewji and Sons, Arusha, Tanzania
American Paper Institute, 260 Madison Avenue, New York, New

York

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How can paper be made in small quantities without electricity?

How can paper be made in small quantities without electricity?

What are the main steps involved in hand papermaking?

What are the main steps involved in hand papermaking?

Hand Papermaking

In many areas of developing countries paper is scarce.

But paper can be made in small shops in small quantities.

Whether paper is made in a home or school workshop or a

Cotton or other rags and waste paper to be recycled are

The cleaned and shredded raw materials are brought to the

The beater--this can range from a kitchen blender to a

Lifting, Couching, and Stacking

When the pulp process is complete, the pulp is transferred

Pressing and Drying

When a sufficient number of sheets have been formed, they

Sizing gives paper a harder finish so that water based

Blotting paper, filter paper, toilet tissue, grey board,

The dried sheets are placed alternately between metal

Sorting and Cutting

After calendering, the sheets are carefully sorted and cut

MAKING PAPER IN THE SMALL WORKSHOP

Papermaking at this scale can be done as hobby, for gifts,

This process assumes that waste paper or cotton cloth will

Equipment and Materials

The following equipment is needed:

Choose paper with minimal printing. Old envelopes are good

Newsprint alone makes a weak pulp, grey in color. It adds

Making the Sheets

Take a lump of the semi-moist pulp you have prepared. Press

1. Blend and mix pulp in blender 3/4 full of water. Add

2. Put mold in box, screen side up and immerse in sink. Rap

3. Pour pulp into box.

4. Holding box down, agitate the water in the box with

6. Hold for 10 seconds or so to drain.

7. Lift up out of water and hold vertically to drain. If

8. Set box on flat surface and carefully remove box. Note:

9. Carefully lay cotton couching cloth over web and smooth

10. Place absorbent felt over couching cloth. Smooth and

11. Remove felt and wring out water.

12. Repeat 10 and 11 until no more water comes out.

13. Couch off sheet, starting at corner and peeling back

14. Place couched sheet, paper side up or down on flat

The sheets can be dried quickly by pressing them with a hot

A very slick surface can be obtained by smoothing the

Sizing and Coating

A simple method of internal sizing uses a combination of

Another simple internal sizing procedure is to add about

MAKING PAPER IN THE MICRO FACTORY

In addition to an identified, reliable market, the small

The U.N. Industrial Development Organization (UNIDO)

Vogler, Jon, and Sarjeant, Peter. Understanding Small-Scale

Appropriate Industrial Technology for Paper Products and

Sheriff Dewji and Sons, Arusha, Tanzania

American Paper Institute, 260 Madison Avenue, New York, New

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