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Disley Tissue: A Brief History and Manufacturing Process

Learn about the history of Disley Tissue, from its origins as a cotton mill to its current status as a leading coated paper manufacturer. Discover the waste paper recycling process and how paper is made, as well as the company's commitment to responsible forest management and water recycling.

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Disley Tissue: A Brief History and Manufacturing Process

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  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. 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. How paper is made

  6. 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. How paper is made

  7. 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. How paper is made

  8. 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. How paper is made

  9. 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. How paper is made

  10. 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. How paper is made

  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. 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 Visit Safety

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