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TABLE D - 7 - 4
DESIGN BASIS
Functional Group Containerboard
Grade Jute liner
Basis Weight 205 g/m3
(42lb/1000sqft)
Production 3COM DMT/day;
100,000 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 27,600
Other Fixed Capital 2,800
Total Fixed Capital 30,000
Working Capital 4,000
Total Capital Required 34,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
A.D.S/F Plant 1,000 95
Pulping - 230
Board Making 4,000 80
Effluent Treatment - 30
Misc. & Auxiliaries 1,000 215
Total 6,000 650
Process S/F pulping
Fiber Furnish 1 00% secondary fiber;
OCC
Pulp Yield n.a.
Mill Location North Central
Boundary Limits S/F preparation through
board making
OPE RATING COST
($/MDMT)
Fiber Furnish 63.3
Other Raw Materials 12.6
Total Raw Materials Cost
Labor + Fringe @ 32%
of Hourly Rate 12.9
Supplies 7.1
Energy 24.3
Factory Overhead 6.5
Total Conversion Costs
Capital-Related Costs
• Total Factory Operating
Cost
GS&A 7.0
Freight Out 12.0
Total Cost of Sales
• Total Delivered Cost
75.9
50.8
23.1
149.8 ($136.5/
MOST)
19.0
168.8 ($153.1/
MOST)
D-17
Arthur DLittleJnc
-------
TABLE B-7-5
ESTIMATED FIXED CAPITAL REQUIREMENT "FOR THE MANUFACTURE OF
LINERBOARD FROM 100% SECONDARY FIBER
Item Cost ($000)
Site Preparation 500
A.D. Secondary Fiber Plant 3,000
Pulping 2,400
Board Machine 10,000
Steam/Power Generation 3,400
Water & Effluent Treatment 2,000
Warehouses and other bldgs. 800
TOTAL DIRECT PLANT COST (DPC) 22,100
Engineering, Const. Supervision & Fee
@ 25% DPC 5,500
TOTAL PHYSICAL PLANT COST (PPC) 27,600
OTHER FIXED CAPITAL @ 10% PPC 2,800
TOTAL FIXED CAPITAL 30,000
Use $30 MM
D-18
Arthur D Little Inc
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TABLE D-7-6
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
LINERBOARD FROM 100% SECONDARY FIBER
DIRECT LABOR
A.D. Secondary Fiber Plant
Foreman
Operator
Stock Preparation
Foreman
Operator
Materials Handling &
makeup Man
Machine Room
Foreman
Machine tender
Back tender
Third hand
Winder operator /Helper
TOTAL DIRECT
INDIRECT LABOR
Shipping & Receiving Foreman
Shipping crew
Unloading crew
Materials handling (within mill)
Effluent and water treatment
Sludge disposal
Steam/Power plant
Utility
TOTAL INDIRECT
Men
per Shift
1
2
1
1
1
1
1
1
1
1
1
3
3
2
1
1
2
3
Shifts
per Day
1
3
1
3
1
1
3
3
3
3
1
1
1
3
3
2
3
1
Total
Men
1
8
1
4
1
1
4
4
4
_4
32
1
3
3
8
4
2
8
_3_
32
D-19
Arthur D Little Inc
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205
200
195
190
fe 185
"35
TJ
I 180
Q
5
w
S 175
.£
2 170
&
O
165
160
155
150
J_
I
100 200 300 400
Capacity, Metric Tons Per Day
500
50
40
30
c
o
Q.
03
O
•§
X
20
10
600
FIGURE D-7-2 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF JUTE LINER
D-20
Arthur D Little Inc
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TABLED-7-7
DESIGN BASIS
Functional Group Containerboard
Grade Blended linerboard
Basis Weight 205 g/m2
(42lb/1000sq ft)
Production 910 MDMT/day;
31 4,000 MDMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS
($000)
Physical Plant 96,700
Other Fixed Capital 9,700
Total Fixed Capital 106,000
Working Capital 11,000
Total Capital Required 117,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Wood Preparation — 80
Pulping 1,300 84
Power & Steam Gen-
eration (incl. re-
covery & liquor
preparation) 1,300 136
A.D. Secondary Fiber
Plant 200 20
Stock Preparation — 50
Paper Making 4,000 360
Effluent Treatment — 30
Misc. & Auxiliaries 800 90
Total 7,600 850
Process Kraft pulping/continuous
digester
Fiber Furnish 80% virgin fiber, 20% S/F
50/50 roundwood/chips
(64% SW, 16%HW) + 20%
OCC
Pulp Yield Unbleached - 52%
Mill Location Southeast
Boundary Limits Wood and S/F preparation
through board making
OPERATING COST*
($/MDMT)
Fiber Furnish 47.9
Other Raw Materials 3.3
Total Raw Materials Cost 51.3
Labor + Fringe @ 32%
of Hourly Rate 13.2
Supplies 9.4
Energy 9.1
Factory Overhead 4.8
Total Conversion Costs 36.3
Capital-Related Costs 25.9
• Total Factory Operating Cost 1 1 3.5 ($103.0/
MOST)
GS&A 7.0
Freight Out 20.0
Total Cost of Sales 27.0
• Total Delivered Cost 140.5 ($127.5/
MOST)
"Totals may not add due to rounding.
D-21
Arthur D Little Inc.
-------
TABLE D--7-8
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
LINERBOARD FROM VIRGIN AND SECONDARY FIBERS (CASE I - 910 TPD)
Item
Cost ($000)
Site Preparation 1,500
Wood Yard & Wood Preparation 3,700
Cooking, Refining, Screening & Washing 9,600
Evaporation & Oxidation 2,700
Causticizing & Lime Reburning 3,800
Chemical Recovery 6,100
A.D. Secondary Fiber System 2,500
Stock Preparation 1,800
Machine Room 26,600
Steam/Power Generation 8,700
Water & Effluent Treatment 3,700
Other Bldgs. and Fire Protection 6,700
TOTAL DIRECT PLANT COST (DPC) 77,400
Engineering, Const. Supervision & Fee
@ 25% DPC 19.300
TOTAL PHYSICAL PLANT COST (PPC) 96,700
OTHER FIXED CAPITAL @ 10% PPC 9,700
TOTAL FIXED CAPITAL 106,400
Use $106 MM
D-22
Arthur D Little Inc
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TABLE D-7-9
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
• LINERBOARD FROM VIRGIN AND SECONDARY FIBERS (Case I)
Direct Labor Total Men*
Wood Yard and Wood Preparation 18
™ Pulp Mill 35
I A.D. Secondary Fiber Plant 4
Stock Preparation 4
I
Machine Room 46
107
Indirect Labor
I
• Utilities (steam, power) 20
I
_ Other (including shipping and
• receiving) 29
Utilities, Water & Effluent
Treatment 14
63
• *For detailed labor schedule, see kraft linerboard
and jute linerboard.
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D-23
Arthur D Little, Inc.
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01
c
CD
a
O
175
170
165
160
155
150
145
140
135
130
125
120
170
160
150
140
130
120
110
100
90
80
70
60
c
o
'a
<3
"8
X
400 600 800 1,000
Capacity, Metric Tons Per Day
1,200
1,400
FIGURE D-7-3 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF BLENDED LINER (Case I)
D-24
Arthur D Little Inc
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TABLE D - 7 - 10
DESIGN BASIS
Functional Group Containerboard
Grade Blended linerboard
Basis Weight 205 g/m2
(42lb/1000sqft)
Production 1140 MDMT/day;
393.000 MDMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 108,500
Other Fixed Capital 10,900
Total Fixed Capital 1 19,000
Working Capital 13,000
Total Capital Required 132,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Wood Preparation - 80
Pulping 1,300 80
Power & Steam Gener-
ation (incl. recovery
and liquor prep ) 1 300 140
A.D. Secondary Fiber
Plant 200 20
Stock Preparation - 50
Board Making 4,000 360
Effluent Treatment — 30
Misc. & Auxiliaries 800 90
Total 7,600 850
Process Kraft pulping/continuous
digester
Fiber Furnish 80% virgin fiber, 20% S/F
50/50 roundwood/chips
(64% SW, 16%HW)+20%
OCC
Pulp Yield Unbleached - 52%
Mill Location Southeast
Boundary Limits Wood and S/F prepara-
tion through board mak-
ing
OPERATING COST*
($/MDMT)
Fiber Furnish 47.9
Other Raw Materials 3.3
Total Raw Materials Cost 51 .2
Labor + Fringe @ 32%
of Hourly Rate 1 1 .8
Supplies 9.1
Factory Overhead 4.3
Total Conversion Costs 35.9
Capital-Related Costs 23.3
• Total Factory Operating
Cost 110.4($100.2/
MOST)
GS&A 7.0
Freight Out 20.0
Total Cost of Sales 27.0
• Total Delivered Cost 137.4 <$124.6/
MOST)
"Totals may not add due to rounding.
D-25
Arthur D Little Inc
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TABLE D-7-11
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
LINERBOARD FROM VIRGIN AND SECONDARY FIBERS (CASE II - 1140 TPD)
Item
Cost ($000)
Site Preparation
Wood Yard & Wood Preparation
Cooking, Refining, Screening & Washing
Evaporation & Oxidation
Causticizing & Lime Reburning
Chemical Recovery
A.D. Secondary Fiber System
Stock Preparation
Machine Room
Steam/Power Generation
Water & Effluent Treatment
Other Bldgs. & Fire Protection
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
1,500
4,400
11,300
3,200
4,500
7,200
3,000
2,000
30,800
9,100
3,700
6.900
87,600
20.900
108,500
10.900
119,400
$119 MM
D-26
Arthur D Little Inc
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TABLE D-7-12
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLENDED LINERBOARD (Case II)
DIRECT LABOR
Wood Yard and Wood Preparation
Foreman
Asst. Foreman
Equip. Operator
Drum Barker Operator
Drum Barker Helper
Chipper Operator
Utility (knife grinder)
Material Handling
Sub-Total
Pulp Mill
Foreman - Pulp Mfg.
Foreman - Recovery
Digester Operator
Helper
Brown Stock Washer Operator
Liquor Evap. Operator
Lime Kiln Operator
Causticizer Operator
Helper
Utility
Sub-Total
A.D. Secondary Fiber Plant
Material Handling
Paper Mill
Foreman
Stock Preparation
Chemical Prep. - Rosin
Machine
Winder & Roll Finishing
Process Engineer
Tester
Shipping
Sub-Total
TOTAL DIRECT
Men
per Shift
1
1
3
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
7
3
1
1
2
Shifts
per Day
2
1
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
3
1
3
3
1
3
3
Total
Men
2
1
6
2
2
2
2
_4
22
4
4
4
4
4
4
4
4
8
_4
44
D-27
4
4
1
28
12
1
4
_8
62
134
Arthur D Little Inc.
-------
TABLE D-7-12 (cont'd)
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLENDED LINERBOARD (Case II)
Men
per Shift
Shifts
per Day
Total
Men
INDIRECT LABOR
Utilities - Steam
Foreman 1
Recovery Boiler Operator 1
Power Boiler Operator 1
Helper 2
Water Treatment (Matl. Handling) 1
Utilities - Power
Foreman - incl. w/steam
Operator 1
Utilities - Water & Effluent Treatment
Foreman 1
Operator Raw Water 1
Operator Waste Treatment 1
Helper 1
Sludge Disposal (driver) 2
Other Allocated
Receiving 10
Instrumentation and Oiler 2
Stores 2
Gate and Watchman 1
Shipping & Receiving Foreman 1
Quality Control 1
TOTAL INDIRECT
1
3
3
3
1
1
3
3
1
2
1
1
1
3
1
1
1
4
4
8
1
1
4
4
1
4
10
2
2
4
1
56
D-28
Arthur D Little Inc
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•g
I
(U
•o
tt
o
o
O>
c
a
O
175
170
165
160
155
150
145
140
135
130
125
120
I
400 600 800 1,000 1,200
Capacity, Metric Tons Per Day
170
160
150
140
130
1,400
c
o
120
110 a
ID
O
"8
x
100 £
90
80
70
60
FIGURE D-7-4 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF BLENDED LINER (Case II)
D-29
Arthur D Little; Inc
-------
TABLED-7-13
DESIGN BASIS
Functional Group Containerboard
Grade NSSC Corrugating
Medium
Basis Weight 127g/m2
(26lb/1000sqft)
Production 410 MDMT/day;
141,OOOMDMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 41,000
Other Fixed Capital 4,100
Total Fixed Capital 45,000
Working Capital 5,000
Total Capital Required 50,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Wood Preparation - 100
Pulping 1,000 150
Power & Steam Gen.
(incl recovery &
liquor prep.) 1,600 160
Stock Preparation — 150
Effluent Treatment - 30
Board Making 4,000 100
Misc. & Auxiliaries 400 110
Total 7,000 800
Process NSSC pulping, Na base
Fiber Furnish 85% virgin, 1 5% S/F
(kraft chippings)
Pulp Yield Unbleached - 75%
Mill Location Southeast
Boundary Limits Wood and S/F preparation
through paperboard making
OPERATING COST*
($/MDMT)
Fiber Furnish 34.9
Other Raw Materials 14.0
Total Raw Materials Cost 48.9
Labor + Fringe @ 32% of
Hourly Rate 19.3
Supplies 8.5
Energy 16.2
Factory Overhead 8.2
Total Conversion Costs 52.1
Capital- Related Costs 24.5
• Total Factory Operating
Cost 125.4
GS&A 7.0 <$"3.7/MDST»
Freight Out 14.0
Total Cost of Sales 21 .0
• Total Delivered Cost 146.4
(S132.8/MDST)
'Totals may not add due to rounding.
D-30
Arthur D Little Inc
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1
1
1
TABLE D-7-14
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
1
1
1
1
1
1
•
"
1
1
1
1
1
1
1
1
CORRUGATING MEDIUM FROM 85% VIRGIN FIBER,
-
Item
Site & Wood Preparation
Cooking, Refining & Washing
Evaporation & Liquid Preparation
Combustion System
Waste Paper System
Stock Preparation
Paper Machine
Steam/Power Generation
Effluent Treatment
Warehouse & Other Buildings
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
D-31
15% SECONDARY FIBER
Cost ($000)
1,400
2,400
2,200
1,400
1,300
1,600
11,000
6,000
2,900
2,600
32,800
8,200
41,000
4,100
45,100
$45 MM
/
Arthur D Little Inc
-------
TABLE D-7-15
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
NSSC CORRUGATING MEDIUM
Direct Labor Total Men*
Wood Yard and Wood Preparation 12
Pulp Mill and Recovery Plant 28
Deinking and Waste Handling 8
Paper Mill 40
Total Direct 88
Indirect Labor 54
* For detailed labor schedule, see kraft linerboard;
reduce the direct labor requirement according to mill
size and modify to include the chemical recovery plant
and deinking operation
D-32
Arthur D Little; Inc
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185
180
175
170
165
3 160
8
o
03
0)
a
0
155
145
140
135
130
125
I
I
I
100 200 300 400
Capacity, Metric Tons Per Day
500
60
50
40
20
o
30 2
Q.
<3
"8
X
LI
10
600
FIGURE D-7-5
OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF NSSC CORRUGATING
MEDIUM
D-33
Arthur D Little Inc
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TABLE D-7-16
DESIGN BASIS
Functional Group Container-board
Grade Corrugating (bogus)
Medium
Basis Weight 127g/m2
(26lb/1000sqft)
Production 300 MDMT/day;
100,000 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 22,100
Other Fixed Capital 2,200
Total Fixed Capital 24,000
Working Capital 4,000
Total Capital Required 28,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Pulping - 230
Board Making 4,000 80
Effluent Treatment - 30
Misr ft Auxiliaries 600 215
Total 4,600 555
'Totals may not add due to rounding.
Process S/F pulping
Fiber Furnish 100% Secondary fiber
(OCC)
Pulp Yield 89%
Mill Location North Central
Boundary Limits S/F preparation through
board making
OPERATING COST
($/MDMT)
Fiber Furnish 64.9
Other Raw Materials 3.5
Total Raw Materials Cost 68.4
Labor + Fringe @ 32% of
Hourly Rate 11.2
Supplies 6.7
Energy 26.5
Factory Overhead 6.3
Total Conversion Costs 50.7
Capital- Related Costs 18.5
• Total Factory Operating
Cost
(S124.8/MDST)
GS&A 7.0
Freight Out 12.0
Total Cost of Sales 19.0
• Total Delivered Cost 156.6
($142.0/MDST)
D-34
Arthur D Little Inc
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1
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1
^B
1
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1
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1
1
1
1
1
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TABLE D-7-17
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
CORRUGATING MEDIUM FROM 100% SECONDARY FIBER
Item Cost ($000)
Site Preparation 500
Pulping 2,400
Board Machine 9,200
Steam Generation 2,500
Water & Effluent Treatment 2,000
Warehouses & other bldgs. 1,100
TOTAL DIRECT PLANT COST (DPC) 17,700
Engineering, Const. Supervision & Fee
@ 25% DPC 4,400
TOTAL PHYSICAL PLANT COST (PPC) 22,100
OTHER FIXED CAPITAL @ 10% PPC 2,200
TOTAL FIXED CAPITAL. 24,300
Use $24 MM
D-35
Arthur D Little Inc
-------
TABLE D-7-18
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
CORRUGATING MEDIUM FROM 100% SECONDARY FIBER
Direct Labor Total Men*
Stock Preparation 6
Machine Room 17
Total Direct 23
Indirect Labor 32
* For detailed labor schedule, see linerboard from 100%
secondary fiber; subtract 9 men for A.D. secondary fiber
plant.
D-36
Arthur D Little; Inc
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174
172
170
168
"S 166
OJ
:
164
«» 162
•f-1
8
•f 16°
i_
o
158
156
154
152
150
Operating Cost
I
I
100 200 300
Capacity, Metric Tons Per Day
400
60
50
40
o
™-> <
30 .t;
Q.
n
O
"8
X
20
10
FIGURE D-7-6 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF BOGUS MEDIUM
D-37
Arthur D Little Inc
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TABLED-7-19
DESIGN BASIS
Functional Group Containerboard
Grade Blended corrugating
medium
Basis Weight 127g/m2
(26lb/1000sqft)
Production 410MDMT/day;
141,000 MDMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 39,600
Other Fixed Capital 4,000
Total Fixed Capital 44,000
Working Capital 5,000
Total Capital Required 49,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Wood Preparation - 70
Pulping (NSSC) 700 100
(S/F) - 80
Qtrwk Prpnaratinn 100
Board Making 4,000 100
Steam & Power Gen.
(incl. recovery &
liquor prep.) 1,200 100
Effluent Treatment - 30
Misc. & Auxiliaries 500 110
Total 6,400 690
Process NSSC pulping, Na base
Fiber Furnish 57% virgin fiber (NSSC),
10% kraft clippings, 33%
OCC
Pulp Yield Unbleached - 75%
Mill Location Southeast
Boundary Limits Wood & S/F preparation
through board making
OPERATING COST*
($/MDMT)
Fiber Furnish 44.7
Other Raw Materials 10.5
Total Raw Materials Cost 55.2
Labor + Fringe @ 32% of
Hourly Rate 19.4
Supplies 8.5
Energy 14.3
Factory Overhead 8.3
Total Conversion Costs 50.4
Capital- Related Costs 23.9
• Total Factory Operating
Cost 129.5($117.5/
GS&A 7.0 MDST)
Freight Out 14.0
Total Cost of Sales 21.0
• Total Delivered Cost 150.5 ($136.5/
MOST)
'Totals may not add due to rounding.
D-38
Arthur D Little; Inc
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TABLE D-7-20
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
CORRUGATING MEDIUM FROM 57% VIRGIN FIBER, 43% SECONDARY FIBER
Item
Cost ($000)
Site & Wood Preparation 1,200
Cooking, Refining & Washing 1,900
Evaporation & Liquor Prep. 1,700
Combustion System 1,100
Waste Paper System 2,000
Stock Preparation 1,300
Paper Machine 11,000
Steam/Power Generation 6,000
Effluent Treatment 2,900
Warehouse & Other bldgs. 2.600
TOTAL DIRECT PLANT COST (DPC) 31,700
Engineering, Const. Supervision & Fee
@ 25% DPC 7,900
TOTAL PHYSICAL PLANT COST (PPC) 39,600
OTHER FIXED CAPITAL @ 10% PPC 4,000
TOTAL FIXED CAPITAL 43,600
Use $44 MM
D-39
Arthur D Little Inc
-------
TABLE D-7-21
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
CORRUGATING MEDIUM FROM VIRGIN AND SECONDARY FIBER
Direct Labor Total Men*
Wood Yard and Wood 12
Preparation
Pulp Mill and Recovery Plant 27
Deinking and Waste Handling 10
Paper Mill 40_
Total Direct 89
Indirect Labor 54
*For detailed labor schedule, see kraft linerboard
except that the direct labor requirement is reduced
according to mill size and modified to include the
chemical recovery plant and deinking operation.
D-40
Arthur D Little; Inc
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I
I
I
I
I
I
1
I
I
I
I
I
I
I
190
185
180
175
v 170
CD
CD
S 165
-
8
o
160
155
'*-*
CO
&
0 150
145
140
135
130
I
I
100 200 300 400
Capacity, Metric Tons Per Day
500
60
50
40
c
o
30 T§
'5.
20
10
600
FIGURE D-7-7 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF BLENDED MEDIUM
D-41
Arthur D Little; Inc
-------
TABLED-7-22
DESIGN BASIS
Functional Group Groundwood Papers
Grade Newsprint
Basis Weight 49 g/m2
(30 lb/3000 sq ft)
Production BOOM DMT/day;
1 70,000 MDMT/yr
Net Operating Days 340/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 52,700
Other Fixed Capital 5,300
Total Fixed Capital 58,000
Working Capital 9,000
Total Capital Required 67,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Wood Preparation - 120
Paper Making 2,700 200
Effluent Treatment — 1 5
Total 3,150 350
Process Integrated to semi -
bleached kraft
Fiber Furnish 100% virgin (75% ground
wood slush pulp, 25%
semi-bleached kraft
slush pulp)
Pulp Yield Groundwood - 95%
Mill Location Northeast
Boundary Limits Wood preparation and
transfer of slush pulp
to paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 105.5
Other Raw Materials 2.8
Total Raw Materials Cost 108.4
Labor + Fringe @ 32%
of Hourly Rate 10.0
Supplies 11.2
Energy 1 2.9
Factory Overhead 2.9
Total Conversion Costs 36.9
Capital-Related Costs 26.2
• Total Factory Operating 171.5 ($155.6/
Cost MOST)
GS&A 12.6
Freight Out 20.0
Total Cost of Sales 32.6
• Total Delivered Cost 204.1 ($185.2/
MOST)
"Totals may not add due to rounding.
D-42
Arthur D Little, Inc
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1
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1
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1
1
1
1
1
1
1
1
1
TABLE D-7-23
ESTIMATED FIXED CAPITAL REQUIREMENT FOR
THE MANUFACTURE OF
NEWSPRINT FROM 100% VIRGIN FIBER
Item
Site Preparation
Stock Preparation
Paper Machine (incl. roll finishing
& winding)
Steam/Power Generation & Dist.
Water & Effluent Treatment
Auxiliary Equipment & bldgs.
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
D-43
Cost ($000)
2,200
3,000
30,000
2,000
2,500
2,500
42,200
10,500
52,700
5,300
58,000
$58 MM
Arthui
-------
TABLE D-7-24
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
NEWSPRINT FROM 100% VIRGIN FIBER
Men per
shift
Shifts
per day
Total
Men
DIRECT LABOR
Stock Preparation:
Foreman
Operator
Beater
Make-up Man
Paper Machine:
Foreman
Machine Tender
Back Tender
Third to Sixth Hands
Roll Finishing & Wrapping
TOTAL DIRECT
1
1
1
1
1
1
1
4
2
1
3
3
1
3
3
3
3
3
1
4
4
1
4
4
4
16
8
46
ALLOCATED INDIRECT LABOR
Auxiliary:
Shipping & Receiving Foreman 1
Shipping & Receiving 4
Materials Handling 1
Tester 1
Steam (Power Plant) 2
Effluent Treatment 1
1
1
3
3
3
2
1
4
4
3
8
2
TOTAL INDIRECT
22
D-44
Arthur D Little Inc
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I
I
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226
224
222
220
- 218
CD
1
I 216
214
o
O
o> 212
*+j
to
S.
O 210
208
206
204
202
I
100 200 300 400
Capacity, Metric Tons Per Day
500
80
70
60
o
50 2
'a
X
il
40
30
20
600
FIGURE D-7-8 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF NEWSPRINT {VIRGIN}
D-45
Arthur D Little; Inc
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TABLE D - 7 - 25
DESIGN BASIS
Functional Group Groundwood Papers
Grade Newsprint
Basis Weight 49 g/m2
(30 lb/3000 sq ft)
Production 300MDMT/day;
102,000 MDMT/yr
Net Operating Days 340/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 36,600
Other Fixed Capital 3,700
Total Fixed Capital 40,000
Working Capital 5,000
Total Capital Required 45,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Pul pi ng& De-inking 500 420
Paper Making 2,700 200
Effluent Treatment — 40
Total 3,800 700
Process S/F pulping and
de-inking
Fiber Furnish 100% old news
Pulp Yield 80% AD S/F to MD
paper
Mill Location Northeast
Boundary Limits S/F preparation through
paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 56.3
Other Raw Materials 9.8
Total Raw Materials Cost 66.1
Labor + Fringe @ 32%
of Hourly Rate 16.4
Supplies 15.2
Energy 31 .7
Factory Overhead 9,6
Total Conversion Costs 72.8
Capital-Related Costs 30.1
• Total Factory Operating 169.0 ($153.3/
Cost MOST)
GS&A 12.6
Freight Out 12.0
Total Cost of Sales 24.6
• Total Delivered Cost 193.6 ($175.6/
MOST)
"Totals may not add due to rounding.
D-46
Arthur D Little Inc
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1
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1
1
1
1
1
1
1
1
1
1
1
1
1
1
TABLE D-7-26
ESTIMATED FIXED CAPITAL REQUIREMENT FOR
THE MANUFACTURE OF
NEWSPRINT FROM 100% SECONDARY FIBER
Item Bldgs
Site Preparation 1,000
De-inking 800
Stock Preparation 200
Paper Machine (incl. roll finishing
& winding) 1,800
Steam/Power Generation & Dist. 400
Auxiliary Equipment & Buildings 1,600
Water & Effluent Treatment 300
TOTAL DIRECT PLANT COST (DPC) 6,100
Engineering, Const. Supervision &
Fee (3 25% DPC 1,500
TOTAL PHYSICAL PLANT COST (PPC) 7,600
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
D-47
Cost ($000)
Eqpt. Total
1,000
3,600 4,400
1,200 1,400
12,600 14,400
2,700 3,100
400 2,000
2,700 3,000
23,200 29,300
5,800 7,300
29,000 36,600
3,700
40,300
Use $40 MM
Arth
Arthur D Little Inc.
-------
TABLE D-7-27
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
NEWSPRINT FROM 100% RECYCLED FIBER
Men per
Shift
Shifts
per Day
Total
Men
DIRECT LABOR
Deinking:
Foreman
Pulper
Helper
Screening Operator
Washer Operator
Trash Handling
Stock Preparation:
Foreman
Operator
Beater
Makeup Man
Paper Machine:
Foreman
Machine Tender
Back Tender
Third to Fifth Hands
Roll Finishing & Wrapping
TOTAL DIRECT
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
3
2
3
3
2
1
3
3
1
1
3
3
3
3
1
4
2
4
4
2
1
4
4
1
1
4
4
12
_4
52
INDIRECT LABOR
Auxiliary:
Shipping & Receiving Foreman
Shipping & Receiving
Materials Handling
Utility
Tester
Effluent & Steam Plant
Sludge Disposal
TOTAL INDIRECT
1
5
3
5
1
2
1
1
1
3
1
3
3
2
1
5
12
5
4
8
2
37
D-48
Arthur D Little Inc
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I
I
I
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I
I
I
I
I
I
I
I
I
235
230
225
220
- 215
T3
tu
I-
Q
O)
c
&
O
210
205
200
195
190
185
180
175
FIGURE D-7-9
I
I
I
100 200 300 400
Capacity, Metric Tons Per Day
500
60
50
40
20
10
600
o
30 |
'a
ro
O
0}
X
OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF NEWSPRINT (SECONDARY)
D-49
Arthur D Little Inc
-------
TABLE D - 7 - 28
DESIGN BASIS
Functional Group Groundwood Papers
Grade Newsprint
Basis Weight 49 g/m2
(30 lb/3000 sq ft)
Production 500 M DMT/day;
1 70,000 MDMT/yr
Net Operating Days 340/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 58,500
Other Fixed Capital 5,900
Total Fixed Capital 64,000
Working Capital 8,000
Total Capital Required 72,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Pulping & De-inking 175 190
Paper Making 2,700 200
Effluent Treatment - 1 5
Misc., incl. Auxiliaries 525 15
Tr>+oi T Ann A.on
Process Newsprint de-inking, inte-
grated to semi -bleached
kraft
Fiber Furnish 67% Virgin (50% ground-
wood slush pulp, 17% SBK
slush pulp), 33% S/F
Pulp Yield 80% AD S/F to MD paper
Mill Location Northeast
Boundary Limits S/F preparation and trans-
fer of slush pulp through
paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 89.3
Other Raw Materials 4.9
Total Raw Materials Cost 94.1
Labor + Fringe® 32%
of Hourly Rate 11.7
Supplies 11.8
Energy 16.7
Factory Overhead 3.9
Total Conversion Costs 44.2
Capital-Related Costs 28.9
• Total Factory Operating 167.2 ($151.7/
Cost MOST)
GS&A 12.6
Freight Out 20.0
Total Cost of Sales 32.6
• Total Delivered Cost 199.8 ($181 .3/
MOST)
"Totals may not add due to rounding.
D-50
Arthur D Little Inc
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1
1
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1
TABLE D-7-29
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE
NEWSPRINT FROM VIRGIN AND SECONDARY FIBERS
Cost ($000)
Item Bldgs. Eqpt.
Site Preparation 2,400
De- Inking 500 2,400
Stock Preparation 500 2,300
Paper Machine (incl. roll finishing
& winding) 4,900 25,100
Steam/Power Generation & Dist. 300 2,200
Water & Effluent Treatment 300 3,200
Auxiliary Equipment & Bldgs. 2,300 400
TOTAL DIRECT PLANT COST (DPC) 11,200 35,600
Engineering, Const. Supervision
& Fee @ 25% DPC 2,800 8,900
TOTAL PHYSICAL PLANT COST (PPG) 14,000 44,500
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
D-51
OF
Total
2,400
2,900
2,800
30,000
2,500
3,500
2,700
46,800
11,700
58,500
5,900
64,400
$64 MM
Arthui
-------
TABLE D-7-30
1
I
I
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF I
NEWSPRINT FROM VIRGIN & SECONDARY FIBERS I
I
Direct Labor Total Men
Deinking 17
Stock Preparation 10
Paper Machine 36
Total Direct 63
Allocated Indirect Labor 31
D-52
Arthur D Little, Inc
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220
218
216
214
- 212
0)
I
-------
TABLE D - 7 - 31
DESIGN BASIS
Functional Group
Grade
Basis Weight
Production
Groundwood Papers
Uncoated printing
paper
57 g/m2
(35lb/3000sqft)
272 MDMT/day;
90,000 MDMT/yr
Net Operating Days 330/yr
Process
Fiber Furnish
Pulp Yield
Mill Location
Integrated to semi-bleached
kraft
100% Virgin (65% ground-
wood slush pulp, 35%SBK)
n.a.
Northeast
Boundary Limits Transfer of slush pulp
through paper making
CAPITAL REQUIREMENTS*
($000)
Physical Plant 34,900
Other Fixed Capital 4,000
Total Fixed Capital
Working Capital
Total Capital Required
38,000
6,000
44,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Paper Making 3,600 380
Effluent Treatment - 20
Misc. & Auxiliaries 600 20
Total 4,400
420
OPERATING COST*
($/MDMT)
Fiber Furnish 97.5
Other Raw Materials 30.6
Total Raw Materials Cost
Labor + Fringe @ 32%
of Hourly Rate 14.6
Supplies 15.3
Energy 18.6
Factory Overhead 4.8
Total Conversion Costs
Capital-Related Costs
• Total Factory Operating
Cost
GS&A 25.0
Freight Out 30.0
Total Cost of Sales
• Total Delivered Cost
128.2
53.3
32.4
214.0(194.17
MOST)
55.0
269.0 ($244.0/
MOST)
'Totals may not add due to rounding
D-54
Arthur D Little Inc
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1
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1
1
•
1
1
••
1
1
^^v
1
1
1
1
1
1
1
TABLD D-7-32
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE
UNCOATED PRINTING PAPER FROM 100% VIRGIN FIBER
Cost ($000)
Item Bldgs . Equip .
Site Preparation 1,500
Stock Preparation 400 1,600
Paper Machine (incl. size press, roll
finishing & winding) 2,800 16,600
Steam/Power Generation & Dist. 300 1,300
Water & Effluent Treatment 100 1,700
Auxiliary Equipment & Bldgs. 1,300 300
TOTAL DIRECT PLANT COST (DPC) 6,400 21,500
Engineering, Const. Supervision & Fee
@ 25% DPC 1,600 5,400
TOTAL PHYSICAL PLANT COST (PPC) 8,000 26,900
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
D-55
OF
Total
1,500
2,000
19,400
1,600
1,800
1,600
27,900
7,000
34,900
3,500
38,400
$38 MM
Arthui
-------
TABLE D-7-33
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE
OF UNCOATED GROUNDWOOD PRINTING PAPER FROM 100% VIRGIN FIBER
Men
per Shift
Shifts
per Day
Total
Men
DIRECT LABOR
Stock Preparation:
Foreman 1
Operator 1
Beater 1
Make-up man 1
Paper Machine:
Foreman 1
Machine Tender 1
Back Tender 1
Third, Fourth, Fifth hand 3
Size press 1
Roll finishing and wrapping 1
TOTAL DIRECT
1
3
3
1
1
4
4
1
1
3
3
3
3
3
1
4
4
12
4
4
39
ALLOCATED INDIRECT LABOR
Auxiliary
Shipping and Receiving Foreman 1
Shipping and Receiving 2
Materials Handling 1
Utility 2
Tester 1
Steam Plant 1
Sludge Disposal 1
TOTAL INDIRECT
1
1
3
1
3
3
2
1
2
3
2
4
4
_2
18
D-56
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315
310
305
300
- 295
IV
2 290
t-
Q
I 285
280
a
o>
Vp
to
a
O 275
270
265
260
255
I
100 200 300
Capacity, Metric Tons Per Day
60
50
40
o
30 g
'5.
T>
X
LU
20
10
400
FIGURE D-7-11 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF UNCOATED GROUNDWOOD PRINTING PAPER
(VIRGIN)
D-57
Arthur D Little Inc
-------
TABLE D - 7 - 34
DESIGN BASIS
Functional Group Groundwood Papers
Grade
Basis Weight
Production
Net Operating Days
Uncoated Printing
Paper
57 g/m2
(35 lb/3000 sq ft)
136 MDMT/day;
45,000 MDMT/yr
(rolls)
330/yr
Process
Fiber Furnish
Pulp Yield
Mill Location
Boundary Limits
Groundwood Pulping plus
SBK market pulp
100% virgin (65% ground-
wood slush pulp, 35% mar-
ket semi-bleached kraft)
n.a.
Northeast
Papermaking integrated
to groundwood pulping
and purchased chemical
market pulp
CAPITAL REQUIREMENTS*
($000)
Physical Plant 24,400
Other Fixed Capital 2,400
Total Fixed Capital** 27,000
Working Capital 4,000
Total Capital Required** 31,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
4,300 610
OPERATING COST
($/MDMT)
Fiber Furnish 149.8
Other Raw Materials 30.6
Total Raw Materials Cost 180.4
Labor + Fringe @ 32%
of Hourly Rate 27.8
Supplies 20.6
Energy 25.1
Factory Overhead 1 5.4
Total Conversion Costs 88.9
Capital-Related Costs 46.0
• Total Factory Operating
Cost 31 5.3
GS&A 25.0
Freight Out 20.0
Total Cost of Sales 45.0
• Total Delivered Cost 360.3
($286.07
MOST)
($326.87
MOST)
'Totals may not add due to rounding.
"Does not include groundwood pulping capital of $5MM
NOTE: Detailed tabulations of fixed capital and labor requirements are not presented for this
model. These requirements were extrapolated from the corresponding data for manufacture of
the same product in an integrated mill. Additional fixed capital is needed by a nonintegrated
mill, primarily for auxiliary facilities, as it does not benefit from the larger scale and economies
obtained by allocating part of the cost of these facilities to an associated pulp mill. With regard
to labor requirements, more manpower is needed to handle market pulp than slush pulp.
Similarly, curves showing how operating costs and fixed capital are related to capacity are
not included with this model. The shapes of the curves would be the same as for the corre-
sponding integrated mill, but displaced vertically to reflect higher unit costs.
D-58
Arthur D Little Inc
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TABLED-7-35
DESIGN BASIS
Functional Group Groundwood Papers
Grade Un coated printing
paper
Basis Weight 57 g/m2
(35lb/3000sqft)
Production 136 MDMT/day;
45,000 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 30,000
Other Fixed Capital 3,000
Total Fixed Capital 33,000
Working Capital 4,000
Total Capital Required 37,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
lien] HtWh\
ing/ iivwvn/
Pulping & De-inking 500 430
Paper Making 3,600 250
Effluent Treatment — 40
Misc. & Auxiliaries 700 40
Total 4,800 760
Process S/F pulping and
de-inking
Fiber Furnish 100% secondary fiber
Pulp Yield 80% AD S/F to MD paper
Mill Location Northeast
Boundary Limits S/F preparation through
paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 73.2
Other Raw Materials 36.9
Total Raw Materials Cost 109.8
Labor + Fringe @ 32%
of Hourly Rate 33.1
Supplies 22.8
Energy 37.2
Factory Overhead 20.7
Total Conversion Costs 1 1 3.6
Capital-Related Costs 56.2
• Total Factory Operating
Cost 279.6 (25S.7/
MOST)
GS&A 25.0
Freight Out 20 0
Total Cost of Sales 45.0
• Total Delivered Cost 324.6 ($294. 5/
MOST)
'Totals may not add due to rounding
D-59
Arthur D Little Inc
-------
TABLE D-7-36
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
UNCOATED PRINTING PAPER FROM 100% SECONDARY FIBER
Cost ($000)
Item
Bldgs. Equip. Total
Site Preparation
De-inking
Stock Preparation
Paper Machine (incl. size press, roll
finishing & winding)
Steam/Power Generation & Dist.
Water & Effluent Treatment
Auxiliary Equipment & Bldgs.
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
900 - 900
400 2,300 2,700
200 800 1,000
1,800 11,100 12,900
300 1,700 2,000
200 2,600 2,800
1,400 300 1,700
5,200 18,800 24,000
1,300 4,700 6.000
6,500 23,500 30,000
3,000
Use
33,000
$33 MM
D-60
Arthur D Little; Inc
-------
I
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I
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
• UNCOATED GROUNDWOOD PRINTING PAPERS FROM 100% SECONDARY FIBER
TABLE D-7-37
Direct Labor Total Men*
Deinking 17
Stock Preparation 10
Paper Machine 25
52
Allocated Indirect Labor 37
Maintenance 23
I
I
I
I
I
*For detailed schedule, see uncoated groundwood printing
papers from 100% virgin fiber; subtract one machine
• hand per shift (4 total) and add deinking, same as
• recycled news.
I
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| Arthur D Little, Inc
D-61
-------
360
355
350
345
- 340
S 335
Q
330
o> 325
"^
05
I
O 320
315
310
305
300
100 200 300
Capacity, Metric Tons Per Day
60
50
40
c
o
30 2
'a.
CO
o
T3
20
10
400
FIGURE D-7-12 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF UNCOATED GROUNDWOOD PRINTING PAPER
(SECONDARY)
D-62
Arthur D Little; Inc
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TABLE D - 7 - 38
DESIGN BASIS
Functional Group Groundwood Papers
Grade Uncoated Printing
paper
Basis Weight 57 g/m2
(35lb/3000sqft)
Production 272 MDMT/day;
90,000 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 39,800
Other Fixed Capital 4,000
Total Fixed Capital 44,000
Working Capital 6,000
Total Capital Required 50,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Pulping & De-inking 175 230
Paper Making 3,600 250
Effluent Treatment — 25
Misc. & Auxiliaries 625 25
Tntal A Af\(\ R^fl
Process Integrated to semi -bleached
kraft
Fiber Furnish 67% Virgin (41% ground-
wood slush pulp + 26% SBK
slush pulp), 33% S/F
Pulp Yield n.a.
Mill Location Northeast
Boundary Limits S/F preparation and trans-
fer of slush pulp through
paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 82.4
Other Raw Materials 30.6
Total Raw Materials Cost 1 13.1
I ahnr + Frinno (3) T90/,
of Hourly Rate 18.4
Ci mnliPQ 1 fi 7
Energy 21.3
Factory Overhead 6.3
Total Conversion " «ts 62.9
Capital-Related Costs 37.6
• Total Factory Operating
Cost 2 13. 6 ($193 .87
MOST)
GS&A 25.0
Freight Out 30.0
Total Cost of Sales 55.0
• Total Delivered Cost 268.6 ($243. 7/
MOST)
"Totals may not add due to rounding
D-63
Arthur D Little Inc
-------
TABLD D-7-39
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
UNCOATED PRINTING PAPER FROM VIRGIN AND SECONDARY FIBERS
Item
Site Preparation
De- inking
Stock Preparation
Paper Machine (incl. size press, & roll
finishing)
Steam/Power Generation & Dist.
Water & Effluent Treatment
Auxiliary Equipment & Bldgs.
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Bldgs.
1,600
300
400
2,800
300
300
1,700
7,400
1,900
9,300
Cost ($000)
Equip .
-
1,800
1,600
16,600
1,700
2,400
300
24,400
6,100
30,500
Use
Total
1,600
2,100
2,000
19,400
2,000
2,700
2,000
31,800
8,000
39,800
4,000
43,800
$44 MM
D-64
Arthur D Little Inc
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TABLE D-7-40
Direct Labor Total Men
• ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
UNCOATED GROUNDWOOD PRINTING PAPER FROM VIRGIN AND SECONDARY FIBERS
I
I
Deinking: same as 100% recycled 15
• less 2
Stock Prep: same as 100% virgin 10
• Paper Machine: same as 100% virgin 29
l "
Allocated Indirect Labor 22
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D-65
| Arthur D Little, Inc
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315
310
305
300
- 295
IV
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S 290
I-
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*-•
V)
a
^c
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285
280
0 275
270
265
260
255
100 200 • 300
Capacity, Metric Tons Per Day
400
60
50
40
C
o
30
•a
0)
20
10
FIGURE D-7-13 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF UNCOATED GROUNDWOOD PRINTING PAPER
(BLENDED)
D-66
Arthur D Little Inc
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TABLE D - 7 - 41
DESIGN BASIS
Functional Group
Grade
Basis Weight
Production
Jumbo Rolls
Converted & Pkgd.
Tissue & Other
Machine Creped
Paper
60% boxed facial
tissue, 40% roll
toilet tissue
n.a.
136MDMT/day;
45,000 MDMT/yr
150MDMT/day;
49,500 MDMT/yr
Net Operating Days
Process
Fiber Furnish
Pulp Yield
Mill Location
Boundary Limits
330/yr
Integrated to bl. kraft
100% virgin bl. kraft
slush pulp (50% SW,
50% HW)
n.a.
Northeast
Transfer of slush pulp
through production of
converted tissue products
CAPITAL REQUIREMENTS*
($000)
Jumbo Roll
Converted & Pkgd.
Total
Physical Plant
Other Fixed Capital
Total Fixed Capital
Working Capital
Total Capital Required
20,000
2,000
22,000
2,000
24,000
31,300 51,300
3,100 5,100
34,000
6,000
40,000
56,000
8,000
64,000
ENERGY REQUIREMENTS
(per MDMT)
Steam
(kg)
Power
(kWh)
Jumbo Rolls
Stock Preparation
Paper Making
Effluent Treatment
Misc. & Auxiliaries
Conversion & Packaging
Converting \
Misc. & Auxiliaries /
Total
150
2,000 150
20
400 20
2,400 340
1,000 30
3,400 370
'Totals may not add due to rounding.
n-67
Arthur D Little Inc
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Fiber Furnish
Other Raw Materials
Total Raw Materials Cost
Labor + Fringe @ 32% of Hourly Rate
Supplies
Energy
Factory Overhead
Total Conversion Costs
Capital-Related Costs
• Total Factory Operating Cost
GS&A
Freight Out
Total Cost of Sales
• Total Delivered Cost
TABLED-7-41 (Confd.)
OPERATING COST*
Jumbo Rolls
($/MDMT)
Converting and Packaging
($/MDMT)*«
161.1
8.5
19.6
10.5
13.1
169.6
231.2
n.a
34.2
81.4
5.2
231.2
51.1
36.7
257.3 ($233.4/MDST)
153.6
66.0
129.4
18.6
379.2
219.6
598.8 ($543.2/MDST)
"Based on.gross weight of converted tissue products, including packaging.
D-68
Arthur D Little Inc
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TABLE D-7-42
ESTIMATED FIXED CAPITAL REQUIREMENT FOR
TISSUE PAPER FROM 100% VIRGIN
Item Bldgs .
Site Preparation 900
Stock Preparation 200
Paper Machine (incl. roll finishing
& Winding) 1,600
Steam/Power Generation & Dist. 100
Water & Effluent Treatment 100
Auxiliary Equipment & Bldgs. - 1,100
TOTAL DIRECT PLANT COST (DPC) 4,000
Engineering, Const. Supervision &
Fee @ 25% DPC 1,000
TOTAL PHYSICAL PLANT COST (PPC) 5,000
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
D-69
THE MANUFACTURE OF
FIBER
Cost ($000)
Equip. Total
900
1,100 1,300
8,300 9,900
700 800
1,700 1,800
200 1,300
12,000 16,000
3,000 4,000
15,000 20,000
2,000
22,000
Use $22 MM
Art
Arthur D Little Inc
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TABLE D-7-43
ESTIMATED FIXED CAPITAL REQUIREMENT FOR CONVERTING TISSUE
PAPER MANUFACTURED FROM 100% VIRGIN FIBER
Item
Cost ($000)
Total Plant Equipment Cost (PEC) 6,000
Mill Building 600
Allocated Auxiliary Facilities (power, 300
steam, etc.)
Allocated Plant Site (railway, parking 700
lot, access roads, fences, etc.)
Shops and Laboratory 1,400
TOTAL DIRECT PLANT COST (DPC) 9,000
Engineering, Const. Supervision & Fee 2,30()
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC) 11,300
OTHER FIXED CAPITAL @ 10% PPC 1,100
TOTAL FIXED CAPITAL 12,400
Use $12 MM
D-70
Arthur D Little Inc
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TABLE D-7-44
ESTIMATED HOURLY LABOR REQUIREMENTS FOR MANUFACTURE OF TISSUE
FROM 100% VIRGIN FIBER
Men
per Shift
DIRECT LABOR
Stock Preparation
Foreman 1
Operator 1
Make-up man 1
Machine Room
Foreman 1
Machine tender 1
Back tender 1
Third hand 1
Fourth hand 1
TOTAL DIRECT LABOR
ALLOCATED INDIRECT LABOR
Auxiliary
Shipping and Receiving Foreman 1
Shipping and Receiving 3
Materials Handling 2
Effluent and water treatment 1
Sludge disposal 1
Steam plant 1
Utility 5
TOTAL INDIRECT LABOR
D-71
Shifts
per Day
1
3
1
1
3
3
3
3
1
1
3
3
2
3
1
Total
Men
1
4
1
1
4
4
4
_4
23
1
3
8
4
2
4
_5
27
Arthur DLittleJnc
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TABLE D-7-45
ESTIMATED HOURLY LABOR REQUIREMENTS FOR TISSUE CONVERTING
Basis: Single line converting (64 MDMT/day)*
DIRECT IABOR
Foreman
Box facial converting
Role toilet converting
Printing
Men per Shifts per Total
Shift day Men
1
9
4
2
Total
3
3
3
3
3
36
16
_!
61
*For plant producing 136 MDMT/day, labor requirements
are doubled.
D-72
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645
640
635
630
- 625
TJ
CD
620
615
610
c
4-»
03
0 605
600
595
590
585
50 100 150
Capacity, Metric Tons Per Day
200
60
50
40
o
<£>
30 |
'a
<3
1
LH
20
10
FIGURE D-7-14 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF BOX FACIAL AND ROLL
TOILET TISSUE (VIRGIN)
D-73
Arthur D Little Inc
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TABLE D - 7 - 46
DESIGN BASIS
Functional Group
Grade
Basis Weight
Production
Net Operating Days
Tissue & Towelling
60% Box Facial;
40% roll toilet tissue
n.a.
70 MDMT/day;
23,000 MDMT/yr
330/yr
Process
Fiber Furnish
Pulp Yield
Mill Location
Boundary Limits
Market Pulp
100% virgin (market pulp)
n.a.
Northeast
Nonintegrated; purchased
market pulp through con-
verting
CAPITAL REQUIREMENTS*
Jumbo Rolls Conv. Total
Physical Plant 12,000 5,700 17,700
Other Fixed Capital 1,200 600 1,800
Total Fixed Capital 13,000 6,000 19,000
Working Capital 4,000
Total Capital Required
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Jumbo Rolls 2,500 520
Converting 1,000 30
23,000
OPERATING COST
($/MDMT)
Fiber Furnish 335.4
Other Raw Materials 8.5
Total Raw Materials Cost 343.9
Labor + Fringe@32%
of Hourly Rate 40.9
Supplies 13.6
Energy 22.6
Factory Overhead 24.0
Total Conversion Costs 101.1
Capital-Related Costs 47.7
• Total Factory Operating
Cost 492.7 ($446.87
MOST)
'Totals may not add due to rounding.
NOTE: Detailed tabulations of fixed capital and labor requirements are not presented for this
model. These requirements were extrapolated from the corresponding data for manufacture of
the same product in an integrated mill. Additional fixed capital is needed by a nonintegrated
mill, primarily for auxiliary facilities, as it does not benefit from the larger scale and economies
obtained by allocating part of the cost of these facilities to an associated pulp mill. With regard
to labor requirements, more manpower is needed to handle market pulp than slush pulp.
Similarly, curves showing how operating costs and fixed capital are related to capacity are
not included with this model. The shapes of the curves would be the same as for the corre-
sponding integrated mill, but displaced vertically to reflect higher unit costs.
D-74
Arthur D Little Inc
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TABLED-7-47
DESIGN BASIS
Functional Group
Grade
Basis Weight
Production
Jumbo Rolls
Converted & Pkgd.
Tissue & Other
Machine Creped Paper
60% boxed facial
tissue, 40% roll toilet
tissue
n.a.
64 MDMT/day;
21,OOOMDMT/yr
70 MDMT/day;
23,000 MDMT/yr
Net Operating Days
Process
Fiber Furnish
Pulp Yield
Mill Location
Boundary Limits
330/yr
S/F pulping and de-inking
100%S/F(40%IBM
card stock, 40% ledger,
20% No. 1 news)
n.a.
Northeast
S/F preparation through
production of converted
tissue products
CAPITAL REQUIREMENTS*
($000)
Jumbo Roll
Convert. & Pkg.
Total
Physical Plant 14,700 5,700
Other Fixed Capital 1,500 600
Total
Working
Fixed Capital 16,000
Capital 1 ,000
Total Capital Required 17,000
6,000
3,000
9,000
ENERGY REQUIREMENTS
(per MDMT)
Steam
(kg)
Jumbo Rolls
De-inking 500
Stock Preparation —
Paper Making 2,000
Effluent Treatment —
Misc. & Auxiliaries 500
Conversion & Packaging
Converting 1 1 000
Misc. & Auxiliaries f
Total
4,000
20,400
2,100
Power
(kWh)
300
150
150
35
35
30
700
22,000
4,000
26,000
'Totals may not add due to rounding.
D-75
Arthur D Little Inc.
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TABLED-7-47(Confd.)
OPERATING COST*
Fiber Furnish
Other Raw Materials
Total Raw Materials Cost
Labor + Fringe @ 32% of Hourly Rate
Supplies
Energy
Factory Overhead
Total Conversion Costs
Capital-Related Costs
• Total Factory Operating Cost
GS&A
Freight Out
Total Cost of Sales
• Total Delivered Cost
Jumbo Rolls
($/MDMT)
199.8
48.1
16.1
27.2
27.6
215.2
Converting and Packaging
($/MDMT)"
357.4
34.2
81.4
5.2
8.5
119.0
58.6
392.8 ($356.3/MDST)
98.5
58.4
357.4
129.4
2Q.O
507.0
157.0
663.9 (S602.3/MDST)
Based on gross weight of converted tissue products, including packaging.
D-76
Arthur D Little Inc
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D-77
Arthur D Little Inc
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TABLE D-7-49
ESTIMATED FIXED CAPITAL REQUIREMENT FOR CONVERTING TISSUE
PAPER MANUFACTURED FROM 100% SECONDARY FIBER
Item Cost ($000)
Total Plant Equipment Cost (PEC) 3,000
Mill Building 300
Allocated Auxiliary Facilities (power, 150
steam, etc.)
Allocated Plant Site (railway, parking area, 350
access roads, fences, etc.)
Shops & Laboratory 700
TOTAL DIRECT PLANT COST (DPC) 4,500
Engineering, Const. Supervision & Fee
@ 25% DPC 1.200
TOTAL PHYSICAL PLANT COST (PPG) 5,700
OTHER FIXED CAPITAL @ 10% PPC 600
TOTAL FIXED CAPITAL 6,300
Use $6 MM
D-78
Arthur D Little Inc
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TABLE D-7-50
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
TISSUE FROM 100% SECONDARY FIBER
DIRECT LABOR
Stock Preparation
Foreman
Operator
Make-up man
Deinking
Pulper
Helper (material handling)
Screening Operator
Washer Operator
Machine Room
Foreman
Machine tender
Back tender
Third hand
TOTAL DIRECT LABOR
INDIRECT LABOR
Auxiliary
Shipping & receiving foreman
Shipping & receiving
Materials handling
Effluent and water treatment
Sludge disposal
Steam plant
Utility
Trash Handling
TOTAL INDIRECT LABOR
Men
per Shift
D-79
1
1
1
1
1
1
1
1
1
1
1
1
3
2
1
1
1
5
1
Shifts
per Day
1
3
1
3
1
3
3
1
3
3
3
1
1
3
3
2
3
1
1
Total
Men
1
4
1
4
1
4
4
1
4
4
_4
33
1
3
8
4
2
4
5
28
Arthur D Little Inc
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700
695
690
685
680
-§ 675
670
665
gj
O 660
655
650
645
640
60
50
40
c
o
30 T3
•^
'a
X
a.
20
10
50 100 150
Capacity, Metric Tons Per Day
200
FIGURE D-7-15 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF BOX FACIAL AND ROLL
TOI LET TISSUE (SECONDARY)
D-80
Arthur D Little Inc
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TABLE D-7-51
ESTIMATED FACTORY OVERHEAD FOR THE MANUFACTURE OF
TISSUE FROM 100% SECONDARY FIBER
(1974 Second Quarter Costs)
Basis: 64 MDMT/Day, 21,000 MDMT/Year, Jumbo Rolls
Position Salary
Plant Manager $ 40,000
Secretary 10,000
Production Manager 25,000
Boss Machine Tender 20,000
Production Clerk 10,000
Technical Superintendent & Quality
Control Manager 20,000
Mill Chemist 14,000
Plant Engineer, Chief 22,000
Maintenance Superintendent 16,000
Process Engineer 16,000
Technician 8,000
Draftsmen 10,000
Personnel Director & Office Manager 20,000
Chief Accountant 16,000
Purchasing Agent 18,000
Assistant 12,000
Paymaster & Safety Director 14,000
Traffic Controller 12,000
Clerical & Secretarial (6) 36,000
Telephone Operator 6,000
Watchmen (4) 24,000
Sub-total, Direct Salaries 369,000
Fringes @ 15% 55,000
Expenses @ 40%, (travel, entertainment, tele-
phone, postage, subscriptions, dues, con-
tributions) 150.000
TOTAL FACTORY OVERHEAD 574,000
Use $580,000
D-81
Arthur D Little Inc
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TABLE D - 7 - 52
DESIGN BASIS
Functional Group
Grade
Basis Weight
Production
Jumbo Rolls
Converted & Pkgd.
Tissue & Other
Machine Creped
Paper
60% boxed facial
tissue, 40% roll
toilet tissue
n.a.
136MDMT/day;
45,000 MDMT/yr
150MDMT/day;
49,500 MDMT/yr
Net Operating Days
Process
Fiber Furnish
Pulp Yield
Mill Location
Boundary Limits
330/yr
Integrated to bl. kraft
67% virgin bl. kraft
slush pulp (50% SW,
50%HW),33%S/F
n.a.
Northeast
Transfer of slush pulp
and S/F preparation
through production of
converted tissue products
CAPITAL REQUIREMENTS*
($000)
Jumbo Roll
Converted & Pkgd.
Total
Physical Plant 22,900 11,300
Other Fixed Capital 2,200 1,100
Total
Working
Fixed Capital 25,000
Capital 2,000
Total Capital Required 27,000
12,000
6,000
18,000
34,200
3,300
37,000
8,000
45,000
ENERGY REQUIREMENTS
(per MDMT)
Jumbo Rolls
De-inking
Stock Preparation
Paper Making
Effluent Treatment
Misc. & Auxiliaries
Conversion & Packaging
Converting i
Misc. & Auxiliaries )
Total
*Totals may not add due to rounding.
Steam
(kg)
175
2,000
425
2,600
1,000
3,600
Power
(kWh)
100
150
150
35
35
470
30
500
D-82
Arthur D Little Inc
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TABLE D - 7 - 52 (Cont'd.)
OPERATING COST
Jumbo Rolls
($/MDMT)
Converting and Packaging
($/MDMT)**
173.7
10.8
24.7
11.7
15.8
10.2
184.4
Fiber Furnish
Other Raw Materials
Total Raw Materials Cost
Labor + Fringe @ 32% of Hourly Rate
Supplies
Energy
Factory Overhead
Total Conversion Costs
Capital-Related Costs
• Total Factory Operating Cost
GS&A
Freight Out
Total Cost of Sales
• Total Delivered Cost
•Based on gross weight of converted tissue products, including packaging.
62.2
42.0
288.7 ($261.9/MDST)
D-83
260.5
n.a.
34.2
81.4
5.2
8.5
260.5
153.6
66.0
129.4
18.6
408.5
219.6
628.2 <$569.9/MDST)
Arthur D Little, Inc
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D-84
Arthur D Little Inc
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TABLE D-7-54
ESTIMATED FIXED CAPITAL REQUIREMENT FOR CONVERTING TISSUE
PAPER MANUFACTURED FROM VIRGIN AND SECONDARY FIBERS
I
_ Item _ Cost ($000)
I Total Plant Equipment Cost 6,000
— Mill Building 600
™ Allocated Auxiliary Facilities (power, 300
steam, etc.)
Allocated Plant Site (railway, parking 700
area, access roads, fences, etc.)
Shops and Laboratory 1,400
_ TOTAL DIRECT PLANT COST (DPC) 9,000
™ Engineering, Const. Supervision & Fee
@ 25% DPC 2,300
I TOTAL PHYSICAL PLANT COST 11,300
(PPC)
OTHER FIXED CAPITAL @ 10% PPC 1.100
12,400
Use $12 MM
D-85
Arthur D Little Inc
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TABLE D-7-55
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
TISSUE FROM 33% S/F, 67% VIRGIN FIBER
Basis: 136 MDMT/Day, 45,000 MDMT/Year, Jumbo Rolls
DIRECT LABOR
Stock Preparation
Foreman
Operator
Make-up Man
Deinking
Pulper
Helper (Material Handling)
Screening Operator
Washer Operator
Trash Handling
Machine Room
Foreman
Machine Tender
Back Tender
Third Hand
Fourth Hand
TOTAL DIRECT LABOR
Men
per Shift
1
1
1
1
1
1
1
1
1
1
1
1
1
Shifts
per Day
1
3
1
3
1
3
3
1
1
3
3
3
3
Total
Men
1
4
1
4
1
4
4
1
1
4
4
4
36
INDIRECT LABOR
Auxiliary
Shipping & Receiving Foreman
Shipping & Receiving
Materials Handling
Effluent & Water Treatment
Sludge Disposal
Steam Plant
Trash Handling
Utility
TOTAL INDIRECT LABOR
1
3
2
1
1
1
1
5
1
1
3
3
2
3
1
1
1
3
8
4
2
4
1
28
D-86
Arthur D Little Inc
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675
670 —
620
615
c
o
a
R>
CJ
"8
x
100 150
Capacity, Metric Tons Per Day
200
FIGURE D-7-16 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF BOX FACIAL AND ROLL
TOILET TISSUE (BLENDED)
D-87
Arthur D Little Inc
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TABLE D - 7 - 56
DESIGN BASIS
Functional Group Folding Boxboard
Grade 18-pt clay coated
(50% sheet, 50%
roll)
Basis Weight n.a.
Production 360 MDMT/day;
11 9,000 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 43,800
Other Fixed Capital 4,400
Total Fixed Capital 48,000
Working Capital 6,000
Total Capital Required 54,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
M/MA/M
(KWn;
Pulping - 220
Board Making 4,500 220
Effluent Treatment - 30
Misc. & Auxiliaries 1,000 180
Total 5,500 650
Process S/F pulping
Fiber Furnish 100% S/F (Top liner:
ledger; filler liner: 90%
news, 20% OCC)
Pulp Yield n.a.
Mill Location North Central
Boundary Limits Preparation of secondary
fiber to board making
OPERATING COST*
($/MDMT)
Fiber Furnish 66.5
Other Raw Materials 1 1 .5
Total Raw Materials Cost 78.0
Labor + Fringe @ 32%
of Hourly Rate 20.1
Supplies 12.3
Energy 22.4
Factory Overhead 1 1 .9
Total Conversion Costs 66.7
Capital-Related Costs 31.0
• Total Factory Operating
Cost 175.7
(159.4/MDST)
GS&A 1 1 .9
Freight Out 15.0
Total Cost of Sales 26.9
• Total Delivered Cost 202.6
($183.8/MDST)
'Totals may not add due to rounding.
D-88
Arthur D Little^ Inc
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1
1
1
1
1
1
I
1
1
1
1
^B
1
1
1
1
1
1
1
TABLE D-7-57
ESTIMATED FIXED CAPITAL REQUIREMENT FOR
18-PT. CLAY-COATED BOXBOARD
Item
Site Preparation
Pulping
Coating Preparation
Board Machine (incl. roll & sheet
finishing)
Steam/Power Generation & Dist.
Water & Effluent Treatment
Warehouse qt Non-Process Buildings
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
D-89
THE MANUFACTURE OF
Cost ($000)
1,300
7,900
1,500
14,600
5,200
2,800
1,700
35,000
8,800
43,800
4,400
48,200
$48 MM
Arthur D Little; Inc
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TABLE D-7-58
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
18-POINT CLAY-COATED BOXBOARD
Direct Labor Total Men
Pulping 24
Machine Crews (less finishing) 36
Finishing 24_
Total Direct 84
Indirect Labor
Shipping and Receiving 20
Steam/Power Plant 6
Effluent Treatment and Misc. 8
Total Indirect 34
D-90
Arthur DLittleJnc
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245
240
235
230
.1 225
0>
73
220
215
D)
C
a 210
a
O
205
200
195
190
100 200 300 400
Capacity, Metric Tons Per Day
500
60
50
40
c
o
ifi
3
-a
0)
X
30
20
10
600
FIGURE D-7-17 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF 18-POINT CLAY-COATED
BOXBOARD
D-91
Arthur D Little, Inc
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TABLE D - 7 - 59
DESIGN BASIS
Functional Group Folding Boxboard
Grade SBS Board
(bleached foodboard)
Basis Weight 293 g/m2
(180lb/3000sqft)
Production 450 MDMT/day;
1 50,000 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 35,100
Other Fixed Capital 3,500
Total Fixed Capital 39,000
Working Capital 9,000
Total Capital Required 48,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Stock Preparation - 150
Board Making 3,000 1 50
Effluent Treatment i
i-..iuv.i.i. K.uiiiii.i-1 • Ann dn
• • . A k •!• • S ^\J\J ^\J
Misc. & Auxiliaries (
Total 3,400 340
Process Integrated to 730 ADMT
bl kraft
Fiber Furnish Kraft slush pulp (60% bl
SW, 40% bl HW)
Pulp Yield n.a.
Mill Location Southeast
Boundary Limits Transfer of slush pulp to
board making
OPERATING COST*
($/MDMT)
Fiber Furnish 135.7
Other Raw Materials 13.0
Total Raw Materials Cost 148.5
Labor & Fringe @ 32% of
Hourly Rate 13.0
Supplies 11.0
Energy 8.5
Factory Overhead 5.0
Total Conversion Costs 37.6
Capital-Related Costs 19.8
• Total Factory Operating Cost 205.9
($186.8/MDST)
GS&A 13.0
Freight Out 30.0
Total Cost of Sales 43.0
• Total Delivered Cost 248.8
($225.7/MDST)
"Totals may not add due to rounding.
D-92
Arthur DLitthlnc
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TABLE D-7-60
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
SBS BOARD
Item
Site Preparation
Stock Preparation
Board Machine & Roll Finishing
Steam/Power Generation & Dist.
Water & Effluent Treatment
Aux. Equip. & Buildings
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
Use
D-93
Cost ($000)
1,200
4,000
15,500
3,500
2,200
1,700
28,100
7,000
35,100
3,500
38,600
$39 MM
Arthur D Little; Inc
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TABLE D-7-61
ESTIMATED HOURLY LABOR REQUIREMENTS FOR
THE MANUFACTURE OF SBS BOARD
Men
per shift
Shifts
per day
Total
Men
DIRECT LABOR
Stock Preparation:
Foreman 1
Operator 1
Beater 1
Make-up Man 1
Paper Machine:
Foreman 1
Machine Tender 1
Back Tender 1
Third to Fifth Hands 4
Roll Finishing & Wrapping 2
Total Direct
1
3
3
1
3
3
3
3
3
1
4
4
1
4
4
4
16
_8
46
ALLOCATED INDIRECT LABOR
Shipping & Receiving Foreman 1
Shipping & Receiving 5
Material Handling 3
Utility 5
Tester 1
Effluent Treatment 1
Total Indirect
1
1
3
2
3
3
1
5
12
10
3
3
34
D-94
Arthur D Little Inc
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266
264
262
260
I 258
"oi
S 256
254
.3
O)
I 252
O
250
248
246
244
100 200 300 400
Capacity, Metric Tons Per Day
500
50
40
o
30
20
10
600
FIGURE D-7-18 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF SBS BOARD
D-95
Arthur D Little Inc
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TABLE D - 7 - 62
DESIGN BASIS
Functional Group Printing & Writing
Papers
Grade Bond paper
Basis Weight 70 g/m2
{47 lb/3300 sq ft)
Production 272 MDMT/day;
90,000 MDMT/yr
(rolls)
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 33,700
Other Fixed Capital 3,000
Total Fixed Capital 37,000
Working Capital 7,000
Total Capital Required 44,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Stock Preparation — 160
Paper Making 2,700 160
Effluent Treatment - 20
Misc. & Auxiliaries 500 20
Total 3,200 360
Process Integrated to bl. kraft
Fiber Furnish 100% virgin bl. kraft slush
pulp (50% SW, 50% HW)
Pulp Yield n.a.
Mill Location Northeast
Boundary Limits Transfer of slush pulp
through paper making
OPE RATING COST*
($/MDMT)
Fiber Furnish 146.6
Other Raw Materials 24.0
Total Raw Materials Cost 170.6
Labor + Fringe @ 32%
of Hourly Rate 1 3.7
Supplies 15.0
Energy 1 4.8
Factory Overhead 5.7
Total Conversion Costs 49.2
Capital-Related Costs 31.6
• Total Factory Operating
Cost 251. 4 ($228.1 /
MOST)
GS&A 34.0
Freight Out 30.0
Total Cost of Sales 64.0
• Total Delivered Cost 315.4 ($286.1 /
MOST)
'Totals may not add due to rounding.
D-96
Arthur D Little Inc
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TABLE D-7-63
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
BOND PAPER FROM 100% VIRGIN FIBER
Cost ($000)
Item
Bldgs. Equip. Total
Site Preparation
Stock Preparation
Paper Machine (incl. roll finishing
& winding)
Steam/Power Generation & Dist.
Water & Effluent Treatment
Auxiliary Equipment & Buildings
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
1,400 - 1,400
400 1,600 2,000
2,800 14,600 17,400
200
200
1,600
1,300
2,600
300
1,600 5,100
8,200 25,500
Use
1,500
2,800
1,900
6,600 20,400 27,000
6,700
33,700
3,000
36,700
$37 MM
D-97
Arthur D Little Inc
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TABLE D-7-64
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BOND PAPER FROM 100% VIRGIN FIBER
Men
per Shift
Shifts
per Day
DIRECT LABOR
Stock Preparation
Foreman
Operator
Beater
Makeup Man
Paper Machine
Foreman
Machine Tender
Back Tender
Helper
Third, Fourth,
Fifth Hands
Roll Finishing & Wrapping
TOTAL DIRECT
ALLOCATED INDIRECT LABOR
Shipping & Receiving Foreman
Shipping & Receiving
Materials Handling
Effluent and Water Treatment
Sludge Disposal
Steam Plant
Utility
Tester
TOTAL INDIRECT
1
1
1
1
1
1
1
1
3
1
1
5
3
I
I
1
5
1
1
3
3
1
1
3
3
1
3
3
1
4
4
1
1
4
4
1
12
_4
36
1
1
3
3
2
3
1
3
1
5
12
4
2
4
5
3
36
D-98
Arthur D Little; Inc
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355
350
345
340
^
| 335
^
l-
1 330
325
a>
c
2 320
O
315
310
305
300
100 200 300
Capacity, Metric Tons Per Day
50
40
30
20
c
o
a
03
O
x
il
10
400
FIGURE D-7-19 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF BOND PAPER (VIRGIN)
D-99
Arthur D Little Inc
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TABLE D - 7 - 65
DESIGN BASIS
Functional Group
Grade
Basis Weight
Production
Net Operating Days
Printing & Writing
Bond paper
70 g/m2
(47 lb/3300 sq ft)
136 M DMT/day;
45,000 MDMT/yr
(rolls)
330/yr
Process
Fiber Furnish
Pulp Yield
Mill Location
Boundary Limits
Market Pulp
100% Virgin (market
pulp)
n.a.
Northeast
Nonintegrated; pur-
chased market pulp
through papermaking
CAPITAL REQUIREMENTS*
($000)
Physical Plant 22,200
Other Fixed Capital 2,200
Total Fixed Capital 24,000
Working Capital 5,000
Total Capital Required 29,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
3,300 550
OPERATING COST
($/MDMT)
Fiber Furnish 305.1
Other Raw Materials 14.0
Total Raw Materials Cost 319.1
Labor + Fringe @ 32%
of Hourly Rate 27.2
Supplies 17.8
Energy 26.2
Factory Overhead 17.1
Total Conversion Costs 88.3
Capital-Related Costs 41.1
• Total Factory Operating
Cost 448.5
GS&A 34.0
Freight Out 22.0
Total Cost of Sales 56.0
• Total Delivered Cost 504.5
($406.8/
MOST)
($457.6/
MOST)
'Totals may not add due to rounding.
NOTE: Detailed tabulations of fixed capital and labor requirements are not presented for this
model. These requirements were extrapolated from the corresponding data for manufacture of
the same product in an integrated mill. Additional fixed capital is needed by a nonintegrated
mill, primarily for auxiliary facilities, as it does not benefit from the larger scale and economies
obtained by allocating part of the cost of these facilities to an associated pulp mill. With regard
to labor requirements, more manpower is needed to handle market pulp than slush pulp.
Similarly, curves showing how operating costs and fixed capital are related to capacity are
not included with this model. The shapes of the curves would be the same as for the
corresponding integrated mill, but displaced vertically to reflect higher unit costs.
D-100
Arthur D Little Inc
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TABLE D - 7 - 66
DESIGN BASIS
Functional Group Printing & Writing
Papers
Grade Bond paper
Basis Weight 70 g/m2
(47 tb/3300 sq ft)
Production 136 MDMT/day;
45,000 MDMT/yr
(rolls)
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 27,300
Other Fixed Capital 2,700
Total Fixed Capital 30,000
Working Capital 5,000
Total Capital Required 35,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
De-inking 500 300
Stock Preparation - 160
Paper Making 2700 160
Effluent Treatment - 20
Misc. & Auxiliaries 600 60
Total 3,800 700
Process S/F pulping and
de-inking
Fiber Furnish 100% S/F
Pulp Yield 82% of AD secondary fiber
to MD paper
Mill Location Northeast
Boundary Limits S/F preparation through
paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 192.3
Other Raw Materials 20.3
Total Raw Materials Cost 212.4
Labor + Fringe @ 32% of
Hourly Rate 31.8
Supplies 19.7
Energy 31.5
Factory Overhead 19.6
Total Conversion Costs 102.7
Capital-Related Costs 51.1
• Total Factory Operating Cost 366.2
($332.2/MDST)
GS&A 34.0
Freight Out 22.0
Total Cost of Sales 56.0
• Total Delivered Cost 422.2
($383.0/MDST)
^Totals may not add due to rounding.
D-101
Arthur D Little Inc
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TABLE D-7-67
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE
BOND PAPER FROM 100% SECONDARY FIBER
Item
Site Preparation
De-inking
Stock Preparation
Paper Machine (incl. roll finishing &
winding)
Steam/Power Generation & Dist.
Water & Effluent Treatment
Auxiliary Equipment & Bldgs.
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Bldgs
900
400
200
1,800
200
200
1,400
5,100
1,300
6,400
Cost ($000)
Equip .
-
2,300
500
9,800
1,300
2,600
300
16,800
4,100
20,900
Use
OF
Total
900
2,700
700
11,600
1,500
2,800
1,700
21,900
5,400
27,300
2,700
30,000
$30 MM
D-102
Arthur D Little Inc
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TABLE D-7-68
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BOND PAPER FROM 100% SECONDARY FIBER
DIRECT LABOR
Stock Preparation
Foreman
Operator
Beater
Makeup Man
Paper Machine
Foreman
Machine Tender
Back Tender
Third, Fourth Hands
Roll Finishing & Wrapping
Deinking
Foreman
Pulper
Helper
Screening Operator
Washer Operator
Trash Handling
TOTAL DIRECT
INDIRECT LABOR
Shipping & Receiving Foreman
Shipping & Receiving
Materials Handling
Effluent & Water Treatment
Sludge Disposal
Steam Plant
Utility
Tester
TOTAL INDIRECT
Men
per Shift
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
6
3
1
1
1
5
1
Shifts
per Day
1
3
3
1
1
3
3
3
3
1
3
2
3
3
2
1
4
4
1
1
4
4
8
4
1
4
2
4
4
48
1
1
3
3
2
3
1
3
1
6
12
4
2
4
5
4
38
D-103
Arthur D Little Inc
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455
450
445
440
435
0)
2 430
425
01
c
420
2
&
O 415
410
405
400
395
100 200 300
Capacity, Metric Tons Per Day
60
50
40
c
o
30 5
'a.
T3
CD
X
20
10
400
FIGURE D-7-20 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF BOND PAPER
(SECONDARY)
D-104
Arthur D Little Inc
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TABLE D - 7 - 69
DESIGN BASIS
Functional Group Printing & Writing
Papers
Grade Bond paper
Basis Weight 70 g/m2
(47 lb/3300 sq ft)
Production 272 MDMT/day;
90,000 MDMT/yr
(rolls)
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 37,800
Other Fixed Capital 3,800
Total Fixed Capital 42,000
Working Capital 8,000
Total Capital Required 50,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
De-inking 175 100
Stock Preparation - 1 60
Panpr Ma if inn 9 7O.O. 1fifl
Effluent Treatment — 20
Misc. & Auxiliaries 525 60
Total 3,400 500
Process Pulp substitute de-inking,
integrated to bleached
kraft
Fiber Furnish 67% virgin bl. kraft slush
pulp, 33% S/F
Pulp Yield 82% AD S/F to MD paper
Mill Location Northeast
Boundary Limits Transfer of slush pulp and
S/F preparation through
paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 158.3
Other Raw Materials 25.9
Total Raw Materials Cost 184.1
Labor + Fringe @ 32% of
Hourly Rate 17.0
Supplies 16.3
Energy 18.4
Factory Overhead 7.2
Total Conversion Costs 59.2
Capital-Related Costs 35.8
• Total Factory Operating Cost 279.1
($253.2/MDST)
GS&A 34.0
Freight Out 30.0
Total Cost of Sales 64.0
($311.3/MDST)
* Tola Is may not add due to rounding.
D-105
Arthur D Little, Inc
-------
TABLE D-7-70
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
BOND PAPER FROM VIRGIN AND SECONDARY FIBERS
Item
Site Preparation
De- inking
Stock Preparation
Paper machine (incl. roll finishing
& winding)
Steam/Power Generation & Dist.
Water & Effluent Treatment
Auxiliary Equipment & Bldgs .
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Bldgs
1,400
300
400
2,800
300
300
1,800
7,300
1,800
9,100
Cost ($000)
Equip .
-
1,800
1,600
14,600
1,500
3,200
300
23,000
5,700
28,700
Use
Total
1,400
2,100
2,000
17,400
1,800
3,500
2,100
30,300
7,500
37,800
3,800
41,600
$42 MM
D-106
Arthur D Little Inc
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TABLE D-7-71
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BOND PAPER FROM VIRGIN AND SECONDARY FIBERS
DIRECT LABOR
Stock Preparation
Foreman
Operator
Beater
Makeup Man
Paper Machine
Foreman
Machine Tender
Back Tender
Helper
Third, Fourth and Fifth Hands
Roll Finishing & Wrapping
Deinking
Foreman
Pulper
Helper
Screening Operator
Washer Operator
Trash Handling
TOTAL DIRECT
INDIRECT LABOR
Shipping & Receiving Foreman
Shipping & Receiving
Materials Handling
Effluent and Water Treatment
Sludge Disposal
Steam Plant
Utility
Tester
TOTAL INDIRECT
Men
per Shift
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
5
3
1
1
1
5
1
Shifts
per Day
1
3
3
1
1
3
1
3
3
1
1
I
3
3
2
3
1
3
Total
Men
1
4
4
1
1
3
3
1
3
3
1
4
4
1
12
4
1
4
1
4
4
51
1
5
12
4
2
4
5
36
D-107
Arthur D Little Inc.
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385
380
375
370
T3
0)
1 365
0)
T3
360
tt 355
o
CJ
O)
c
'« 350
o.
O
345
340
335
330
100 200 300
Capacity, Metric Tons Per Day
400
50
40
o
30
a
CO
CJ
•o
(U
x
20
10
FIGURE D-7-21 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF BOND PAPER (BLENDED)
D-108
Arthur D Little Inc
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Functional Group
Grade
TABLE D - 7 - 72
DESIGN BASIS
Printing, Writing, & Process
Related
Book paper, uncoated Fiber Furnish
Integrated to bleached
kraft
100% virgin bleached kraft
slush pulp (20% SW, 80%
HW)
Basis Weight 70 g/m2
(47 lb/3300 sq ft)
Production 272 MDMT/day;
90,000 MDMT/yr
(rolls)
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 36,700
Other Fixed Capital 3,700
Total Fixed Capital 40,000
Working Capital 7,000
Total Capital Required 47,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Stock Preparation - 150
Paper Making 3,600 200
Effluent Treatment - 20
Misc. & Auxiliaries 600 20
Total 4,200 390
Pulp Yield n.a.
Mill Location Northeast
Boundary Limits Transfer of slush pulp
through paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 125.1
Other Raw Materials 43.5
Total Raw Materials Cost 168.6
Labor + Fringe @ 32% of
Hourly Rate 14.3
Supplies 16.5
Energy 1 8.4
Factory Overhead 6.5
Total Conversion Costs 55.8
Capital-Related Costs 34.2
• Total Factory Operating 258.6 ($234.67
Cost MOST)
GS&A 34.0
Freight Out 30.0
Total Cost of Sales 64.0
• Total Delivered Cost 322.6 ($292.7/
MOST)
"Totals may not add due to rounding.
D-109
Arthur D Little Inc
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TABLE D-7-73
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
BOOK PAPER FROM 100% VIRGIN FIBER
Cost ($000)
Item
Site Preparation
Stock Preparation
Paper machine (incl. size press, roll
finishing & winding)
Steam/Power Generation & Dist.
Water & Effluent Treatment
Auxiliary Equipment & Bldgs.
TOTAL DIRECT PLANT COST (DPC)
Engineering, const, supervision & fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Bldgs.
1,400
400
2,800
300
200
1,600
6,700
1,600
8,300
Equip .
-
1,600
16,600
1,600
2,600
300
22,700
5,700
28,400
Use
Total
1,400
2,000
19,400
1,900
2,800
1,900
29,400
7,300
36,700
3,700
40,400
$40 MM
D-110
Arthur D Little; Inc
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TABLE D-7-74
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BOOK PAPER FROM 100% VIRGIN FIBER
Direct Labor Total Men*
Stock Preparation 10
Paper Machine 30
40
I
Allocated Indirect Labor 36
I
I
I
*For detailed labor schedule, see bond paper from 100%
I virgin fiber; add 1 machine hand per shift (4 total)
for size press
I
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D-lll
Arthur DLittleJnc
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365
360
355
350
f
| 345
OJ
5 340
o
O
O)
c
335
330
325
320
315
310
100 200 300
Capacity, Metric Tons Per Day
50
40
30
c
o
nj
+2
'o.
O
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TABLE D - 7 - 75
DESIGN BASIS
Functional Group Printing & Writing
Grade Uncoated book paper
Basis Weight 70 g/m2
(47 lb/3300 sq ft)
Production 1 36 M DMT/day;
45,000 MDMT/yr
(rolls)
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 23,800
Other Fixed Capital 2,400
Total Fixed Capital 26,000
Working Capital 5,000
Total Capital Required 31,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
4,300 580
Process Market Pulp
Fiber Furnish 100% virgin (market pulp)
Pulp Yield n.a.
Mill Location Northeast
Boundary Limits Nonintegrated; purchased
market pulp through paper-
making
OPERATING COST*
($/MDMT)
Fiber Furnish 279.3
Other Raw Materials 43.5
Total Raw Materials Cost 322.8
Labor + Fringe @ 32%
of Hourly Rate 27.8
Supplies 19.4
Energy 30.6
Factory Overhead 17.1
Total Conversion Costs 94.9
Capital-Related Costs 44.4
• Total Factory Operating
Cost 462.1 ($419.17
MOST)
GS&A 34.0
Freight Out 22.0
Total Cost of Sales 56.0
Total Delivered Cost 518.1 ($469.97
MOST)
*Totals may not add due to rounding.
NOTE: Detailed tabulations of fixed capital and labor requirements are not presented for this
model. These requirements were extrapolated fron the corresponding data for manufacture of
the same product in an integrated mill. Additional fixed capital is needed by a nonintegrated
mill, primarily for auxiliary facilities, as it does not benefit from the larger scale and economies
obtained by allocating part of the cost of these facilities to an associated pulp mill. With regard
to labor requirements, more manpower is needed to handle market pulp than slush pulp.
Similarly, curves showing how operating costs and fixed capital are related to capacity are
not included with this model. The shapes of the curves would be the same as for the
corresponding integrated mill, but displaced vertically to reflect higher unit costs.
D-113
Arthur DLitthlnc
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TABLE D - 7 - 76
DESIGN BASIS
Functional Group Printing, Writing, &
Related
Grade Book paper, uncoated
Basis Weight 70 g/m2
(47 lb/3300 sq ft)
Production 136MDMT/day;
45,000 MDMT/yr
(Rolls)
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 29,300
Other Fixed Capital 2,900
Total Fixed Capital 32,000
Working Capital 5,000
Total Capital Required 37,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(ka) (kWh)
De-inking 500 300
Stock Preparation - 150
Paper Making 3,600 200
Effluent Treatment - 20
Misc & Auxiliaries 700 60
Total 4 800 730
Process S/F pulping and
de-inking
Fiber Finish 100% S/F
Pulp Yield 82% of AD secondary fi-
ber to MD paper
Mill Location Northeast
Boundary Limits S/F preparation through
paper making
OPERATING COST*
(S/MDMT)
Fiber Furnish 167.5
Other Raw Materials 49.3
Total Raw Materials 216.7
Labor + Fringe @ 32%
of Hourly Rate 33.1
Supplies 21.5
Energy 36.5
Factory Overhead 20.7
Total Conversion Costs 1 1 1 .8
Capital-Related Costs 54.4
• Total Factory Operating
Cost 382.9 ($347.4/
MOST)
GS&A 34.0
Freight Out 22.0
Total Cost of Sales 56.0
• Total Delivered Cost 438.9 ($398.2/
MOST)
Totals may not add due to rounding
D-114
Arthur D Little Inc
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1
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1
1
1
1
•i
1
1
1
1
1
1
1
1
1
1
TABLE D-7-77
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE
OF BOOK PAPER FROM 100% SECONDARY FIBER
Cost ($000)
Item Bldgs. Equip.
Site Preparation 900
De-inking 400 2,300
Stock Preparation 200 500
Paper Machine (incl. size press, roll 1,800 11,100
finishing & winding)
Steam/Power Generation & Dist. 300 1,500
Water & Effluent Treatment 200 2,500
Auxiliary Equipment & Bldgs. 1,400 300
TOTAL DIRECT PLANT COST (DPC) 5,200 18,300
Engineering, Const. Supervision & Fee
@ 25% DPC 1,300 4,500
TOTAL PHYSICAL PLANT COST (PPC) 6,500 22,800
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
D-115
Total
900
2,700
700
12,900
1,800
2,800
1,700
23,500
5,800
29,300
2,900
32,200
$32 MM
Arthur
-------
TABLE D-7-78
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BOOK PAPER FROM 100% SECONDARY FIBER
Direct Labor Total Men*
Stock preparation 10
Paper machine 25
De inking L7_
52
Allocated Indirect Labor 38
*For detailed labor schedule, see bond paper from 100% secondary
fiber; add 4 machine hands for size press
D-116
Arthur D Little Inc
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Q
470
465
460
455
450
445
440
(3
o> 435
a
O 430
425
420
415
410
100 200 300
Capacity, Metric Tons Per Day
60
50
40
o
30 2
•a
-------
TABLE D - 7 - 79
DESIGN BASIS
Functional Group Printing, Writing, &
Related
Grade Book paper, un-
coated
Basis Weight 70 g/m2
(47 lb/3300 sq ft)
Production 272 MDMT/day;
90,000 MDMT/yr
(rolls)
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 42,900
Other Fixed Capital 4,300
Total Fixed Capital 47,000
Working Capital 8,000
Total Capital Required 55,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
De-inking 250 150
Stock Preparation — 1 50
Paper Making 3,600 200
Effluent Treatment — 20
Misc. & Auxiliaries 650 40
Total 4,500 560
Process Pulp substitute de-inking,
integrated to bleached kraft
Fiber Furnish 50% virgin bl kraft slush
pulp, 50% S/F
Pulp Yield 82% MD paper to AD
S/F
Mill Location Northeast
Boundary Limits Transfer of slush pulp and
S/F preparation through
paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 149.6
Other Raw Materials 47.0
Total Raw Materials Cost 196.4
Labor + Fringe @ 32% of
Hourly Rate 17.6
Supplies 18.3
Factory Overhead 7.9
Total Conversion Costs 66.4
Capital-Related Costs 40.1
• Total Factory Operating Cost 302.9
($274.8/MDST)
GS&A 34.0
Freight Out 30.0
Total Cost of Sales 64.0
• Total Delivered Cost 366 9
($332.9/MDST)
'Totals may not add due to rounding.
D-118
Arthur D Little; Inc
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1
1
1
1
1
•
1
1
1
•
1
1
••
1
1
••1
1
1
1
1
1
1
TABLE D-7-80
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE
BOOK PAPER FROM VIRGIN AND SECONDARY FIBERS
Cost ($000)
Item Bldg. Equip.
Site Preparation 1,400
De- inking 500 2,700
Stock Preparation 400 1,600
Paper Machine (incl. size press, roll
finishing & winding) 2,800 16,600
Steam/Power Generation & Dist. 300 1,900
Water & Effluent Treatment 400 3,400
Auxiliary Equipment & Bldgs. 2,000 300
TOTAL DIRECT PLANT COST (DPC) 7,800 26,500
Engineering, Const. Supervision & Fee
@ 25% DPC 1,900 6,700
TOTAL PHYSICAL PLANT COST (PPC) 9,700 33,200
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
D-119
OF
Total
1,400
3,200
2,000
19,400
2,200
3,800
2,300
34,300
8,600
42,900
4,300
47,200
$47 MM
Arthur!
-------
TABLE D-7-81
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BOOK PAPER FROM VIRGIN AND SECONDARY FIBERS
Direct Labor Total Men*
Stock preparation 10
Paper machine 30
Deinking 17
57
Allocated Indirect Labor 36
*For detailed labor schedule, see bond paper from virgin
and secondary fibers; add 4 machine hands for size press
and 2 helpers for deinking.
D-120
Arthur D Little Inc
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415
410
405
400
- 395
0)
-------
TAB I
DESI
Functional Group Industrial Packaging,
Converting & Misc.
Grade Unbl. kraft bag paper
Basis Weight 93 g/m2
(56 lb/3000 sq ft)
Production 210 MDMT/day;
69,300 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 25,000
Other Fixed Capital 2,500
Total Fixed Capital 28,000
Working Capital 3,000
Total Capital Required 31,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Stock Preparation - 220
Paper Making 4,000 100
Effluent Treatment — 50
Misc. & Auxiliaries 600 _ 170
Total 4,600 540
'Totals may not add due to rounding.
.E D - 7 - 82
GN BASIS
Process Integrated to unbl. kraft
pulp mill
Fiber Furnish 100% unbl. SW kraft slush
pulp
Pulp Yield n.a.
Mill Location Southeast
Boundary Limits Transfer of slush pulp
through paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 90.2
Other Raw Materials 1 1 .0
Total Raw Materials Cost
Labor + Fringe @ 32% of
Hourly Rate 17.6
Supplies 8.3
Energy 10.5
Factory Overhead 5.9
Total Conversion Costs
Capital- Related Costs
• Total Factory Operating
Cost
GS&A 7.0
Freight Out 18.0
Total Cost of Sales
• Total Delivered Cost
101.2
42.3
30.9
174.3
($158.1 /MOST)
25.0
199.3
($180.8/MDST)
D-122
Arthur D Little Inc
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I
I TABLE D-7-83
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
• UNBLEACHED KRAFT BAG PAPER FROM 100% VIRGIN FIBER
I
I
I
Item Cost ($000)
Site Preparation 1,500
Stock Preparation 1,000
Paper Machine 12,000
1
Steam/Power Generation & Dist. 2,000
• Water & Effluent Treatment 2,600
Auxiliary Equipment & Building 900
I TOTAL DIRECT PLANT COST (DPC) 20,000
•Engineering, Const. Supervision & Fee
@ 25% DPC 5.000
_ TOTAL PHYSICAL PLANT COST (PPC) 25,000
• OTHER FIXED CAPITAL @ 10% PPC 2,500
• TOTAL FIXED CAPITAL* 27,500
Use $28 MM
*For papermaking only; plant investment for slush pulp man-
ufacture is in addition and estimated at $ 24 million.
I
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D-123
I Arthur DLittleJnc
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TABLE D-7-84
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
UNBLEACHED KRAFT BAG PAPER FROM 100% VIRGIN FIBER
Direct Labor
Stock Preparation
Machine Crew
Wrapping
Roll Handling
Chemical Preparation &
Handling
Total Men
4
16
4
8
33
Allocated Indirect Labor
Foreman
Material Handling
Paper Tester
Instrumentation
Effluent Disposal
Power & Steam
Watchman and Gate
Shipping
Technician
1
4
2
1/2
1
1
1
3
_1
14 1/2
D-124
Arthur D Little, Inc
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235
230
225
220
£ 215
-------
TABLE D - 7 - 85
DESIGN BASIS
Functional Group Packaging Papers
Grade Unbleached kraft bag
Basis Weight 93 g/m2
(57 lb/3000 sq ft)
Production 1 20 M DMT/day;
39,600/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 16,900
Other Fixed Capital 1,700
Total Fixed Capital 19,000
Working Capital 5,000
Total Capital Required 24,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
4,100 630
Process Market pulp
Fiber Furnish 100% virgin (market pulp)
Pulp Yield n.a.
Mill Location Northeast
Boundary Limits Nonintegrated; purchased
market pulp through pa-
permaking
OPERATING COST
(S/MDMT)
Fiber Furnish 306.3
Other Raw Materials 11.0
Total Raw Materials Cost 317.3
Labor + Fringe @ 32%
of Hourly Rate 29.5
Supplies 8.4
Energy 32.2
Factory Overhead 1 5.5
Total Conversion Costs 85.6
Capital-Related Costs 36.6
• Total Factory Operating
Cost 439.5 ($398.6/
MOST)
GS&A 7.0
Freight Out 1 5.0
Total Cost of Sales 22.0
• Total De I ivered Cost 46 1 .5 ($4 1 8.6/
MOST)
'Totals may not add due to rounding.
NOTE: Detailed tabulations of fixed capital and labor requirements are not presented for this
model. These requirements were extrapolated from the corresponding data for manufacture of
the same product in an integrated mill. Additional fixed capital is needed by a nonintegrated
mill, primarily for auxiliary facilities, as it does not benefit from the larger scale and economies
obtained by allocating part of the cost of these facilities to an associated pulp mill. With regard
to labor requirements, more manpower is needed to handle market pulp than slush pulp.
Similarly, curves showing how operating costs and fixed capital are related to capacity are
not included with this model. The shapes of the curves would be the same as for the
corresponding integrated mill, but displaced vertically to reflect higher unit costs.
D-126
Arthur D Little Inc
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TABLE D - 7 - 86
DESIGN BASIS
Functional Group Industrial Packaging,
converting and Misc.
Grade Unbl. kraft bag paper
Basis Weight 93 g/m2
(57 lb/3000 sq ft)
Production 120 MDMT/day;
39,600 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 18,800
Other Fixed Capital 1,900
Total Fixed Capital 21,000
Working Capital 3,000
Total Capital Required 24,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Pulping, Cleaning &
Stock Prep. - 300
Paper Making 4,000 100
Water & Effluent
Treatment — 60
Misc. & Auxiliaries 600 170
Total 4,600 630
Process S/F pulping
Fiber Furnish 100% S/F (20% dbl. kraft
lined corr. cuts, 80% P/S
unbl. kraft grades)
Pulp Yield 93%
Mill Location Northeast
Boundary Limits S/F preparation through
paper making
OPERATING COST*
(S/MDMT)
Fiber Furnish 99.8
Other Raw Materials 11.5
Total Raw Materials Cost 111.4
Labor + Fringe @ 32% of
Hourly Rate 31.7
Supplies 8.8
Energy 32.2
Factory Overhead 16.4
Total Conversion Costs 89.1
Capital-Related Costs 40.9
• Total Factory Operating
Cost 241-4
GS&A 7.0 ($218-9/MDST>
Freight Out 15.0
Total Cost of Sales 22.0
• Total Delivered Cost 263.4
($238.9/MDST)
'Totals may not add due to rounding.
D-127
Arthur D Little Inc
-------
TABLE D-7-87
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
UNBLEACHED KRAFT BAG PAPER FROM 100% SECONDARY FIBER
Item Cost ($000^
Site Preparation 900
Pulping & Stock Preparation 1,500
Paper Machine 8,600
Steam Generation/Distribution 1,500
Water & Effluent Treatment 1,900
Auxiliary Equipment & Buildings 600
TOTAL DIRECT PLANT COST (DPC) 15,000
Engineering, Const. Supervision & Fee
@ 25% DPC 3,800
TOTAL PHYSICAL PLANT COST (PPC) 18,800
OTHER FIXED CAPITAL @ 10% PPC 1,900
TOTAL FIXED CAPITAL 20,700
Use $21 MM
D-128
Arthur D Little Inc
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1
1
1
1
1
1
1
1
1
1
1
1
1
^M
1
TABLE D-7-88
ESTIMATED HOURLY LABOR REQUIREMENT FOR
UNBLEACHED KRAFT BAG PAPER FROM 100%
Direct Labor
Pulping
Stock Prep.
Machine Crew
Wrapping
Roll Handling
Chemical Prep. & Handling
Allocated Indirect Labor
Working Foremen (1 shift)
Material Handling
Paper Tester
Instrumentation
Effluent Disposal
Steam Generation
Watchman and Gate
Receiving and Shipping
Technician
D-129
THE MANUFACTURE OF
SECONDARY FIBER
Total Men
4
4
16
4
8
_JL
37
4
6
4
1
2
3
3
6
1
30
Arthur D Little Inc
-------
o>
k.
0)
295
290
285
280
275
0)
2 270
I-
Q
1 265
u
8
01 260
c
O 255
250
245
240
235
100 200 300
Capacity, Metric Tons Per Day
60
50
40
c
o
30 |
'a
20
10
400
FIGURE D-7-26 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF UNBLEACHED KRAFT
BAG PAPER (SECONDARY)
D-130
Arthur D Little; Inc
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TABLE D - 7- 89
DESIGN BASIS
Functional Group Industrial Packaging,
converting & Misc.
Grade Unbl. kraft bag paper
Basis Weight 93 g/m2
(57lb/3000sqft)
Production 210 MDMT/day;
69,300 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 26,000
Other Fixed Capital 2,600
Total Fixed Capital 29,000
Working Capital 3,000
Total Capital Required 32,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Pulping & Stock Prep - 240
Paper Making 4,000 100
Water & Effluent
Treatment — 60
Misc. & Auxiliaries 600 160
Total 4,600 560
Process Integrated to unbl. kraft
pulp mill
Fiber Furnish 70% unbl. SW kraft, 30%
S/F (24% P/S unbl. kraft
grades, 6% dbl. kraft lined
corr. cuts)
Pulp Yield 93% for S/F
Mill Location Southeast
Boundary Limits Transfer of slush pulp and
S/F production through
paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 92.7
Other Raw Materials 11.0
Total Raw Materials Cost 103.6
Labor + Fringe® 32% of
Hourly Rate 18.1
Supplies 8.3
Energy 10.7
Factory Overhead 6.2
Total Conversion Costs 43. 1
Capital- Related Costs 32.0
• Total Factory Operating
Cost 178'8
(S162.2/MDST)
GS&A 7.0
Freight Out 18.0
Total Cost of Sales 25.0
• Total Delivered Cost 203.8
($184.8/MDST)
D-131
Arthur DLittleJnc
-------
TABLE D-7-90
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
UNBLEACHED KRAFT BAG PAPER FROM VIRGIN AND SECONDARY FIBERS
Item Cost ($000)
Site Preparation 1,500
Pulping (Secondary Fiber) 1,000
Stock Preparation 800
Paper Machine 12,000
Steam & Power Generation/Distribution 2,000
Water & Effluent Treatment 2,600
Auxiliary Equipment & Buildings 900
TOTAL DIRECT PLANT COST (DPC) 20,800
Engineering, Const. Supervision & Fee
@ 25% DPC 5,200
TOTAL PHYSICAL PLANT COST (PPC) 26,000
OTHER FIXED CAPITAL @ 10% PPC 2,600
TOTAL FIXED CAPITAL * 28,600
Use $29 MM
* Does not include investment required for unbleached SW Kraft slush
pulp manufacture.
D-132
Arthur D Little; Inc
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1
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1
1
1
1
1
1
1
I
1
1
1
1
1
1
1
1
TABLE D-7-91
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
UNBLEACHED KRAFT BAG PAPER FROM VIRGIN AND SECONDARY FIBERS
Direct Labor Total Men
Stock Preparation 6
Machine 16
Wrapping 4
Roll Handling 8
Chemical Prep. & Handling 1
35
Allocated Indirect Labor
Foreman 1
Material Handling 4
Paper Tester 2
Instrumentation 1/2
Effluent Disposal 1
Power & Steam 1
Watchman and Gate 1
Shipping 3
Technician 1
14 1/2
D-133
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Arthur D Little; Inc.
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235
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TABLE D - 7 - 92
DESIGN BASIS
Functional Group Industrial Packaging,
converting and Misc.
Grade Tube Paper
Basis Weight 146g/m2
(90 lb/3000 sq ft)
Production 240 MDMT/day;
79,200 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 25,000
Other Fixed Capital 2,500
Total Fixed Capital 28,000
Working Capital 4,000
Total Capital Required 32,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Stock Preparation - 230
Paper Making 4,000 105
Water & Effluent
Treatment — 50
Misc. & Auxiliaries 600 180
Total 4,600 565
Process Integrated to unbl. kraft
pulp mill
Fiber Furnish 100% unbl. SW kraft slush
pulp
Pulp Yield n.a.
Mill Location Southeast
Boundary Limits Transfer of slush pulp
through paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 90.2
Other Raw Mated als 11.0
Total Raw Materials Cost 101.1
Labor + Fringe @ 32% of
Hourly Rate 15.4
Supplies 8.3
Energy 10.8
Factory Overhead 5.2
Total Conversion Costs 39.6
Capital- Related Costs 27.0
• Total Factory Operating
Cost 167'8
($152.2/MDST)
GS&A 7.0
Freight Out 15.0
Total Cost of Sales 22.0
• Total Delivered Cost 189.8
($172.1/MDST)
D-135
Arthur D Little; Inc.
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TABLE D-7-93
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
TUBE PAPER FROM 100% VIRGIN FIBER
Item Cost ($000)
Site Preparation 1,500
Stock Preparation 1,000
Paper Machine 12,000
Steam & Power Generation/Distribution 2,000
Water & Effluent Treatment 2,600
Auxiliary Equipment & Buildings 900
TOTAL DIRECT PLANT COST (DPC) 20,000
Engineering, Const. Supervision & Fee
@ 25% DPC 5,000
TOTAL PHYSICAL PLANT COST (PPC) 25,000
OTHER FIXED CAPITAL
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TABLE D-7-94
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF TUBE
PAPER FROM 100% VIRGIN FIBER
Direct Labor
Stock Preparation
Machine crew
Wrapping
Roll Handling
Chemical Preparation &
Handling
Allocated Indirect Labor
Foreman
Material Handling
Paper tester
Instrumentation
Effluent disposal
Power and steam
Watchman and gate
Shipping
Technician
Total Men
4
16
4
8
33
1
4
2
1/2
1
1
1
3
1
14 1/2
D-137
Arthur D Little Inc
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220
215
210
5 200
h-
Q
5 195
C
V-1
ro
190
185
180
175
170
100 200 300
Capacity, Metric Tons Per Day
50
40
30
I
20
10
400
FIGURE D-7-28 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF TUBE PAPER (VIRGIN)
D-138
Arthur D Little; Inc
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TABLE D - 7 - 95
DESIGN BASIS
Functional Group Industrial Packaging,
Converting & Misc.
Grade Tube paper
Basis Weight 146 g/m2
(90 lb/3000 sq ft)
Production 136 M DMT/day;
45,000 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 18,800
Other Fixed Capital 1,900
Total Fixed Capital 21 ,000
Working Capital 3,000
Total Capital Required 24,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Pulping - 315
Paper Making 4,000 105
Water & Effluent
Treatment 60
Misc. & Auxiliaries 600 180
Total 4,600 660
Process S/F pulping
Fiber Furnish 100% S/F (20% dbl. kraft
lined corr. cuts, 80% P/S
unbl. kraft grades)
Pulp Yield 93%
Mill Location Northeast
Boundary Limits S/F preparation through
paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 99.8
Other Raw Materials 1 1 .5
Total Raw Materials Cost 1 1 1 .3
Labor + Fringe @ 32% of
Hourly Rate 28.1
Supplies 8.8
Energy 32.9
Factory Overhead 14.4
Total Conversion Costs 84.2
Capital-Related Costs 36.0
• Total Factory Operating
Cost 231'6
(S210.1/MDST)
GS&A 7.0
Freight Out 12.0
• Total Delivered Cost 250.6
($227.3/MDST)
D-139
Arthur D Little; Inc
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TABLE D-7-96
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
TUBE PAPER FROM 100% "SECONDARY FIBER
Item
Cost ($000)
Site Preparation 900
Pulping 1,500
Paper Machine 8,600
Steam Generation/Distribution 1,500
Water & Effluent Treatment 1,900
Auxiliary Equipment & Buildings 600
TOTAL DIRECT PLANT COST (DPC) 15,000
Engineering, Const. Supervision & Fee
@ 25% DPC 3,800
TOTAL PHYSICAL PLANT COST (PPC) 18,800
OTHER FIXED CAPITAL @ 10% PPC 1,900
TOTAL FIXED CAPITAL 20,700
Use $21 MM
D-140
Arthur DLittleJnc
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TABLE D-7-97
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
TUBE PAPER FROM 100% SECONDARY FIBER
Direct Labor Total Men
Pulping 4
Stock Prep. 4
Machine crew 16
Wrapping 4
Roll handling 8
Chemical prep. & Handling 1
37
Indirect Labor
Working foreman (I/shift) 4
Material handling 6
Paper tester 4
Instrumentation 1
Effluent disposal 2
Steam generation 3
Watchman and gate 3
Receiving and shipping 6
Technician 1
30
D-141
Arthur D Little; Inc
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280
275 —
270 —
265 —
?? 260
01
S 255
250
245
tt
cS
O)
c
'•p
ro
^
O 240
235
230
225
220
Capital
100 200 300
Capacity, Metric Tons Per Day
60
50
40
o
30 5
a
20
10
400
FIGURE D-7-29 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF TUBE PAPER
(SECONDARY)
D-142
Arthur D Little Inc
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TABLE D - 7 - 98
DESIGN BASIS
Functional Group Industrial Packaging,
Converting & Misc.
Grade Tube paper
Basis Weight 146g/m2
(90lb/3000sqft)
Production 240 MDMT/day;
79,200 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 26,500
Other Fixed Capital 2,700
Total Fixed Capital 29,000
Working Capital 4,000
Total Capital Required 33,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Pulping - 200
Stock Preparation - 90
Paper Making 4,000 105
Treatment — 60
Misc. & Auxiliaries 600 180
Total .4,600 635
Process Integrated to unbl. kraft
pulp mill
Fiber Furnish 30% unbl. SW kraft, 70%
S/F ( 1 4% dbl. kraft lined
corr. cuts, 56% P/S unbl.
kraft grades)
Pulp Yield 93% for S/F
Mill Location Southeast
Boundary Limits Transfer of slush pulp and
S/F preparation through
paper making
OPERATING COST*
($/MDMT)
Fiber Furnish 96.8
Other Raw Materials 11.0
Total Raw Materials Cost 107.8
Labor + Fringe @ 32% of
Hourly Rate 16.2
Supplies 8.3
Energy 11.6
Factory Overhead 5.6
Total Conversion Costs 41.7
Capital-Related Costs 28.2
• Total Factory Operating
Cost 177.7
GS&A 7.0 (S195.8/MDST)
Freight Out 15.0
Total Cost of Sales 22.0
• Total Delivered Cost 199.6
(S181.0/MDST)
'Totals may not add due to rounding.
B-143
Arthur D Little Inc
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TABLE D-7-99
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
TUBE PAPER FROM VIRGIN AND SECONDARY FIBERS
Item
Cost ($000)
Site Preparation
Pulping (Secondary Fiber)
Stock Preparation
Paper Machine
Stean/Power Generation/Distribution
Water & Effluent Treatment
Auxiliary Equipment & Buildings
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL*
Use
1,500
1,700
500
12,000
2,000
2,600
900
21,200
5.300
26,500
2,700
29,200
$29MM
*For papermaking only; for prescribed quantities of virgin
and secondary fiber slush pulp manufacture, add $8 million
(derived estimate)
D-144
Arthur D Little Inc
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I Stock preparation 4
Pulping 4
Machine crew 16
•Wrapping 4
Roll Handling 8
Chemical preparation and handling 1
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TABLE D-7-100
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
TUBE PAPER FROM VIRGIN AND SECONDARY FIBER
Direct Labor Total Men
Allocated Indirect Labor
I Foreman 1
Material handling 4
Paper Tester 2
Instrumentation 1/2
•Effluent disposal 1
Power and Steam Generation 1
Watchman and Gate 1
Shipping 3
Technician 1
- 14 1/2
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D-145
Arthur D Little Inc
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230
225
220
215
0)
S 210
205
a
*
200
O 195
190
185
180
100 200 300
Capacity, Metric Tons Per Day
50
40
30 I
a.
a
U
20 1
10
400
FIGURE D-7-30 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF TUBE PAPER (BLENDED)
D-146
Arthur D Little; Inc
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TABLED-7-101
DESIGN BASIS
Functional Group Const. Paper & Paper-
board
Grade Roofing felt
Basis Weight 510g/m3
(50lb/480sqft)
Production 136 M DMT/day;
45,000 MDMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 1 1 ,500
Other Fixed Capital 1,200
Total Fixed Capital 13,000
Working Capital 1 ,000
Total Capital Required 14,000
ENERGY REQUIREMENTS
(per MDMT)
Steam Power
(kg) (kWh)
Pulping
Mechanical 200 140
S/F 200 90
Stnrk Prpnaratinn *3fi
Paper Making 2,600 140
Effluent Treatment
and Misc. 500 40
Total 3,500 440
Process Integrated to converting
operation
Fiber Furnish 55% waste paper, 45%
mechanical SW fiber
Pulp Yield 99.5% mech. pulping,
94% S/F pulping
Mill Location North Central
Boundary Limits Wood and S/F prepara-
tion through felt making
OPE RATING COST*
($/MDMT)
Fiber Furnish 33.7
Other Raw Materials 1.8
Total Raw Materials Cost 35.5
Labor + Fringe @ 32%
of Hourly Rate 18.2
Supplies 5.2
Energy 21 .9
Factory Overhead 1 1 .3
Total Conversion Costs 56.7
Capital-Related Costs 22.0
• Total Factory Operating Cost 114.2 (S103.6/
MOST)
GS&A 2.5
Freight Out n.a.
Total Cost of Sales 2.5
• Total Delivered Cost 116.7 ($105.9/
\A r\c-r\
"Totals may not add due to rounding.
D-147
Arthur D Little Inc
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TABLE D-7-102
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
ROOFING FELT
Item
Cost ($000)
Site Preparation 300
Pulping (secondary fiber) 2,000
Pulping & Stock Prepration (wood) 2,600
Papermaking 3,000
Steam/Power Generation/Distribution 600
Water & Primary Effluent Treatment 300
Auxiliary Equipment & bldgs. 400
TOTAL DIRECT PLANT COST (DPC) 9,200
Engineering, Const. Supervision & Fee
@ 25% DPC 2.300
TOTAL PHYSICAL PLANT COST (PPC) 11,500
OTHER FIXED CAPITAL @ 10% PPC 1.200
TOTAL FIXED CAPITAL 12,700
Use $13 MM
D-148
Arthur D Little Inc
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TABLE D-7-103
ESTIMATED HOURLY LABOR REQUIREMENTS FOR
THE MANUFACTURE OF ROOFING FELT
Men per
Shift
DIRECT LABOR
Secondary Fiber
Preparation:
Pulper Man}
Cleaning )
Bale Handling &
Breaking
Sub-Total
Mechanical Wood :
Chip Unloading
Scale Operator
Chip Recovery &
Washing
Pressure Refining &
Cleaning
Sub-Total
Felt Manufacture:
Machine Crew
Roll Handling &
Storage
Sub-Total
TOTAL DIRECT
INDIRECT LABOR
Raw Matl's. Handling
Stores
Testing
Process Engineer
Instrumentation
Oiler
Foreman
Paper Machine
Shipping & Rec'g.
TOTAL INDIRECT
1
1/2
1
1
1
1
4
1
3
1
1
1/2
1/2
1
1
1
1
Shifts per
Day Total Men
3
~J
3
1
1
1
3
3
3
1
1
1
1
1
1
1
3
1
4
2
—
6
1
1
1
4_
16
_4
20
33
3
1
1
1/2
1/2
1
1
4
_1
12
D-149
Arthur D Little Inc
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140
135
130
125
120
115
o> 110
c
a
O 105
100
95
90
Capital
100 200 300
Capacity, Metric Tons Per Day
50
40
30 -2
20
'5.
cS
•8
10
400
FIGURE D-7-31 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF ROOFING FELT
D-150
Arthur D Little Inc
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TABLE D - 7 -104
DESIGN BASIS
Functional Group Market Pulp
Grade Bleached SW kraft
Basis Weight n.a.
Production 730 ADMT/day;
252,000 ADMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 127,700
Other Fixed Capital 12,800
Total Fixed Capital 140,000
Working Capital 13,000
Total Capital Required 153,000
ENERGY REQUIREMENTS
(per ADMT)
Steam Power
(kg) (kWh)
Wood Preparation - 120
Pulping 1,970 130
Bleaching 3,620 100
Drying 3000 130
Power & Steam Gen.
(incl. recovery
& liquor prep.) 1,970 200
Effluent Treatment - 20
Misc. & Auxiliaries 1,480 30
Total 12,040 730
Process Continuous kraft pulping,
C-E-D-E-D bleaching
Fiber Furnish 100% virgin fiber (soft-
wood from 50/50 round-
wood/chips)
Pulp Yield 42%
Mill Location Southeast
Boundary Limits Wood preparation through
market pulp production
OPERATING COST*
($/ADMT)
Fiber Furnish 54.1
Other Raw Materials 19.0
Total Raw Materials Cost 73.1
Labor + Fringe @ 32% of
Hourly Rate 18.8
Supplies 12.0
Energy 8.6
Factory Overhead 4.9
Total Conversion Costs 44.2
Capital-Related Costs 42.7
• Total Factory Operating
Cost 160.0
GS&A 13.0 <$145.1/ADST)
Freight Out 30.0
Total Cost of Sales 43.0
• Total Delivered Cost 203.0
($184.1/ADST)
'Totals may not add due to rounding.
D-151
Arthur D Little; Inc
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TABLE D-7-105
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
BLEACHED SOFTWOOD KRAFT MARKET PULP IN THE SOUTHEAST
Item
Site Preparation
Wood Yard & Wood Preparation
Digester
Evaporators
Causticizing
Recovery Boiler
Power Boiler
Turbine Generator
Bleach Plant & Chemical Prep.
Power Distribution
Steam Distribution
Pulp Dryer & Pulp Storage
Water Treatment
Effluent Treatment
Shops, Stores & Mill Services
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
Bldgs.
4,000
2,000
3,000
400
1,200
800
1,400
200
1,600
-
-
2,500
400
100
700
18,300
4,400
22,700
2,300
25,000
$25 MM
Cost ($000)
Equip.
-
7,500
9,300
1,200
5,500
13,800
10,900
2,900
9,600
1,600
1,800
9,800
1,600
6,100
2,300
83,900
21,100
105,000
10,500
115,500
$115 MM
Total
4,000
9,500
12,300
1,600
6,700
14,600
12,300
3,100
11,200
1,600
1,800
12,300
2,000
6,200
3,000
102,000
25,500
127,700
12,800
140,500
$140 MM
NOTE: Totals may not add due to rounding
* Includes tall oil recovery
D-152
Arthur D Little; Inc
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TABLE D-7-106
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLEACHED SOFTWOOD KRAFT MARKET PULP IN THE SOUTHEAST
Direct Labor Total Men*
• Wood Yard and Wood 22
Total Direct 119
Indirect Labor 57
Preparation
• Pulp Mill 68
Pulp Dryer 29
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•market pulp in the Northeast and adjust for pulp yield
and wood density.
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D-153
Arthur D Little, Inc
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245
240 —
190
185
200
— 190
90
80
200 400 600 800
Capacity, Metric Tons Per Day
1,000 1,200
FIGURE D-7-32 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF BLEACHED SOFTWOOD
KRAFT MARKET PULP (SOUTHEAST)
D-154
Arthur D Little Inc
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TABLE D-7-107
ESTIMATED FACTORY OVERHEAD FOR THE MANUFACTURE OF BLEACHED KRAFT PULPC
($000 per year)
Position
Plant Manager
Assistant
Production Supervisor
Pulp Mill Manager
Administrative Assistant
Technical Director
Process Engineer Manager ,
Process Engineers (4-3-2)
Technicians (4-3-2)
Clerical (2-1-1)
Quality Control Manager
Lab Chemist
Plant Engineer, Chief
Steam and Power
Chief Electrician
Chief Mechanical
Draftsmen (4-3-2)
Purchasing and Traffic Control
Manager
Shipping and Receiving
Purchasing Agent
Traffic Control
Clerical (4)
Public Relations and Personnel
Director
Safety
Personnel Administrator
Secretaries (8)
Clerks and Telephone Operators (7)
Watchmen (4)
Cost Accountants (2)
Production (ADMT/day)
1090
60
25
40
30
15
28
25
56
32
13
22
14
30
22
22
22
32
22
21
22
22
28
22
14
18
48
35
40
30
730
45
20
30
22
12
22
18
42
24
6
18
12
25
18
18
18
24
20
14
14
14
21
18
12
14
36
25
40
20
360
40
-
25
20
—
20
_
28
16
6
16
12
25
16
16
16
16
18
14
12
12
14
18
12
24
20
40
20
D-155
Arthur DLittleJnc
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TABLE D-7-107
(cont'd)
ESTIMATED FACTORY OVERHEAD FOR THE MANUFACTURE OF BLEACHED KRAFT PULP
($000 per year)
a
Production (ADMT/day)
Position
Sales
Manager
Liaison Engineers (3)
Secretaries (3)
TOTAL SALARIES
Fringe Benefits on Salaried
Personnel @ 16%
Other Expenses Proportional to Salaries
Office supplies, communications
Travel and entertainment
Dues, subscriptions, donations
Legal
Accounting
Public relations, advertising,
welfare
Total Other Expenses
1090
40
45
21
916
147
1063
105
66
26
52
52
13
730
30
30
14
696
111
807
80
50
20
40
40
10
360
25
30
14
545
87
632
62
39
16
31
31
8
314
240
187
TOTAL FACTORY OVERHEAD
(excl. administration)
$ 1377
$ 1047
$ 819
Table applies to hardwood or softwood pulp from the Northeast
or Southeast
Numbers correspond to the three production volumes.
D-156
Arthur D Little Inc
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TABLE D - 7 -108
DESIGN BASIS
Functional Group Market Pulp
Grade Bleached SW kraft
Basis Weight n.a.
Production 730 ADMT/day;
252,000 ADMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 127,700
Other Fixed Capital 12,800
Total Fixed Capital 140,000
Working Capital 15,000
Total Capital Required 155,000
ENERGY REQUIREMENTS
(per ADMT)
Steam Power
(kg) (kWh)
Wood Preparation - 120
Pulping 1,970 130
Bleaching 3,620 100
Drying 3 000 130
Power & Steam Gen.
(incl. recovery
& liquor prep.) 1,970 200
Effluent Treatment - 20
Misc. & Auxiliaries 1,480 30
Total 12,040 730
Process Continuous kraft pulping,
C-E-D-E-D bleaching
Fiber Furnish 100% virgin fiber (softwood
from 50/50 roundwood/
chips
Pulp Yield 42%
Mill Location Northeast
Boundary Limits Wood preparation through
market pulp production
OPERATING COST*
($/ADMT)
Fiber Furnish . 86.9
Other Raw Materials 21.0
Total Raw Materials Cost 107.9
Labor + Fringe @ 32% of
Hourly Rate 16.5
Supplies 12.0
Energy 18.3
Factory Overhead 4.9
Total Conversion Costs 51.6
Capital-Related Costs 42.7
• Total Factory Operating
Cost 202.1
GS&A 13.0 <$183.3/ADST)
Freight Out 22.0
Total Cost of Sales 35.0
• Total Delivered Cost 237.1
($215.0/ADST)
*Totals may not add due to rounding.
D-157
Arthur D Little; Inc
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TABLE D-7-109
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
BLEACHED SOFTWOOD KRAFT MARKET PULP IN THE NORTHEAST
Item
Site Preparation
Wood Yard & Wood Preparation
Digester
Evaporators
Causticizing
Recovery Boiler
Power Boiler
Turbine Generator
Bleach Plant & Chemical Prep.
Power Distribution
Steam Distribution
Pulp Dryer & Pulp Storage
Water Treatment
Effluent Treatment
Shops, Stores & Mill Services
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
Bldgs.
4,000
2,000
3,000
400
1,200
800
1,400
200
1,600
-
-
2,500
400
100
700
18,300
4,400
22,700
2,300
25,000
$25 MM
Cost ($000)
Equip.
-
7,500
9,300
1,200
5,500
13,800
10,900
2,900
9,600
1,600
1,800
9,800
1,600
6,100
2,300
83,900
21,100
105,000
10,500
115,500
$115 MM
Total
4,000
9,500
12,300
1,600
6,700
14,600
12,300
3,100
11,200
1,600
1,800
12,300
2,000
6,200
3,000
102,000
25,500
127,700
12,800
140,500
$140 MM
NOTE: Totals may not add due to rounding
D-158
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Wood Yard and Wood 25
I Preparation
Pulp Mill 68
TABLE D-7-110
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLEACHED SOFTWOOD KRAFT MARKET PULP IN THE NORTHEAST
Direct Labor Total Men*
Pulp Dryer 29
Total Direct 122
Indirect Labor 57
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kraft market pulp in the Northeast and adjust for
• pulp yield and wood density.
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280
275
270
265
^ 260
CD
CU
S 255
250
CD 245
c
O 240
235
230
225
220
200
190
180
170
160
o
150 =
140 IS
'o.
130 1
120
110
100
90
80
200 400 600 800
Capacity, Metric Tons Per Day
1,000 1,200
FIGURE D-7-33 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF BLEACHED SOFTWOOD
KRAFT MARKET PULP (NORTHEAST)
D-160
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TABLED-7-111
DESIGN BASIS
Functional Group Market Pulp
Grade Bleached HW kraft
Basis Weight n.a.
Production 730 ADMT/day;
252,000 ADMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS
($000)
Physical Plant 120,000
Other Fixed Capital 12,000
Total Fixed Capital 132,000
Working Capital 12,000
Total Capital Required 144,000
ENERGY REQUIREMENTS
/•**%» AI"\IMIT\
(per AUM 1 )
Steam Power
ttfn\ /L-IAfht
\Kg) IKWnl
Wood Preparation - 110
Pulping 1,810 120
Bleaching 3,290 90
Drying 3,000 130
Power & Steam Gen.
liquor prep.) 1,810 180
Effluent Treatment - 20
Misc. & Auxiliaries 1,350 60
Total 11,260 710
Process Continuous kraft pulping,
C-E-D-E-D bleaching
Fiber Furnish 100% virgin fiber (hard-
wood from 50/50 round-
wood/chips)
Pulp Yield 46%
Mill Location Southeast
Boundary Limits Wood preparation through
market pulp production
OPERATING COST*
($/ADMT)
Fiber Furnish 40.2
Other Raw Materials 18.0
Total Raw Materials Cost 58.3
Labor + Fringe© 32% of
Hourly Rate 17.4
Supplies 12.0
Energy 9.5
Factory Overhead 4.8
Total Conversion Costs 43.6
Capital- Related Costs 41.4
• Total Factory Operating
Cost 143.2
GS&A 13.0 <$129.9/ADST)
Freight Out 30.0
Total Cost of Sales 43.0
• Total Delivered Cost 186.2
($168.9/ADST)
'Totals may not add due to rounding.
NOTE: Curves relating operating cost and fixed capital to capacity are not included for this
model. The shapes of these curves would be the same as for a mill in the Northeast (see follow-
ing model), but the operating cost curve would be displaced vertically to reflect lower unit costs.
D-161
Arthur D Little; Inc
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TABLE D-7-112
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE
BLEACHED HARDWOOD KRAFT MARKET PULP IN THE SOUTHEAST*
Item
Site Preparation
Wood Yard & Wood Preparation
Digester
Evaporators
Causticizing
Recovery Boiler
Power Boiler
Turbine Generator
Bleach Plant & Chemical Prep.
Power Distribution
Steam Distribution
Pulp Dryer & Pulp Storage
Water Treatment
Effluent Treatment
Shops, Stores & Mill Services
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
Bldgs.
4,000
1,700
2,600
400
1,100
800
1,100
200
1,600
-
-
2,500
400
100
700
17,200
4,100
21,300
2,100
23,400
$23 MM
Cost ($000)
Equip .
6,200
8,100
1,100
4,900
13,800
9,000
2,900
9,600
1,600
1,800
9,800
1,600
6,100
2,300
78,800
19,900
98,700
9,900
108,600
$109 MM
OF
Total
4,000
7,900
10,700
1,500
6,000
14,600
10,100
3,100
11,200
1,600
1,800
12,300
2,000
6,200
3,000
96,000
24,000
120,000
12,000
132,000
$132 MM
NOTE: Totals may not add due to rounding
*Costs also apply to pulp mills in the Northeast
D-162
Arthur D Little Inc
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TABLE D-7-113
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLEACHED HARDWOOD KRAFT MARKET PULP IN THE SOUTHEAST
Direct Labor Total Men*
_ Wood Yard and Wood 19
• Preparation
Pulp Mill 68
Pulp Dryer 29
Total Direct 116
Indirect Labor 54
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market pulp in the Northeast
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D-163
Arthur D Little; Inc
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TABLED-7- 114
DESIGN BASIS
Functional Group Market Pulp
Grade Bleached HW kraft
Basis Weight aa.
Production 730 ADMT/day;
252,000 ADMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 120,000
Other Fixed Capital 1 2,000
Total Fixed Capital 132,000
Working Capital 12,000
Total Capital Required 144,000
ENERGY REQUIREMENTS
(per ADMT)
Steam Power
(kg) (kWh)
Wood Preparation — 110
Pulping 1,810 120
Bleaching 3,290 90
Drying 3,000 130
Power & Steam Gen.
(incl. recovery &
liquor prep.) 1,810 180
Effluent Treatment - 20
Misc. & Auxiliaries 1,350 60
Total 11,260 710
Process Continuous kraft pulping,
C-E-D-E-D bleaching
Fiber Furnish 100% virgin fiber (hard-
wood from 50/50 round-
wood/chips)
Pulp Yield 46%
Mill Location Northeast
Boundary Limits Wood preparation through
market pulp production
OPERATING COST**
($/ADMT)
Fiber Furnish 55.1
Other Raw Materials 18.0
Total Raw Materials Cost 73.2
Labor + Fringe @ 32% of
Hourly Rate 16.1
Supplies 12.0
Energy 20.3
Factory Overhead 4.2
Total Conversion Costs 52.5
Capital- Related Costs 41.4
• Total Factory Operating
Cost 167.0
GS&A 12.6 <$151-5/ADST)
Freight Out 22.0
Total Cost of Sales 34.6
• Total Delivered Cost 201.6
($182.9/ADST)
Detailed investment schedule same as for pulp mills in the Southeast. (See preceding model.)
Totals may not add due to rounding.
D-164
Arthur DLittleJnc
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TABLE D-7-115
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLEACHED HARDWOOD KRAFT MARKET PULP IN THE NORTHEAST
Basis: Fringe benefit at 32% hourly rate
DIRECT LABOR
Wood Yard & Wood Prep.
Foreman
Asst. Foreman
Equip. Operator
Drum Barker Operator
Drum Barker Helper
Chipper Operator
Utility (knife grinder)
Sub-Total
Pulp Mill
Foreman - Pulp Mfg.
Foreman - Recovery
Digester Operator
Helper
Brown Stock Washer Op.
Bleach Plant Operator
Bleach Plant Helper
Screening & Cleaning
Helper
Bleach Liq. Prep.
Liquor Evap. Operator
Lime Kiln Operator
Causticizer Operator
Helper
Utility
Sub-Total
Rate
($/hr)
5.81
5.24
4.94
4.11
3.59
4.37
4.75
4.60
4.76
Men per
Shift
1
1
3
1
2
1
1
7.00
6.84
5.40
4.71
4.81
4.77
4.45
4.45
4, .56
4, .51
4, .48
4.62
4.45
4.45
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1
1
1
1
1
1
2
2
1
1
1
2
1
D-165
Shifts Total
per Day Men
2
1
2
2
2
2
2
2
1
6
2
4
2
_2
19
3
3
3
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
8
8
4
4
4
8
4
68
Cost
($000 yr/
w/Fringe
29.47
13.30
75.06
20.86
36.40
22.13
24.10
221.32
70.50
69.35
54.78
47.73
48.77
48.31
45.08
90.12
92.45
45.76
45.42
46.81
90.14
45.08
82.03
Arthur DLitthlrx
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TABLE D-7-115
(Cont'd)
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLEACHED HARDWOOD KRAFT MARKET PULP IN THE NORTHEAST
Basis: Fringe Benefit at 32% Hourly Rate
Rate Men per
DIRECT LABOR (cont'd)
Pulp Dryer
Foreman
Operator
Back Tender
Scale Man
Materials Handling
Pulp Tester
Shipping
Sub-Total
TOTAL DIRECT
INDIRECT LABOR
Utilities - Steam
Foreman
Recovery Boiler
Operator
Power Boiler
Operator
Helpers
Water Treatment
(Matl. Handling)
Utilities - Power
($/hr)
6.73
5.81
5.02
5.02
4.94
4.35
4.94
5.06
4.80
7.18
5.22
5.22
4.71
4.94
Shift
1
1
1
1
1
1
2
1
1
1
2
1
Shifts
per day
1
3
3
3
3
3
3
1
3
3
3
1
Total
Men
1
4
4
4
4
4
8
29
116
1
4
4
8
1
Cost
($000/yr
w/Fringe)
17.04
58.94
50.86
50.86
50.04
44.15
100.08
371.97
1,413.59
18.21
52.93
52.93
95.46
12.51
Foreman - incl. w/steam
Operator
5.59
1
3
4
56.63
Utilities Water & Effluent Treatment
Foreman
Operator Raw Water
Operator Waste
Treatment
Helper
Sludge Disposal
(driver)
5.02
4.71
4.71
4.33
4.56
1
1
1
1
2
1
3
3
1
2
1
4
4
1
4
12.71
47.73
47.73
10.98
46.23
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Arthur D Little; Inc
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1
1
•
1
1
^^v
1
1
1
1
1
1
1
1
1
1
1
TABLE D-7-115 (Cont'd)
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLEACHED HARDWOOD KRAFT MARKET PULP IN THE NORTHEAST
Basis: Fringe Benefit at 32% Hourly Rate
Rate Men per Shifts Total
($/hr) Shift per day Men
INDIRECT LABOR (Cont'd)
Other Allocated
Receiving 4.33 8 1 8
Instrumentation 5.13 2 1 2
Stores 4.45 2 1 2
Gate & Watchman 4.33 1 3 4
Shipping & Receiving
Foreman 5.02 1 1 1
Quality Control 5.70 1 1 1
TOTAL INDIRECT 4.83 54
D-167
Cost
($000/yr
w/Fringe)
87.84
26.00
22.54
43.91
12.71
14.44
661.49
Arthur DLittl
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240
235
230
225
22°
CD
5 215
210
o
o
o>
c
205
CD
O 200
195
190
185
180
I I
190
180
170
160
150
c
o
140 S
130 ]S
'a
120 1
110
100
90
80
70
200 400 600 800
Capacity, Metric Tons Per Day
1,000 1,200
FIGURE D-7-34 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF BLEACHED HARDWOOD
KRAFT MARKET PULP (NORTHEAST)
D-168
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TABLED-7-116
DESIGN BASIS
Functional Group Market Pulp
Grade Unbl. kraft from
OCC
Basis Weight n.a.
Production 300 ADMT/day;
1 00,000 ADMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 21 ,600
Other Fixed Capital 2,200
Total Fixed Capital 24,000
Working Capital 4,000
Total Capital Required 28,000
ENERGY REQUIREMENTS
(per ADMT)
Steam Power
(kg) (kWh)
Asphalt Dispersion 1,000 100
Drying 4,000 130
Other Process - 80
Misc & Auxiliaries 1 000 160
Total 6,000 470
'Totals may not add due to rounding.
Process Asphalt dispersion of OCC,
non-integrated
Fiber Furnish 100% S/F (OCC)
Pulp Yield 86% AD pulp to AD S/F
as rec'd.
Mill Location North Central
Boundary Limits S/F preparation through
market pulp production
OPERATING COST
($/ADMT)
Fiber Furnish 63.8
Other Raw Materials 3.0
Total Raw Materials Cost 66.8
Labor + Fringe @ 32% of
Hourly Rate 11.2
Supplies 5.6
Energy 23.4
Factory Overhead 5.7
Total Conversion Costs 45.9
Capital-Related Costs 18.4
• Total Factory Operating
Cost 131-1
($118.9/ADST)
GS&A 5.6
Freight Out 12.0
Total Cost of Sales 17.6
• Total Delivered Cost 148.7
($134.9/ADST)
NOTE: Models describing the manufacture of market pulp from waste paper are dissimilar to
those previously presented for market pulp, in order to reflect the factors that influence the
make or buy decision rather than the economy of scale of dried market pulp. Accordingly, the
curves showing how capital and operating cost are related to capacity were developed for slush
pulp rather than market pulp.
D-169
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TABLE D-7-117
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
UNBLEACHED KRAFT MARKET PULP
Item Cost ($000)
A.D. Secondary Fiber Plant 3,400
Pulp Dryer 7,000
Steam & Power Generation 3,400
Water & Effluent Treatment 2,000
Warehouses and other Buildings 1,500
TOTAL DIRECT PLANT COST (DPC) 17,300
Engineering, Const. Supervision & Fee
@ 25% DPC 4,300
TOTAL PHYSICAL PLANT COST (PPC) 21,600
OTHER FIXED CAPITAL @ 10% PPC 2,200
TOTAL FIXED CAPITAL 23,800
*
Use $24 MM
* If flash dryer, use $18 million
Dryer less $3.5 MM
Steam & Power less $1 MM (no turbine, lower steam)
D-170
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TABLE D-7-118
• ESTIMATED HOURLY LABOR REQUIREMENTS
FOR THE MANUFACTURE OF UNBLEACHED KRAFT MARKET PULP FROM OCC
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Note: If flash dryer, use 18 Direct
Direct Labor Total Men
A.D. Secondary Fiber 9
Pulp Dryer 17
Total Direct 26
Indirect Labor 32
28 Indirect
46 total
D-171
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180
170
160
150
H
Q 140
a 13°
O)
^C
| 120
O
110
100
90
c
O
* <
25 50 75
Capacity, Metric Tons Per Day
100
FIGURE D-7-35 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF SLUSH PULP FROM OCC
(ASPHALT DISPERSION)
D-172
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TABLED-7-119
DESIGN BASIS
Functional Group Market Pulp
Grade Groundwood (second-
ary newsprint)
Basis Weight n.a.
Production 300ADMT/day;
100,000 ADMT/yr
Net Operating Days 330/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 25,100
Other Fixed Capital 2,500
Total Fixed Capital 28,000
Working Capital 4,000
Total Capital Required 32,000
ENERGY REQUIREMENTS
(per ADMT)
Steam Power
(kg) (kWh)
De-inking 500 300
Drying 3,000 130
Misc. & Auxiliaries 600 80
Total 4,100 510
"Totals may not add due to rounding.
Process Newsprint de-inking, non-
integrated
Fiber Furnish 100% S/F (No. 1 news)
Pulp Yield 83% AD pulp to AD S/F
as rec'd.
Mill Location Northeast
Boundary Limits S/F preparation through
market pulp production
OPERATING COST
($/ADMT)
Fiber Furnish 54.5
Other Raw Materials 8.6
Total Raw Materials Cost 63.1
Labor + Fringe @ 32% of
Hourly Rate 11.8
Supplies 8.0
Energy 28.7
Factory Overhead 7.0
Total Conversion Costs 55.5
Capital-Related Costs 21.4
• Total Factory Operating
Cost 140.0
GS&A 11.6 '^27.0/ADST)
Freight Out 12.0
Total Cost of Sales 23.6
• Total Delivered Cost 163.6
(S148.4/ADST)
NOTE: Models describing the manufacture of market pulp from waste paper are dissimilar to
those previously presented for market pulp, in order to reflect the factors that influence the
make or buy decision rather than the economy of scale of dried market pulp. Accordingly, the
curves showing how capital and operating cost are related to capacity were developed for slush
pulp rather than market pulp.
D-173
Arthur D Little; Inc.
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TABLE D-7-120
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
GROUNDWOOD MARKET PULP
Item
Cost ($000)
Site Preparation
Deinking
Pulp Dryer
Steam & Power Generation
Water & Effluent Treatment
Warehouses and Other Buildings
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPG)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
1,000
A, 400
7,000
3,100
3,000
1,600
20,100
5,000
25,100
2,500
27,600
Use $28 MM*
* If flash dryer, use $22 million
Dryer less $3.5 MM
Steam less $1.0 MM
D-174
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Deinking 17
I Pulp Dryer 17_
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TABLE D-7-121
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
GROUNDWOOD MARKET PULP FROM SECONDARY NEWSPRINT
Direct Labor Total Men
Total Direct 34
Indirect Labor 32
D-175
Arthur D Little, Inc.
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180
170
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Ol
150
140
130
120
110
100
10
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TABLED-7-122
DESIGN BASIS
Functional Group General
Grade Bl. kraft softwood
slush pulp
Basis Weight n.a.
Production 730 ADMT/day;
252,000 ADMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 103,100
Other Fixed Capital 10,300
Total Fixed Capital 113,000
Working Capital 9,000
Total Capital Required 112,000
ENERGY REQUIREMENTS
(per ADMT)
Steam Power
(kg) (kWh)
Wood Preparation - 1 20
Pulping 1,970 130
Bleaching 3,620 100
Power & Steam Gen. 1 ,970 200
(incl. recovery
& liquor prep.)
Effluent Treatment — 40
Misc. & Auxiliaries 1,480 30
Total 9,040 620
Process Continuous kraft pulping,
C-E-D-E-D bleaching
Fiber Furnish 100% virgin fiber; soft-
wood from 50% roundwood
& 50% chips
Pulp Yield 42%
Mill Location Southeast
Boundary Limits Wood preparation through
bleached pulp Production
OPE RATING COST*
($/ADMT)
Fiber Furnish 54.1
Other Raw Materials 18.4
Total Raw Materials Cost 72.5
Labor + Fringe @ 32%
of Hourly Rate 14.1
Supplies 7.9
Energy 3.6
Factory Overhead 3.6
Total Conversion Costs 29.1
Capital-Related Costs 34.4
• Total Factory Operating
Cost 136.0 ($123.4/
ADST)
GS&A
Freight Out
Total Cost of Sales n.a.
• Total Delivered Cost n.a.
"Totals may not add due to rounding.
D-177
Arthur D Little, Inc.
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TABLE D-7-123
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE
BLEACHED SOFTWOOD KRAFT SLUSH PULP IN THE SOUTHEAST
Item
Site Preparation
Wood Yard & Wood Preparation
Digester*
Evaporators
Causticizing
Recovery Boiler
Power Boiler
Turbine Generator
Bleach Plant & Chemical Prep.
Power Distribution
Steam Distribution
Water Treatment
Effluent Treatment
Shops, Stores & Mill Services
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
Bldgs.
3,100
2,000
3,000
400
1,200
800
1,100
200
1,600
-
-
400
100
500
14,400
3,500
17,900
1,800
19,700
$20 MM
Cost ($000)
Equip .
_
7,500
9,300
1,200
5,500
13,800
8,400
2,400
9,600
1,300
1,400
1,600
4,300
1,800
68,100
17,100
85,200
8,500
93,700
$94 MM
OF
Total
3,100
9,500
12,300
1,600
6,700
14,600
9,500
2,600
11,200
1,300
1,400
2,000
4,400
2,300
82,500
20,600
103,100
10,300
113,400
$113 MM
NOTE: Totals may not add due to rounding
*Includes tall oil recovery
D-178
Arthur D Little Inc.
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TABLE D-7-124
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLEACHED SOFTWOOD KRAFT SLUSH PULP IN THE SOUTHEAST
Direct Labor Total Men*
Wood Yard and Wood 22
Preparation
Pulp Mill 68^
Total Direct 90
Indirect Labor 42
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I *For detailed labor schedule, see bleached hardwood kraft
market pulp in the Northeast. (Adjust pulp yield and wood
• density, and delete the drying process.)
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D-179
Arthur D Little, Inc.
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180
175 —
170
125 —
120
200 400 600 800
Capacity, Metric Tons Per Day
60
50
1,000 1,200
FIGURE D-7-37 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF BLEACHED SOFTWOOD KRAFT SLUSH PULP
(SOUTHEAST)
D-180
Arthur D Little Inc
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TABLE D - 7 - 125
DESIGN BASIS
Functional Group General
Grade Bl. kraft softwood
slush pulp
Basis Weight n.a.
Production 730 ADMT/day;
252,000 ADMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 103,100
Other Fixed Capital 10,300
Total Fixed Capital 113,000
Working Capital 11,000
Total Capital Required 124,000
ENERGY REQUIREMENTS
(per ADMT)
Steam Power
(kg; (kWh)
Wood Preparation - 120
Pulping 1,970 130
Bleaching 3,620 100
Power & Steam Gen. 1 ,970 200
(incl. recovery
& liquor prep.)
Effluent Treatment — 40
Misc. & Auxiliaries 1,480 30
Total 9,040 620
Process Continuous kraft pulping,
C-E-D-E-D bleaching
Fiber Furnish 100% virgin fiber; soft-
wood from 50% roundwood
& 50% chips
Pulp Yield 42%
Mill Location Northeast
Boundary Limits Wood preparation through
bleached pulp Production
OPERATING COST*
($/ADMT)
Fiber Furnish 86.9
Other Raw Materials 20.4
Total Raw Materials Cost 107.3
Labor + Fringe @ 32%
of Hourly Rate 12.4
Supplies 7.9
Energy 7.7
Factory Overhead 3.6
Total Conversion Costs 31.5
Capital-Related Costs 34.4
• Total Factory Operating
Cost 173.2 ($157.1/
ADST)
GS&A
Freight Out
Total Cost of Sales n.a.
• Total Delivered Cost n.a.
*Totals may not add due to rounding.
D-181
Arthur D Little; Inc
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TABLE D-7-126
ESTIMATED FIXED CAPITAL REQUIREMENT
FOR THE
BLEACHED SOFTWOOD KRAFT SLUSH PULP IN THE
Item
Site Preparation
Wood Yard & Wood Preparation
Digester
Evaporators
Causticizing
Recovery Boiler
Power Boiler
Turbine Generator
Bleach Plant & Chemical Prep.
Power Distribution
Steam Distribution
Water Treatment
Effluent Treatment
Shops, Stores & Mill Services
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
Bldgs.
3,100
2,000
3,000
400
1,200
800
1,100
200
1,600
-
-
400
100
500
14,400
3,500
17,900
1,800
19,700
$20 MM
MANUFACTURE
NORTHEAST
Cost ($000)
Equip .
_
7,500
9,300
1,200
5,500
13,800
8,400
2,400
9,600
1,300
1,400
1,600
4,300
1.800
68,100
17,100
85,200
8,500
93,700
$94 MM
OF
Total
3,100
9,500
12,300
1,600
6,700
14,600
9,500
2,600
11,200
1,300
1,400
2,000
4,400
2,300
82,500
20,600
103,100
10,300
113,400
$113 MM
NOTE: Totals may not add due to rounding
D-182
Arthur D Little; Inc
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TABLE D-7-127
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLEACHED SOFTWOOD KRAFT SLUSH PULP IN THE NORTHEAST
Direct Labor Total Men*
Wood Yard and Wood Preparation 25
Total Direct 93
Indirect Labor 42
Pulp Mill
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*For detailed labor schedule, see bleached hardwood kraft
market pulp in the Northeast. (Adjust for pulp yield and
_ wood density, and delete the drying process.)
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D-183
Arthur D Little, Inc
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210
205
200
195
190
185
CJl
.£ 180
+->
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TABLED-7-128
DESIGN BASIS
Functional Group General
Grade Bl. hardwood kraft
slush pulp
Basis Weight n.a.
Production 730 ADMT/day;
252,000 ADMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 95,700
Other Fixed Capital 9,600
Total Fixed Capital 105,000
Working Capital 8,000
Total Capital Required 113,000
ENERGY REQUIREMENTS
(per ADMT)
Steam Power
(kg) (kWh)
Wood Preparation - 110
Pulping 1,810 115
Bleaching 3,290 95
Power & Steam Gen.
(incl. recovery &
liquor prep.) 1,810 180
Effluent Treatment - 20
Misc. & Auxiliaries 1,350 45
Total 8,260 565
Process Continuous kraft pulping;
C-E-D-E-D bleaching
Fiber Furnish 100% virgin fiber; hard-
wood from 50/50 round-
wood/chips
Pulp Yield Bleached - 44%
Mill Location Southeast
Boundary Limits Wood preparation through
bleached pulp
OPERATING COST*
($/ADMT)
Fiber Furnish 40.2
Other Raw Materials 17.4
Total Raw Materials Cost 57.7
Labor + Fringe® 32%
of Hourly Rate 12.7
Supplies 7.9
Energy 3.8
Factory Overhead 3.5
Total Conversion Costs 27.7
Capital-Related Costs 33.1
• Total Factory Operating
Cost 11 8.5 ($107.5/
ADST)
GS&A
Freight Out
Total Cost of Sales n.a.
• Total Delivered Cost n.a.
"Totals may not add due to rounding.
D-185
Arthur D Little Inc.
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TABLE D-7-129
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
BLEACHED HARDWOOD KRAFT SLUSH PULP IN THE SOUTHEAST
Cost ($000)
Item
Site Preparation
Wood Yard & Wood Prep.
Pulp Mill
Evaporators
Causticizing
Recovery Boiler
Power Boiler
Turbine Generator
Bleach Plant & Chemical Prep.
Power Distribution
Steam Distribution
Water Treatment
Effluent Treatment
Shops, Stores & Mill Services
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPG)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Bldgs.
3,000
1,700
2,600
400
1,100
800
800
200
1,600
-
-
400
100
500
13,200
3,200
16,400
1,600
18,000
Equip .
-
6,200
8,100
1,100
4,900
13,800
7,000
2,300
9,600
1,300
1,400
1,600
4,300
1,800
63,400
15,900
79,300
8,000
87,300
Use
Total
3,000
7,900
10,700
1,500
6,000
14,600
7,800
2,500
11,200
1,300
1,400
2,000
4,400
2,300
76,600
19,100
95,700
9,600
105,300
$105 MM
D-186
Arthur DLittleJnc
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TABLE D-7-130
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLEACHED HARDWOOD KRAFT SLUSH PULP IN THE SOUTHEAST
Direct Labor Total Men*
I Wood Yard and Wood 19
Preparation
Pulp Mill 68_
Total Direct 87
I
Indirect Labor 39
1
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I*For detailed labor schedule, see bleached hardwood kraft
market pulp in the Northeast and delete the drying process
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D-187
Arthur D Little, Inc.
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en
155
150
145
140
135
130
125
<§• 120
115
110
105
100
I
200 400 600 800
Capacity, Metric Tons Per Day
I
150
140
130
120
110
o
100 =
90
a
<3
o>
80 .5
70
60
50
40
1,000 1,200
FIGURE D-7-39 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF BLEACHED HARDWOOD KRAFT SLUSH PULP
(SOUTHEAST)
D-188
Arthur D Little Inc
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TABLED-7- 131
DESIGN BASIS
Functional Group General
Grade Bl kraft hardwood
slush pulp
Basis Weight n.a.
Production 730 ADMT/day;
252,000 ADMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 95,700
Other Fixed Capital 9,600
Total Fixed Capital 105,000
Working Capital 9,000
Total Capital Required 114,000
ENERGY REQUIREMENTS
(per ADMT)
Steam Power
(kg) (kWh)
Wood Preparation - 110
Pulping 1,810 115
Bleaching 3,290 95
Power & Steam Gen.
(incl. recovery &
liquor prep.) 1,810 180
Effluent Treatment - 20
Misc. & Auxiliaries 1,350 45
Total 8,260 565
Process Continuous kraft pulping;
C-E-D-E-D bleaching
Fiber Furnish 100% virgin fiber; hardwood
from 50/50 roundwood/
chips
Pulp Yield Bleached -44%
Mill Location Northeast
Boundary Limits Wood preparation through
bleached pulp
OPERATING COST*
($/ADMT)
Fiber Furnish 55.1
Other Raw Materials 17.4
Total Raw Materials Cost 72.5
Labor + Fringe @ 32% of
Hourly Rate 12.0
Supplies 7.9
Factory Overhead 3.0
Total Conversion Costs 31.1
Capital-Related Costs 33.1
• Total Factory Operating Cost 136.7
($124.0/ADST)
GS&A
Freight Out
Total Cost of Sales n.a.
o Total Delivered Cost n.a.
'Totals may not add due to rounding.
D-189
Arthur D Little, Inc.
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TABLE D-7-132
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
BLEACHED HARDWOOD KRAFT SLUSH PULP IN THE NORTHEAST
Cost ($000)
Item
Site Preparation
Wood Yard & Wood Prep.
Pulp Mill
Evaporators
Causticizing
Recovery Boiler
Power Boiler
Turbine Generator
Bleach Plant & Chemical Prep.
Power Distribution
Steam Distribution
Water Treatment
Effluent Treatment
Shops, Stores & Mill Services
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Bldgs.
3,000
1,700
2,600
400
1,100
800
800
200
1,600
-
-
400
100
500
13,200
3,200
16,400
1,600
18,000
Equip.
-
6,200
8,100
1,100
4,900
13,800
7,000
2,300
9,600
1,300
1,400
1,600
4,300
1,800
63,400
15,900
79,300
8,000
87,300
Use
Total
3,000
7,900
10,700
1,500
6,000
14,600
7,800
2,500
11,200
1,300
1,400
2,000
4,400
2,300
76,600
19,100
95,700
9,600
105,300
$105 MM
D-190
Arthur D Little Inc
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TABLE D-7-133
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
BLEACHED HARDWOOD KRAFT SLUSH PULP IN THE NORTHEAST
Direct Labor Total Men*
Indirect Labor 39
• Wood Yard and Wood Preparation 19
Pulp Mill 68
I
Total Direct 87
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• *For detailed labor schedule, see bleached hardwood kraft
market pulp in the Northeast and delete the drying process.
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D-191
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Arthur D Little Inc
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175
170
165
160
155
D
< 150
-
8
145
O 140
135
130
125
120
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200 400 600 800
Capacity, Metric Tons Per Day
1,000
150
140
130
120
110
c
o
100
90
80
70
60
50
o
•$
X
40
1,200
FIGURE D-7-40 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF BLEACHED HARDWOOD KRAFT SLUSH PULP
(NORTHEAST)
D-192
Arthur D Little Inc
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TABLED-7-134
DESIGN BASIS
Functional Group General
Grade Unbl. SW kraft slush
pulp
Basis Weight n.a.
Production 730 ADMT/day;
252,000 ADMT/yr
Net Operating Days 345/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 76,400
Other Fixed Capital 7,700
Total Fixed Capital 84,000
Working Capital 6,000
Total Capital Required 90,000
ENERGY REQUIREMENTS
(per ADMT)
Steam Power
(kg) (kWh)
Wood Preparation — 107
Digester (incl. washing
& screening) 1,734 111
Power/Steam Gen.
(incl. recovery &
liquor prep.) 1,734 173
Water Supply - 20
Misc. & Auxiliaries 867 19
Total 4,335 450
Process Continuous kraft pulping
Fiber Furnish 100% virgin SW fiber from
50/50 roundwood/chips
Pulp Yield 48%
Mill Location Southeast
Boundary Limits Wood preparation through
pulping
OPERATING COST*
($/ADMT)
Fiber Furnish 46.4
Other Raw Materials 0
Total Raw Materials Cost 46. 4
Labor + Fringe© 32% of
Hourly Rate 10.2
Supplies 6.4
Energy (0.8)
Factory Overhead 3.4
Total Conversion Costs 19.4
Capital-Related Costs 25.6
• Total Factory Operating
Cost 91.3
($82.8/ADST)
GS&A Not applicable
Freight Out -
Total Cost of Sales -
• Total Delivered Cost
"Totals may not add due to rounding.
D-193
Arthur D Little, Inc.
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TABLE D-7-135
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
UNBLEACHED SOFTWOOD KRAFT SLUSH PULP
Cost $(000)
Item
Site Preparation
Wood Yard & Wood Preparation
Digester
Evaporators
Causticizing
Recovery Boiler
Power Boiler
Turbine Generator
Power Distribution
Steam Distribution
Water Treatment
Effluent Treatment
Shops, Stores & Mill Services
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
Use
Bldgs.
2,900
1,800
2,800
400
1,100
800
700
200
-
-
300
100
400
11,500
2,900
14,400
1,500
15,900
$16 MM
Equip .
-
6,900
8,600
1,100
5,100
12,700
5,400
2,300
1,100
900
1,000
2,800
1,700
49,600
12,400
62,000
6,200
68,200
$68 MM
Total
2,900
8,700
11,400
1,500
6,200
13,500
6,100
2,500
1,100
900
1,300
2,900
2,100
61,100
15,300
76,400
7,700
84,100
$84 MM
D-194
Arthur D Little Inc
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TABLE D-7-136
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
UNBLEACHED SOFTWOOD KRAFT SLUSH PULP
Direct Labor Total Men*
Indirect Labor 42
• Wood Yard and Wood Preparation 18
Pulp Mill 39^
• Total Direct 57
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J| *For detailed labor schedule, see bleached hardwood kraft
market pulp in the Northeast. (Adjust for pulp yield and
_ wood density, and delete bleaching and drying processes.)
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D-195
Arthur D Little, Inc.
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130
125
120
115
110
105
100
0>
c
IS 95
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90
85
80
75
200 400 600 800
Capacity, Metric Tons Per Day
1,000
140
120
100
c
o
CO
+.J
'a.
a)
X
80
60
40
1,200
FIGURE D-7-41 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT
CAPACITY FOR THE MANUFACTURE OF UNBLEACHED SOFTWOOD
KRAFT SLUSH PULP (SOUTHEAST)
D-196
Arthur D Littk Inc
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TABLE D - 7 - 137
DESIGN BASIS
Functional Group General
Grade Groundwood slush
pulp
Basis Weight n.a.
Production 400 ADMT/day;
136,000 ADMT/yr
Net Operating Days 340/yr
CAPITAL REQUIREMENTS*
($000)
Physical Plant 20,100
Other Fixed Capital 2,000
Total Fixed Capital 22,000
Working Capital 3,000
Total Capital Required 25,000
ENERGY REQUIREMENTS
(per ADMT)
Steam Power
(kg) (kWh)
Wood Preparation - 25
Pulping - 1,350
Effluent Treatment — 15
Misc. & Auxiliaries 140 10
Total 140 1,400
Process Stone groundwood
Fiber Furnish 100% softwood (spruce/
fir)
Pulp Yield Unbleached - 95%
Mill Location Northeast
Boundary Limits Wood preparation
through pulping
OPERATING COST*
(S/ADMT)
Fiber Furnish 37.7
Other Raw Materials 2.0
Total Raw Materials Cost 39.7
Labor + Fringe @ 32%
of Hourly Rate 12.9
Supplies 3.5
Energy 10.8
Factory Overhead 5.7
Total Conversion Costs 32.9
Capital-Related Costs 12.4
• Total Factory Operating
Cost 85.1 ($77.27
ADST)
GS&A
Freight Out
Total Cost of Sales n.a.
• Total Delivered Cost n.a.
'Totals may not add due to rounding.
D-197
Arthur D Little, Inc.
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TABLE D-7-138
ESTIMATED FIXED CAPITAL REQUIREMENT FOR THE MANUFACTURE OF
GROUNDWOOD SLUSH PULP
Item
Cost ($000")
Site Preparation
Wood Yard
Stone Groundwood
Stock Preparation
Paper Machine (roll finishing & winding)
Steam/Power Generation & Dist.
Water & Effluent Treatment
Auxiliary Equipment & Buildings
TOTAL DIRECT PLANT COST (DPC)
Engineering, Const. Supervision & Fee
@ 25% DPC
TOTAL PHYSICAL PLANT COST (PPC)
OTHER FIXED CAPITAL @ 10% PPC
TOTAL FIXED CAPITAL
600
3,200
9,500
Use
1,000
1,500
300
16,100
4.000
20,100
2,000
22,100
$22 MM
D-198
Arthur D Little Inc
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TABLE D-7-139
ESTIMATED HOURLY LABOR REQUIREMENTS FOR THE MANUFACTURE OF
GROUNDWOOD SLUSH PULP FROM 100% VIRGIN FIBER
Shift Position
DIRECT LABOR
Wood Yard and Wood Preparation:
Foreman
Equipment Operator
Drum Operator
Utility
Laborer
Stone Groundwood:
Foreman
Stock Runner
Stone Sharpenter
Grinder Man
Loader
Laborer
Total Direct
INDIRECT LABOR
Receiving Foreman
Receiving crew
Material Handling
Utility
Effluent & Water Treatment
Sludge Disposal
Tester
Men
Per Shift
I
3
2
1
4
1
1
2
2
4
2
1
4
3
5
1
1
1
Shifts
Per Day^
2
2
2
2
2
3
3
3
3
3
3
1
1
3
2
3
2
1
Total
Men
2
6
4
2
8
4
4
8
8
16
_8
70
1
4
12
10
4
2
1
Total Indirect
34
D-199
Arthur D Little; Inc.
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120
115
110
105
100
H 95
S
D
o
O
O)
c
90
85
80
75
70
65
60
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200 400 600 800
Capacity, Metric Tons Per Day
I
1,000
60
50
40
c
o
30 3
73
a)
X
20
10
1,200
FIGURE D-7-42 OPERATING COST AND TOTAL FIXED CAPITAL VERSUS PLANT CAPACITY
FOR THE MANUFACTURE OF GROUNDWOOD SLUSH PULP
D-200
Arthur D Little, Inc
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1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
MOISTURE CONTENT
Product
Linerboard
Corrugating Medium
Newsprint
Groundwood Papers
Tissue
Folding Boxboard
Bond Paper
Book Paper
Bag Paper
Tube Paper
Roofing Felt
Market Pulp
APPENDIX D-8
AND FIBER SUPPLY FOR VIRGIN AND BLENDED MODELS
Fiber Supply for
Virgin and Blended
Moisture Content Models
8% Pulpwood
7% Pulpwood
7% Slush Pulp
7% Slush Pulp
7% Slush Pulp
7% Slush Pulp
7% Slush Pulp
7% Slush Pulp
8% Slush Pulp
8% Slush Pulp
4.7% Pulpwood
10% Pulpwood
D-201
Arthur
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APPENDIX D-9
SAMPLE CALCULATION OF SENSITIVITY CHART
Sample Calculation: Sensitivity of the Manufacturing
cost of Unbleached Kraft Liner to
Key Variables (see Figure D-9-1)
1. Scale of Operations:
Best Guess: 910 MTPD
Possible High: 1370 MTPD, + 50% from best guess
Possible Low: 545 MTPD, - 40% from best guess
Curves of operating cost versus capacity are presented in Appendix D;
Figure D-9-1 deals with unbleached kraft liner. In preparing esti-
mates of operating cost versus capacity, we considered raw materials,
operating and packaging supplies, utilities, and cost of sales as
unit costs independent of mill capacity. Direct and indirect labor,
maintenance labor and supplies, factory overhead, and capital-related
costs were estimated for each model. From Figure D-9-1, operating
costs for unbleached kraft liner at 545 MTPD (-40%) are $150/MDMT,
and at 1370 MTPD (+50%) they are $132/MDMT. These two points are
plotted to form Line 1 in the sensitivity chart. This relationship
is indicated as linear for simplicity; more accurately, it should be
shown as a curve passing through the two end points and the origin.
2. Delivered Cost of Fiber (Pulpwood);
Best Guess: $31/cunit (weighted average of softwood and hardwood)
Possible High: $37/cunit, +20% from best guess
Possible Low: $25/cunit, -20% from best guess
From the operating cost statement for unbleached kraft liner (Table
IX-E-3), the total cost of pulpwood is $43.8/MDMT of product. A
20% variation is equal to $8.8/MDMT, giving a range in delivered
cost of $128.6 to $146.2/MDMT. These points form Line 2.
3. Fixed Capital;
Best Guess: $110 million
Possible High: $138 million, + 25% from best guess
Possible Low: $99 million, - 10% from best guess
From the operating cost statement, total capital-related costs are
$26.9/MDMT of product, and are directly proportional to total capital.
A +25% variation is equal to $6.7/MDMT, or a delivered cost of $144.I/
MDMT; a -20% variation is equal to $2.7/MDMT, or a delivered cost of
$134.7/MDMT. These two points form Line 3.
D-203
Arthur!) I.ittlelnc
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Deliveied Cost,S/MDMT
60%
Possible Decrease
in Variable
40% I 60%
Possible Increase
in [Variable
Q
KEY VARIABLES
1. Scale of Operations, MTPD
2. Delivered Cost of Fiber,* S/Cunit
3. Fixed Capital, $ Million
4. Cost of Energy, S/MMBtu
Percent
Variation
+50, -40
+20, -20
+25, -10
+50, -10
Best
Guess
910
31
110
1.0
Possible
High
1370
37
138
1.5
Possible
Low
545
25
99
0.9
'Average Pulpwood Cost
FIGURE D-9-1
SENSITIVITY OF THE MANUFACTURING
COST OF UNBLEACHED KRAFT LINER
TO KEY VARIABLES
D-204
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4. Cost of Energy;
Best Guess: $1.0/MM Btu
Possible High: $1.5/MM Btu, +50% from best guess
Possible Low: $0.9/MM Btu, -10% from best guess
For simplicity, we have assumed that the cost of purchased power would
vary directly with fuel cost. From the operating cost statement, the
total cost of fuel and purchased power is $6.9/MDMT. A +50% variation
is equal to $3.5/MDMT, or a delivered cost of $140.9/MDMT. A -10%
variation is equal to $0.7/MDMT, or a delivered cost of $136.7/MDMT.
These two points form Line 4.
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APPENDIX E - GLOSSARY
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APPENDIX E-1
GENERAL TERMS AND ABBREVIATIONS
AD. Air dry. AD pulp contains 10C* moisture.
ADMT. Air-dried metric ton. (See p. IX-A-2.)
BD. Bone dry — i.e., Wr moisture.
BK. Bleached kiaft pulp
Bogus Medium. Corrugating medium manufactured from sec-
ondary fiber.
Broker. One who bu> s waste paper stock from dealers and
others. (See p. V-19.)
CF. Chemical fiber. Same as CP.
Collectable tonnage. The quantity of waste paper economi-
cally available for recovery . (See p. V-2.)
Consumption rate. The amount of waste paper consumed, as
a percentage of the total papermaking fiber used. Also called
"furnish rate" and "recycling rate." (See p. V-2.)
Cord. 128 cubic feet of stacked roundvvood with bark. An
average cord of softwood is equivalent to 0.83 cumt.an average
cord of hardwood is equivalent to 0.79 cunit.
CP. Chemical pulp. Same a* CF.
Cunit. 100 cubic feet of solid wood.
DI. Demking. A category of high-quality waste paper which.
after appropriate treatment for ink removal, yields a replacement
for virgin fiber.
"G" Factor. Generation factor. (See p. VTI-8 )
GW. Groundwood (or other mechanical) pulp.
HW. Hardwood, may refer to grade of either pulp or wood.
Integrated. Refers to virgin fiber pulping and papermaking
operations combined at a single plant location.
Jumbo rolls. Interim product in converted tissue manu-
facture.
Jute linerboard. Lmerboard manufactured from secondary
fiber.
Man-year. Equivalent to 2200 man-hours.
Market pulp. Dned pulp mill product sold to non-integrated
paper and board manufacturers. (See p. 111-79.)
MDMT. Machine-dried metric ton (Seep IX-A-2.)
Mixed papers. A category of waste paper. (See p. V-8 ft.)
MSW. Municipal solid \vaste.
MT. Metric ton (1000 kilograms, or approximately 2200
pounds).
News. Old newspapers, a category of waste paper. Also
called "old news." (See p V-8 ff.)
Non-integrated. Refers to paper or board making operations
not located with a virgin fiber pulping operation but possibly
including on-site pulping of secondary fiber.
NSSC. Neutral sulfite semi-cnemical, a specific wood pulping
process and pulp grade.
OCC Old corrugated containers, a category of waste paper.
(See p. V-8 ff.)
PCC. Precipitated calcium carbonate.
PCF. Population concentration factor. (See p. VIM.)
PPC. Physical plant cost.
Primary pickup. Cost of waste paper at its source 'See
p. VMS.)
P'S. Pulp substitute, a category of high-quality waste paper
which requires a nominal amount of treatment prior to use as a
replacement for virgin fiber. (See p. V-8 ff.)
Recovery rate. Amount of waste paper collected, as a per-
centage of original paper products consumed. (See p. V'-l.)
ROI. Return on investment. (Total capital requirements for
integrated mills have been determined in a special way - see
p. IX-A-6.)
SBK. Semi-bleached kraft pulp.
SBS. Solid bleached sulfate. used with reference to paper-
board made from bleached kraft wood pulp
Scavenger. A collector of waste paper. (See p. V-19.)
S/F. Secondary fiber, papermakmg fiber made from waste
paper.
Slush pulp. The u"dned inill product transferred u> inte-
grated paper and I iard aiakmg or pulp drying (See p. 1X-A-5 ff.)
Sorting and balifig. Ine cost of processing waste paper for
delivery to the mil!. (See p. VI-18.)
SW. Softwood.
Ton (Tor ST>. Short ton. 2000 pounds.
TPD. Tons per day.
UBK. Unbleached kraft pulp
Virgin fiber. Papermaking fiber from original wood sources.
including forest industry residues
Waste paper dealer. One who buys waste paper stock from
scavengers and ty pically sorts and bales. (See p. V-19 i
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APPENDIX E-2
WOOD RESOURCE TERMS
(Reproduced from "The Outlook for Timber in the United States," Forest Resource Report No. 20,
Forest Service, U.S. Department of Agriculture, October 1973)
Acceptable tree. Growing-stock tree of commercial
species that meets specified standards of size and quality,
but not qualifying as desirable tree.
Allowable harvest. The volume of timber that would be
cut on commercial timberland during a given period under
specified management plans aimed at sustained production
of timber products.
Coarse residue. Plant residue that is suitable for chip-
ping, such as slabs, edgings, and veneer cores.
Commercial timberland. Forest land producing or
capable of producing crops of industrial wood and not
withdrawn from timber utilization. (Note: Areas quali-
fying as commercial timberland have the capability of
producing in excess of 20 cubic feet per acre per year of
industrial wood in natural stands. Currently inaccessible
and inoperable areas are included, except when the areas
involved are small and unlikely to become suitable for
production of industrial wood in the foreseeable future.)
Cord. A pile of stacked wood containing 128 cubic feet
within its outside surfaces. The standard dimensions are 4
by 4 by 8 feet.
Cropland. Land under cultivation within the past 24
months, including cropland harvested, crop failures, culti-
vated summer fallow, idle cropland used only for pasture,
orchards, and land in soil improving crops, but excluding
land cultivated in developing improved pasture.
Deferred forest land. National Forest land that meets
productivity standards for commercial timberland, but
under stud'y for possible inclusion in the Wilderness
System.
Desirable tree. Growing-stock tree (a) having no
serious defects in quality limiting present or prospective
use for timber products, (b) of relatively high vigor, and
(c) containing no pathogens that may result in death or
serious deterioration before rotation age. (Note: This is
the type of tree forest managers try to grow; that is, the
tree favored in cultural operations. In over-rotation-agc
stands, desirable trees are low-risk trees.)
Diameter classes. A classification of trees based on
diameter outside bark, measured at breast height (4-J^
feet above the ground). (Note: D.b.h. is the common ab-
breviation for diameter at breast height. Two-inch diam-
eter classes are commonly used in Forest Survey, with
the even inch the approximate midpoint for a class. For
example, the 6-inch class includes trees 5.0 through 6.9
inches d.b.h., inclusive.)
Farm. A place of 10 or more acres from which the sale of
agricultural products totaled $50 or more annually, or a
place of less than 10 acres from which the sale of agricul-
tural products totaled $250 or more during the previous
year.
Farm and miscellaneous lands. Privately owned lands
other than in forest industry ownership.
Fine residues. Residues not suitable for chipping, such
as sawdust, shavings, and veneer clippings.
Forest land. Land at least 10 percent occupied by forest
trees of any size, or formerly having had such tree cover,
and not currently developed for nonforest use. (Note:
The minimum area for classification of forest land is 1 acre.
Roadside, streamside, and shelterbelt strips of timber
must have a crown width at least 120 feet wide to qualify
as forest land. Unimproved roads and trails, streams, or
other bodies of water or clearings in forest areas are classed
as forest if less than 120 feet in width.) Also see definitions
for land area, commercial timberland, noncommercial
forest land, productive-reserved forest land, stocking, and
unproductive forest land.
Forest site productivity class. A classification of forest
land in terms of potential cubic-foot volume growth per
acre at culmination of mean annual increment in fully
stocked natural stands.
Forest type. A classification of forest land based upon
the species forming a plurality of live-tree stocking. Type
is determined on the basis of species plurality of all live
trees that contribute to stocking.
Growing-stock trees. Live trees of commercial species
qualifying as desirable or acceptable trees. Excludes rough,
rotten, and dead trees.
Growing-stock volume. Net volume in cubic feet of
growing-stock trees 5.0 inches d.b.h. and over from a 1-foot
stump to a minimum 4.0-inch top diameter ovitside bark of
the central stem or to the point where the central stem
breaks into limbs.
Growth impact. Mortality plus growth loss.
Growth loss. Timber loss due to (a) delay in restocking
or deficiencies in stocking resulting from damage by
insects, disease, animals, fire, or adverse weather, and
(b) the reduction in growth due to changes in timber
type, defoliation, reduction of tree vigor, increase in cull
percent, or deterioration of site due to destructive agents.
Hardwoods. Dicotyledonous trees, usually broad-leaved
and deciduous.
Indian lands. Tribal lands held in fee by the Federal
Government, but administered for Indian tribal groups,
and Indian trust allotments.
Industrial wood. All roundwood products, except fuel-
wood.
Ingrowth. The number or net volume of trees that grow
large enough during a specified year to qualify as saplings,
poletimber, or sawtimber.
Land area.
a. Bureau of the Census. The area of dry land and land
temporarily or partly covered by water, such as
marshes, swamps and river flood plains (omitting
tidal flats below mean high tide); streams, sloughs,
estuaries and canals less than % of a statute mile
in width; and lakes, reservoirs and ponds less than
40 acres in area.
b. Forest Survey. Same as the Bureau of the Census
except minimum width of streams, etc. is 120 feet
and minimum size of lakes, etc. is 1 acre.
Limbwood. That part of the tree above the stump which
does not meet the requirement for saw logs and upper-
stem portions, including all live, sound branches to a
minimum of 4 inches outside bark.
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Log scale. A measure of the board-foot content of
roundwood. Local scale may include Scribner, Doyle or
other rules. The international %-inch log rule is used as
standard in the Forest Survey.
Logging residues. Unused portions of trees cut or killed
by logging.
Mortality. Number or sound-wood volume of live trees
dying from natural causes during a specified period.
Multiple-use management. The management of land
resources aimed at achieving optimum yields of products
and services from a given area without impairing the
productive capacity of the site.
National Forest lands. Federal lands which have been
legally designated as National Forests or purchase units,
and other lands under the administration of the Forest
Service, including experimental areas and Bankhead-Jones
Title III lands.
Net annual growth. The increase in volume of trees
during a specified year. Components of net annual growth
include the increment in net volume of trees at the begin-
ning of the specified year surviving to its end, plus the
net volume of trees reaching the minimum size class
during the year, minus the volume of trees that died
during the year, and minus the net volume of trees that
became rough or rotten trees during the year.
Net volume in board feet. The gross board-foot volume
of trees less deductions for rot or other defect affecting
use for lumber.
Net volume in cubic feet. Gross volume in cubic feet
less deductions for rot.
Noncommercial forest land. (1) Unproductive forest
land incapable of yielding crops of industrial wood, because
of adverse site conditions and (2) productive forest land
reserved for nontimber uses.
Noncommercial species. Tree species of typically small
size, poor form, or inferior quality which normally do not
develop into trees suitable for industrial wood products.
Nonforest land. Land that has never supported forests
and lands formerly forested where use for timber manage-
ment is precluded by development for other uses. (Note:
Includes areas used for crops, improved pasture, residential
areas, city parks, improved roads of any width and ad-
joining clearings, powerline clearings of any width, and
1- to 40-acre areas of water classified by the Bureau of the
Census as land. If intermingled in forest areas, unimproved
roads and nonforest strips must be more than 120 feet
wide, and clearings, etc., more than 1 acre in size, to
qualify as nonforest land.)
Nonstocked areas. Commercial timberland less than 10
percent occupied with growing-stock trees.
Old-growth stands. Stands in which 50 percent or more
of the area is occupied by old-growth timber.
Old-growth timber. Trees that are at least 100 years old.
Other removals. The net volume of growing-stock trees
removed from the inventory by cultural operations such
as timber-stand improvement, by land clearing and by
changes in land use, and not utilized for timber products.
Pasture and rangeland. Land which is currently im-
proved for grazing by cultivation, seeding or irrigation,
and natural grasslands.
Plant byproducts. Wood products such as pulp chips
obtained incidental to production of other manufactured
products.
Plant residues. Waste materials from the manufacture of
lumber, plywood and other wood products. Includes slabs,
edgings, trimmings, miscuts, sawdust, shavings, veneer
cores and clippings, and pulp screenings.
Poletimber stands. Stands at least 10 percent occupied
with growing-stock trees of which half or more of this
stocking is in poletimber and/or sawtimber trees, and with
poletimber stocking exceeding that of sawtimber.
Prescribed burning. The application of fire to land under
such conditions of weather, soil moisture, and other factors
as presumably will accomplish specific silvicultural,
wildlife, grazing, or fire-hazard-reduction purposes.
Primary wood-processing plants. Plants using round
wood products such as suw logs, pulpwood bolts, veneer
logs, etc.
Productive-reserved forest land. Forest land sufficiently
productive to qualify as commercial timberland, but
withdrawn from timber utilization through statute or
administrative designation.
Removals. Volumes of timber removed from the growing-
stock inventory, including timber products, logging
residues, and other removals such as land clearing.
Rotation. The period of years between establishment of
a stand of timber and the time when it is considered ready
for final harvest and regeneration.
Rotten tree. Live tree of commercial species that does
not contain, now or prospectively, at least one 12-foot saw
log or two noncontiguous saw logs each 8 feet or longer,
and/or does not meet regional specifications for freedom
from defect primarily because of rot; that is, when more
than 50 percent of the cull volume in a tree is rotten.
Rough tree. (1) Live tree of commercial species that
does not contain, now or prospectively, at least one 12-foot
saw log or two noncontiguous saw logs each 8 feet or
longer, and/or does not meet regional specifications for
freedom from defect primarily because of roughness or
poor form, and (2) live tree of noncommercial species.
Roundwood products. Logs, bolts, or other round sections
cut from trees for industrial or consumer use.
Roundwood equivalent. The volume of logs or other
round products required to produce woodpulp, lumber, or
other processed products.
Salvable dead trees. Standing or down dead trees that
are considered merchantable by regional standards.
Sampling error. The probable error of an estimated total
or average that arises from taking a sample rather than
making a complete inventory or measurement.
Saplings. Live trees 1.0 inch to 5.0 inches in diameter
at breast height.
Saw-log portion. That part of the bole of sawtimber trees
between the stump and the saw-log top.
Saw logs. Logs meeting minimum regional standards of
diameter, length, and defect. Logs must be at least 8 feet
long, have a minimum diameter inside bark of 6 inches for
softwoods and 8 inches for hardwoods and maximum defect
as specified by regional standards.
Sawtimber stands. Stands at least 10 percent occupied
with growing-stock trees, with half or more of total
stocking in sawtimber or poletimber trees, and with
sawtimber stocking at least equal to poletimber stocking.
Sawtimber trees. Live trees of commercial species
containing at least one 12-foot saw log or two noncontigu-
ous 8-foot logs, and meeting regional specifications for
freedom from defect. Softwood trees must be at least 9.0
inches in diameter breast height, except in California,
Oregon, Washington, and coastal Alaska where the
minimum diameter is 11.0 inches. Hardwood trees must
be at least 11.0 inches in diameter in all States.
Secondary wood-processing plants. Plants using pri-
mary manufactured products such as lumber, wood-
pulp, veneer, or plywood.
Seedling and sapling stands. Stands at least 10 percent
occupied with growing-stock trees of which more than half
of the stocking is saplings and/or seedlings.
Seedlings. Live trees less than 1.0 inch in diameter at
breast height that are expected to survive according to
regional standards.
Site preparation. Removal or deadening of unwanted
vegetation prior to planting trees, including prescribed
burning, use of herbicides, and disking and other mechani-
cal means of removing vegetative cover.
Softwoods. Coniferous trees, usually evergreen having
needles or scalelike leaves.
Stand improvement. Measures such as thinning, release
cutting, girdling, weeding, or poisoning of unwanted trees
aimed at improving growing conditions.
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Stand-size class. A classification of forest land based on
the size class of growing-stock trees on the area; that is,
sawtimber, poletimber, or seedlings and saplings.
Stocking. The degree of occupancy of land by trees,
measured by basal area and/or number of trees by size or
age and spacing, compared to a stocking standard, i.e.,
the basal area and/or number of trees required to fully
utilize the growth potential of the land.
Timber demand. The volume of timber that would be
purchased at specified prices at a specified point in time
under specified or implied assumptions relating to popula-
tion, income, and other technological or institutional factors.
Timber supply (or timber harvest). Net volume of round-
wood products available to forest industries from all sources
at specified or implied price levels.
Tree size class. A classification of trees based on diameter
at breast height, including sawtimber trees, poletimber
trees, saplings and seedlings.
Trend level. Estimate based on a curve or regression
equation constructed from observed values over time.
Unproductive forest land. Forest land incapable of
producing 20 cubic feet per acre of industrial wood under
natural conditions because of adverse site conditions such
as sterile soils, dry climate, poor drainage, high elevation,
steepness, or rockiness.
Unregulated forest land. Commercial timberland in
National Forests not organized for timber production
under sustained-yield principles, including experimental
forests, recreation and administrative sites, and tracts of
commercial timberland so remote from manufacturing
centers that scheduling sustained periodic harvest is
impractical.
Upper stems. That part of the bole of sawtimber trees
above the saw-log top to a minimum top diameter of 4.0
inches outside bark or to the point where the central stem
breaks into limbs.
Wilderness area. An area of undeveloped Federal land
retaining its primeval character and influence, without
permanent improvements or human habitation, which is
protected and managed so as to preserve natural conditions.
Young-growth stands. Stands in which 50 percent or
more of the stand is occupied by sawtimber trees less than
100 years old.
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APPENDIX F - U.S. ASSOCIATIONS IN THE
PAPER AND ALLIED TRADES
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APPENDIX F
U. S. ASSOCIATIONS IN THE PAPER AND ALLIED TRADES
ACOUSTICAL INSULATING MATERIALS
ASSOCIATION
205 W. Touhy Ave.
Park Ridge, IL 60068
Tel- 312-692-5178
Exec vice pres: James E. Nolan
AIR POLLUTION CONTROL ASSN.
4400 Fifth Ave.
Pittsburgh, PA 15213
Tel: 412-621-1100
Exec vice pres., sec: Dr. Lewis H. Rogers
AMERICAN BOOK PUBLISHERS COUNCIL
1 Park Ave.
New York, NY 10016
Tel- 212-689-8920
AMERICAN BOOKSELLERS ASSN. INC.
175 Fifth Ave.
New York, NY 10010
Tel: 212-254-5520
Exec, dir: Joseph A. Duffy
AMERICAN CHEMICAL SOCIETY
1155 Sixteenth St., N.W.
Washington, DC 20036
Tel- 202-872-4000
Exec, sec: B. R. Stanerson
AMERICAN EDUCATIONAL PUBLISHERS
INSTITUTE
432 Park Ave. South
New York, NY 10016
Tel' 212-679-6488
Exec, dir- Austin J. McCaffrey
AMERICAN FOREST INSTITUTE
(formerly American Forest Products
Industries, Inc.)
1619 Massachusetts Av., N.W.
Washington, DC 20036
Tel- 202-667-7807
Exec, vice pres- George C. Cheek
AMERICAN HAROBOARO ASSOCIATION
20 North Wacker Dr.
Chicago, IL 60606
Tel: 312-236-8009
Exec, sec J. Mason Meyer
AMERICAN INSTITUTE OF CHEMISTS
79 Madison Ave.
New York, NY 10016
Tel- 212-686-1421
Exec sec- Paul B. Slawter, Jr.
AMERICAN MANAGEMENT ASSN.
PACKAGING DIVISION
135 West 50th St.
New York. NY 10020
Tel- 212-586-8100
Pres: Alexander B. Trowbridge
Sec: Robert Butler
AMERICAN NEWSPAPER PUBLISHER'S ASSN.
Traffic & Newsprint Dept.
P.O. Box 17407, Dulles Int'l Airport
Washington, DC 20041
Tel- 703-620-9500
Mgr. Traffic & Newsprint Dept:
J. F, Prendergast, Jr.
AMERICAN PAPER INSTITUTE
260 Madison Ave.
New York, NY 10016
Tel: 212-889-6200
Chairman: David L. Luke, 3rd
Vice chmn: Dan Int-Hout, Jr.
Pres: Edwin A. Locke, Jr.
Sr. Vice Pres: John F. Darrow
Vice Pres., Paperboard: J. Rodney Edwards
Vice Pres., Pulp & Raw Materials:
Ronald J. Shnn
Vice Pres., Public Affairs: William J. Brooks
Sec.-Treas: Albert S. Thomas
Washington, DC Offices
1619 Massachusetts Av. NW, Rm 530, 20036
Tel 202-667-8878
Paper Group1 Divisions — Glassme &
Greaseproof, Kraft & Packaging, Newsprint,
Printing-Writing Tissue, Vegetable
Parchment
Paperboard Group Divisions — Eastern Div.,
Eastern Contamerboard, Pacific Coast,
Southern Containerboard, Western
Boxboard, Western Containerboard,
Combination Paperboard, Corrugating
Materials, Southern Boxboard, Bleached
Paperboard
Pulp & Raw Materials Groups: Divisions —
Pulp Producers, Pulp Consumers, Raw
Materials, Other Fibers (excluding cotton
and paper stock)
Personnel Administration & Industrial
Relations, Industrial Safety Section
Public Affairs: Sections — Biologica1 &
Chemical Research, Financial Services,
Public Relations & Publications, State
& Local Relations, Transportation &
Distribution, Technical Services
AMERICAN PULPWOOD ASSN.
605 Third Ave.
New York, NY 10016
Tel: 212-687-2272
Exec, vice pres: W. S. Bromley
ASPHALT ROOFING MANUFACTURERS ASSN.
(formerly Asphalt Roofing Industry Bureau)
757 Third Ave.
New York, NY 10017
Tel: 212-421-2690
Mng dir: H. H. Whittemore
ASSOCIATION OF AMERICAN
WOODPULP IMPORTERS
150 E. 42nd St
New York, NY 10017
Sec- William McNair
ASSOCIATION OF REPRODUCTION
MATERIALS MANUFACTORIES
Suite 607
901 N. Washington St.
Alexandria, VA 22314
Tel: 703-683-5455
Exec, sec Preston B. Bergin
BOSTON PAPER TRADE ASSN.
10 High St.
Boston, MA 02110
Tel 617-542-5256
Sec. treas Norrnan E. Scott
BOXBOARD RESEARCH & DEVELOPMENT ASSN.
350 South Burdick Mall
Ka'amazoo, Ml 49006
Tel 616-344-0394
Sec. tieas- Alan R Johnson
BUILDING MATERIALS RESEARCH
INSTITUTE, INC.
60 East 42nd St.
New York, NY 10017
Tel- 212-682-6320
Exec. dir. Raymond M. McNeal
CHEMURGIC COUNCIL
350 Fifth Ave.
New York, NY 10001
Teh 212-524-0153
Sec- Dr. Hairy J. Prebluda
COMPOSITE CAN & TUBE INSTITUTE
(formerly National Fibre Can & Tube Assn )
1725 Eye St., NW
Washington, DC 20006
Tel- 202-223-4840
Exec, vice pres, sec: William E. Hughes
CONTAINERIZATION INSTITUTE INC.
(formerly Bulk Packaging & Contamenzatr ,.
Institute)
15 East 40th St.
New York, NY 10016
Tel: 212-686-1824
Exec, sec: Glenn Mather
CORRUGATED CONTAINER INSTITUTE
P.O Box 1572
108 S. Kentucky Ave., P.O. Box 1752
Lakeland. EL 33802
Tel 813-683-2891
Mng dir: R, M. Reese
DATA PROCESSING SUPPLIES ASSN.
1116 Summer St.. P.O. Box 1333
Stamford, CT 06904
Tel: 203-323-3143
Exec, dir- C. A. Greathouse
THE DISPOSABLES ASSN.
10 East 40th St
New York, NY 10016
Tel- 212-686-9170
Exec, vice pres and sec' Charles J. Corey
DRINKING STRAW INSTITUTE
1116 Sumrie- S,., PO Box 1333
Stan-.forri. CT 06904
Te! 203-323 3143
Exec dir C. A. Greathouse
EMPIRE STATE FOREST PRODUCTS ASsN.
89 LL .'low St.
Saratoga Springs, NY 12866
Tel 518-584-59Q5
Sec Stanley W. •'amilton
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APPENDIX F
(Continued)
EMPIRE STATE PAPER ASSN., INC.
800 New Loudon Rd.
Latham, NY 12110
Tel: 518-785-9370
Sec- Edgar F. Radigan
ENVELOPE MANUFACTURERS ASSN.
1 Rockefeller Plaza
New York, NY 10020
Tel- 212-245-5885
Exec, vice pres: William H. McManus
FELT MANUFACTURERS COUNCIL
OF NORTHERN TEXTILE ASSN.
211 Congress St.
Boston, MA 02110
Tel: 617-542-8220
Sec: William F. Sullivan
FIBRE BOX ASSN.
224 S. Michigan Ave.
Chicago, IL 60604
Tel: 312-663-0250
Sec: Thomas J. Muldoon
FLEXOGRAPHIC TECHNICAL ASSN. INC.
1416 Avenue M
Brooklyn, NY 11230
Tel: 212-998-2100
Sec: George J. Parisi
FOOD TRAY & BOARD ASSN DIV., SINGLE
SERVICE INSTITUTE
250 Park Ave.
New York, NY 10017
Tel: 212-697-4545
Exec, vice pres. Robert W. Foster
FOREST PRODUCTS RESEARCH SOCIETY
2801 Marshall Ct.
Madison. Wl 53705
Tel: 608-231-1361
Exec, sec: K. E. Huddleston
FOURDRINIER KRAFT BOARD INSTITUTE
280 Park Ave.
New York, NY 10017
Tel. 212-687-9226
Pres. A. Rodney Boren
FOURDRINIER WIRE COUNCIL
1625 Eye St., NW
Washington, DC 20006
Tel: 202-347-5611
Sec. treas- John D. Ferry
GARDEN STATE PAPER TRADE ASSN.
521 Fifth Ave.
New York, NY 10017
Tel: 212-687-2345
Dir. & counsel: Reuben A. Barshay
GRAPHIC ARTS TECHNICAL FOUNDATION
4615 Forbes Ave.
Pittsburgh, PA 15213
Tel: 412-621-6941
Exec, dir: William H. Webber
GRAVURE TECHNICAL ASSN.
60 East 42nd St.
New York, NY 10017
Tel: 212-661-8936
Exec, vice pres: W. R. Daum
GREATER BOSTON PAPER BOX ASSN.
15 Rusfield St.
Boston, MA 02119
Sec.-treas: Victor G. Mitchell
GUMMED INDUSTRIES ASSN., INC.
551 Fifth Ave.
New York, NY 10017
Tel: 212-986-8213
Mng. dir: Robert W. McKellar
INDUSTRIAL SAFETY EQUIPMENT ASSN., INC.
1 Stone PI, PO Box 515
Bronxville, NY 10708
Tel: 914-779-9602
Sec.-treas: C. N. Sumwalt, Jr.
INSTITUTE OF ELECTRICAL & ELECTRONICS
ENGINEERS
345 E. 47th St.
New York, NY 10017
Tel. 212-752-6800
Gen. mgr: Donald G. Fink
INSTRUMENT SOCIETY OF AMERICA, PULP
AND PAPER INDUSTRY DIVISION
400 Stanwix St.
Pittsburgh, PA 15222
Tel: 412-281-3171
Exec, dir: Herbert S. Kmdler
Div. dir: R. L. Stoughton
(Consolidated Papers, Inc.)
INTERNATIONAL BROTHERHOOD OF PULP,
SULPHITE AND PAPER MILL WORKERS
118 Broadway
John P. Burke Building
Fort Edwards, NY 12828
Tel: 518-747-3361
Pres.-sec: Joseph P. Tonelli
LABEL MANUFACTURERS NATIONAL
ASSN., INC.
Room 511, Wilson Plaza Bldg.
2425 Wilson Blvd.
Arlington, VA 22201
Tel 703-528-8444
Exec, dir: Francis R. Cawley
MAGAZINE PUBLISHERS ASSN.
575 Lexington Ave.
New York, NY 10022
Tel: 212-727-0055
METROPOLITAN BAG & PAPER
DISTRIBUTORS ASSN., INC.
521 Fifth Ave.
New York, NY 10017
Tel: 212-687-2345
Dir. & counsel: Reubrr A Barshay
MIAMI VALLEY PAPER SHIPPERS ASSN., INC.
845 East Ave.
Hamilton, OH 45011
Tel: 513-863-2065
Sec: John D. Nichols
MIDWEST PAPER ASSN.
PO Box 374
Carpentersville, IL60110
Tel. 312-381-8989
Exec dir: Warren W. Findlmg
NATIONAL ACOUSTICAL CONTRACTORS ASSN.
1201 Waukegan Rd.
Glenville, IL 60025
Tel: 312-724-7700
Exec, sec: C. A. Wangman
NATIONAL ASSN. OF GREETING CARD
PUBLISHERS
200 Park Av., New York, N. Y. 10017
Tel: 212-972-0072
NATIONAL ASSN. OF PURCHASING
MANAGEMENT
11 Park Place, New York, N. Y. 10007
Tel: 212-267-3677
Executive vice president: G. W. Howard Ahl
NATIONAL ASSN. OF SANITARY MILK
BOTTLE CLOSURE MANUFACTURERS
P.O. Box 26
Canastota, N. Y. 13032
Secretary: Laurence F. Read
NATIONAL ASSN. OF SECONDARY
MATERIAL INDUSTRIES, INC.
330 Madison Ave.. New York, N. Y. 10017
Tel: 212-867-7330
Secretary-treasurer: M. J. Mighdoll
NATIONAL BUSINESS FORMS ASSN.
300 N. Lee St., Alexandria, Va. 22314
Executive director: Meredith Smith, Jr.
NATIONAL COUNCIL OF THE PAPER
INDUSTRY FOR AIR & STREAM
IMPROVEMENT INC.
260 Madison Av., New York, N. Y. 10016
Tel: 212-889-5416
Executive director: Ernest J. Bolduc, Jr.
NATIONAL FLEXIBLE PACKAGING ASSN.
12025 Shaker Boulevard
Cleveland, Ohio 44120
Tel: 216-921-0078
Managing director: E. C. Merkle
NATIONAL OFFICE PRODUCTS ASSN.
1500 Wilson Blvd, Suite 1200
Arlington, Va. 22209
Tel: 703-525-2668
Sec: William Goss
NATIONAL PAPER BOX ASSN.
231 Kings Highway East
Haddonfield, N. J. 08033
Tel: 609-429-7377
Executive director: Norman T. Baldwin
NATIONAL PAPER TRADE ASSN., INC.
420 Lexington Ave., New York, N. Y. 10017
Tel: 212-686-4542
Executive vice pres: Glenn Leach
NATIONAL REFUSE SACK COUNCIL, INC.
(Division of Paper Shipping Sack Mfgrs.
Assn.)
60 East 42nd St., New York, N. Y. 10017
Tel: 212-867-6420
Executive director: C. G. Peterman
NATIONAL SAFETY COUNCIL, PULP &
PAPER SECTION
425 N. Michigan Ave., Chicago, III. 60611
Tel: 312-527-4800
Staff representative: Thomas F. Powers
NATIONAL SCHOOL SUPPLY &
EQUIPMENT ASSN.
79 W. Monroe St., Chicago, III. 60603
Tel: 312-236-6970
Executive vice presrdent: Dave McCurrach
NATIONAL SHOEBOARD CONFERENCE, INC.
P.O. Box 1495. Boston, Mass. 02104
Tel. 617-864-6900
Secretary: Stanley M. Jacks
NEWSPRINT INFORMATION COMMITTEE
150 East 42nd St.
New York, NY 10017
Tel: 212-697-5600
Exec. sec. John H. O'Connell
NORTHWEST PULP & PAPER ASSN.
2633 t.'stlake Ave. E
Seattle. ,VA 98102
Tel. 206-325-3277
Exec sec: Dona-Id J. Benson
NORTHWESTERN PAPER TRADE ASSN.
900 Farmers & Mechanics Bank Building
Minneapolis, MN 54402
Tel 612-335-9331
Sec1 Roger W. Schnobnch
F-2
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PACIFIC COAST ASSN. OF PULP AND PAPER
MANUFACTURERS
621 S.VV. Morrison St., Suite 930
Portland, OR 97205
Tel: 503-228-7491
Sec: R. W. Hess
PACIFIC COAST PAPER BOX
MANUFACTURERS ASSN.
5959 W. Century Blvd.
Los Angeles. CA 90045
Tel- 213-670-4432
Sec: Edwin A. Mozley
PACKAGE DESIGNER'S COUNCIL
PO Box 3753, Grand Central Sta.
New York, NY 10017
Tel- 212-682-1980
Exec, dir Mrs. Glory Harris
PACKAGING INSTITUTE, U.S.A.
342 Madison Ave.
New York, NY 10017
Tel: 212-687-8875
Exec, dir: Charles A. Feld
PAPER BAG INSTITUTE INC.
41 East 42nd St.
New York, NY 10017
Tel 212-697-9020
Fxec. sec: William R. Gardiner
PAPER CLUB OF NEW YORK
3 Ann St.
Bergenfield, NJ 07621
Sec Daniel 0. Reich
PAPER INDUSTRY MANAGEMENT ASSN.
2570 Devon Ave.
Des Plaines, IL 60018
Tel: 312-827-7126
Exec, sec: H. Mac Gregor Tuttle
Divisions and chairmen: Conn. Valley (R. C.
Malloch), Miami Valley (R. E. Kash),
Michigan (F. J. Fragomili), New York''
Canadian (A. St. Jacques), Northeastern
(C. H. Reed), Northwestern (J Dunlap),
Pacific Coast (W. H. Youngchild), Pen-Jer-
Del (L. J Schroth), Southeastern (H P.
Brodnax), Southern (C. S Flenniken),
Southwestern (C. F. Lowery), Industrial
Affiliates (G. P. Wennes, Jr.)
PAPER MAKERS ADVERTISING ASSN. INC.
90 Elm St.
Westfield, MA 01085
Tel: 413-568-1986
Exec sec' Fred S. Van Voorhis
PAPER MERCHANTS ASSN. OF NEW YORK
93 Worth St
New York, NY 10013
TP| 212-267-9680
Sec- John G. Crowe
PAPER MILL MEN'S CLUB OF SOUTHERN
CALIFORNIA
21026 Renwick Rd.
Glendoia, CA 91740
Tel 213-963-2358
Sec Pole- Belculfmr-
APPENDIX F
(Continued
PAPER SHIPPING SACK MANUFACTURERS
ASSN., INC.
60 E. 42nd St.
New York, NY 10017
Tel 212-867-6420
Exec vice-pres- C. G Peterman
PAPER STATIONERY AND TABLET
MANUFACTURERS ASSN., INC.
444 Madison Ave.. Suite 2301
Now York, NY 10022
Tel 212-753-4496
Exec sec Frank Cowa/i Jr
PAPER STOCK INSTITUTE OF AMERICA
330 Madison Ave.
New York, NY 10017
Tel: 212-867-7330
Sec: Elinor B. Roberts
PAPER TRADE ASSOCIATION OF
PHILADELPHIA, INC.
1900 Arch St.
Philadelphia, PA 19103
Tel- 215-564-3484
Exec, sec: Robert G. Clifton
PAPERBOARD PACKAGING COUNCIL
(Merger of Folding Paper Box Assn. and the
Institute for Better Packaging)
1800 K St., NW
Washington, DC 20006
Tel 202-872-0180
Pres: Russell C. Flom
PLATE, CUP & CONTAINER INSTITUTE DIV.,
SINGLE SERVICE INSTITUTE INC.
250 Park Ave.
New York, NY 10017
Tel: 212-697-4545
Exec, dir: Robert W. Foster
PRESSURE SENSITIVE TAPE COUNCIL
1201 Waukegan Rd.
Glenview, IL 60025
Tel: 312-724-7700
Sec. R. G. Bradeen, Jr.
PRINTING INDUSTRIES OF AMERICA, INC.
1730 N. Lynn St.
Arlington, VA 22209
c/o Sorg Printing Co. of Calif.
424 E. 15th St.
Los Angeles, CA 90015
Sec: James J. Woods
PRINTING PAPER CREDIT GROUP
1900 Cherry St.
Philadelphia, PA 19103
Sec: Miss Anne I. Meenan
PULP CHEMICALS ASSN.
60 East 42nd St.
New York, NY 10017
Tel: 212-697-4816
Sec: Douglas E. Campbell
PULP & PAPER MACHINERY ASSN.
The Black Clawson Co.
200 Park Ave.
New York, NY 10017
Teh 212-972-4440
Sec: Carl C. Landegger
PULP & PAPER MANUFACTURERS ASSN.
(LAKE STATES)
Irving Zuelke Building, 12th Floor
Appleton, Wl 54911
Tel: 414-734-5778
Exec, sec: V. G. Cornelius
PULP, PAPER & PAPERBOARD EXPORT ASSN.
OF THE U.S.
90 Park Ave.
New York, NY 10016
Tel: 212-682-4347
Sec. treas R. L. Kerridge
PULP AND PAPER TRAFFIC LEAGUE
c/o Fibre Box Association
224 So. Michigan Ave.
Chicago, IL 60604
Tel: 312-663-0250
Dir. of Trans: T. R. Lynch
Gen. traffic mgr: R. M. Renwick
(c/o Kimberly-Clark of Canada Ltd.
2 Carlton St., Toronto, Ont , Canada)
SALESMEN'S ASSN. PAPER & ALLIED
INDUSTRIES
18 Palisade Ave.
Yonkers, NY 10701
Tel: 914-476-1780
Sec: Jerome Kinoy
SALES ASSN. OF THE PAPER INDUSTRY
260 Madison Ave.
New York, NY 10016
Tel: 212-889-6200
Treas Miss Anne G. Toomey
SOCIETY OF PACKAGING AND HANDLING
ENGINEERS
14 E Jackson St.
Chicago, IL 60604
Tel: 312-427-6123
SODA PULP MANUFACTURERS ASSN.
2 Greenwich Plaza
Greenwich, CT 06830
Tel. 203-661-3648
S°c: William M. Barrett
SOU1HEASTERNERS, INC.
PO Box 7272
Richmond, VA 23224
Sec.-treas: Charles M. Bechtler
WHOLESALE STATIONERS ASSN., INC.
O'Hare Office Bldg II
10600 W Higgms Rd.
Rosemont, IL 60018
Tel 312-297-6882
Sec: Bernard Seltzer
WISCONSIN PAPER GROUP
268 Sanford St.
Menasha, Wl 54952
Tel: 414-722-2863
Gen. mgr: James W Vander Hyden
WISCONSIN PAPER AND PULP
MANUFACTURERS' TRAFFIC ASSOCIATION
79 W Monroe St., Room 1221
Chicago, IL 60603
Tel 312-236-8950
Gen. traffic mgr. and sec. J. E. Hart
Source: Lockwood's Directory, 1973
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Prozaction Agency
Region Vj Lll;:.ury
230 South Dearborn Street
Chicacc. Illinois 606QU
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