MARKET STUDY OF
MOLECULAR CHLORINE-
FREE AND TOTALLY
CHLORINE-FREE
BLEACHED PAPER
U.S. Environmental
Protection Agency
Washington, D.C.
December, 1992
Prepared for:
Regulatory Impacts Branch
Economics, Exposure and Technology Division
Office of Pollution Prevention and Toxics
U.S. Environmental Protection Agency
Washington, D.C.
Prepared by:
Abt Associates Inc.
Cambridge, MA
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ACKNOWLEDGEMENTS
This report was prepared by Abt Associates Inc. of Cambridge, Massachusetts for the U.S. EPA Office
of Pollution Prevention and Toxics, Economics, Exposure and Technology Division, Regulatory Impact Branch
under EPA Contract No. 68-DO-0020, Task 1-08 and EPA Contract No. 68-D2-0175, Task 1-12. Susan Krueger
and Pat Szarek served as Task Managers. The Abt Associates staff for this project was:
Project Management - Randi Currier/Penelope Schafer
Technical Review - Penelope Schafer/Marianne Beauregard
Analysts - Kim Mitchell
Liz Arriaza
Substantial contributions to the report were also made by Eastern Research Group, Inc., Amendola
Engineering, Inc., and Scott Zimmerman.
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TABLE OF CONTENTS
GLOSSARY i
EXECUTIVE SUMMARY iii
CHAPTER 1: INTRODUCTION 1-1
1.1 Background 1-1
1.2 Areas for Future Research 1-3
1.3 Overview of the Report .1-3
CHAPTER 2: BLEACHED PULP AND PAPER MARKETS 2-1
2.1 Introduction to Pulp and Paper Markets 2-1
2.2 Major Paper Product Categories 2-4
2.3 Major Paperboard Product Grades 2-13
2.4 Overview of the Major Pulp, Paper, and Paperboard Producers 2-22
2.5 Bleached Paper Products 2-25
2.6 Conclusions 2-44
CHAPTER 3: CHARACTERISTICS OF BLEACHED PAPER 3-1
3.1 Factors Affecting Paper Attributes 3-1
3.2 Summary 3-10
CHAPTER 4: CHARACTERISTICS OF MARKETS FOR UNBLEACHED
AND ALTERNATIVELY BLEACHED PRODUCTS 4-1
4.1 Commercially Available Unbleached or Alternatively Bleached Paper Products 4-1
4.2 Paper Market: Consumer Groups . . 4-23
4.3 Paper Market: Unbleached versus Alternatively Bleached 4-24
4.4 The European Market 4-26
4.5 Inhibiting Factors Slowing Conversion from Molecular Chlorine Bleaching 4-29
4.6 Future Trends 4-34
APPENDIX 2.A BLEACHED AND UNBLEACHED PULP PRODUCTION VOLUMES 2A-1
APPENDK 2.B COMPREHENSIVE LISTING OF ALL MILL OUTPUTS FOR ALL
PAPER AND PAPERBOARD GRADES 2B-1
APPENDIX 2.C MILLS AND FIRMS PRODUCING PRODUCTS WITH HIGH OR
MEDIUM BLEACHED PULP CONTENT 2C-1
APPENDIX 2.D BUREAU OF CENSUS DATA 2D-1
APPENDIX 3.A OVERVIEW OF THE PULPING PROCESS 3LA-1
Note: Appendices' numbers correspond to chapters in which they are referenced.
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GLOSSARY
The following definitions referring to bleaching processes have been adopted for this report:
Alternatively Bleached - Variant term for molecular chlorine-free or totally chlorine-free
bleached paper (see below).
Bleaching - The process of chemically treating fibers to reduce or remove coloring
matter so that the pulp is improved in terms of whiteness or brightness.
Chlorine Bleached - Bleached with molecular chlorine (Cy or a chlorine compound.
Molecular Chlorine-free (MCF) - Bleached without the use of molecular chlorine
(e.g., bleached with sodium hypochlorite, chlorine dioxide, oxygen, ozone, and/or
hydrogen peroxide) - also referred to as Elemental Chlorine-free (ECF).
Totally Chlorine-free (TCP) - Bleached without the use of molecular chlorine (CLJ and
chlorine compounds (e.g., bleached with hydrogen peroxide, ozone, and/or oxygen).
Unbleached - Produced without being treated with bleaching agents.
Unrebleached - Produced from recycled paper feedstock without the use of additional
bleach. Feedstock may or may not have been bleached.
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EXECUTIVE SUMMARY
The investigation summarized in this report sought to identify opportunities for reducing
the amounts of chlorinated organics released to the environment as a result of the production of
paper and paperboard. The reductions could result from changes in:
• the processes used to produce pulp and paper, and
• the demand for chlorine bleached products.
This report examines market demand for molecular chlorine-free (MCF) and totally chlorine-free
(TCP) bleached paper products as well as paper products that are unbleached and bleached with
reduced amounts of chlorine. The report also examines the impact of chlorine bleaching on the
quality of the product, as well as some of the technological problems of bleaching without the
use of chlorine. By examining both the technical and the market considerations, this analysis
provides a foundation for exploring the question of where and to what degree the use of
chlorinated organics by the pulp and paper industry might be reduced.
The purpose of this report is to provide background information for the Pulp and Paper
Cluster, a workgroup established by EPA to coordinate the activities of various EPA offices
affecting the pulp and paper industry. Originally written in late 1990 and early 1991, the report
was sent out for public review and comment. Responses to the comments that fell within the
scope of this report were incorporated. This report summarizes readily available and easily
obtainable information in the expectation that greater detail would be forthcoming as a result of
the Office of Water's development of effluent guidelines and the Office of Air's development
of maximum achievable control technology (MACT) standards for the pulp and paper industry.
Major Findings
The major findings of this report are discussed below. They are grouped into three
categories, corresponding to Chapters 2, 3, and 4 in the analysis.
Three Paper and Paperboard Grades Consume the Majority of Bleached Pulp
Pulp production is the first of the three principle steps in manufacturing paper and
paperboard products. The other two steps are paper production and paper conversion (e.g.,
manufacturing envelopes, tablets, gummed labels and tape). The major product categories (in
terms of quantity of products shipped) are: Containerboard (about 32%), Printing and Writing
Paper (30%), Boxboard (10%), Newsprint (8%), Tissue (7.5%), Packaging and Industrial Paper
(7%), and Other Paperboards (6%) (see Figure 1). Of the approximately 71 million tons of pulp
(including recycled pulp) used in paper production in the United States in 1988, about 30 percent
was bleached, although not all with chlorine. According to the 1989 Lockwood-Post Directory,
74 of the 104 mills that used chlorine bleaching were controlled by the 20 largest paper
companies (see Figure 2).
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Figure 1
U.S. Paper Products Shipments
(Percentage of Total U.S. Paper and Paperboard Production by Weight. 1988)*
9.6%
(7.014,000 tons)
6.0%
(4,369.000 tons)
8.2%
(5,982,000 tons)
32.2%
(23J563.000 tons)
7.5%
(5.476,000 tons)
6.9%
(5,047.000 tons)
This figure uses data from tables 2.1 and 2.4 in Chapter 2 of this report.
Source: 1989 API Statistics of Paper, Paperboard, and Wood Pulp.
•Percentages do not sum to 100.0% due to rounding.
29.7%
(21,793,000 tons)
D Newsprint
I Printing/Writing
I Packaging/Industrial
111 Tissue
I Containerboard
H Boxboard
• Other Paperboard
IV
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Figure 2
Bleached Kraft Mill Capacity and Total Mill Capacity for Top 20 U.S. Producers, 1988
(Tons per day)
20,000
2 15.000
8. '
10
I
>; 10,000 -
c
a
~ 5,000
a.
a.
1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 18 19 20
Top 20 U.S. Companies
Bleached Kraft
Mill Capacity
Unbleached Kraft
Mill Capacity
This figure uses data from table 2.8 in Chapter 2 of this report.
Source: Lockwood-Post 1989. and ERQ industry estimates.
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Whether or not pulp is bleached largely depends on the specific paper product for which
it will be used. The analysis, therefore, categorized paper and paperboard product grades by
the amount of bleached pulp they used. The total amount of bleached pulp used for a particular
grade depends on both the total amount of the grade produced and the percentage of bleached
pulp included. While both recycled fibers and virgin pulp can be bleached, this analysis
identifies products that compel the initial use of bleach and therefore focuses on the use of
bleached virgin fibers.
Three grade segments combined use over 85 percent of the bleached virgin kraft pulp
(see Figure 2.5, Chapter 2):
• Printing and writing papers (58%),
• Solid bleached paperboard (mostly boxboard) (16%),
• Tissue (13%).
Future efforts to reduce or eliminate the use of chlorine-based bleaching chemicals may be most
usefully focused on these three grade segments, with particular focus on printing and writing
papers.
Technological Constraints on Reducing Chlorine Use Are Decreasing
No simple relationship exists between the use of chlorine and the type of paper products
produced. For this reason, it is not easy to determine whether or not chlorine use is necessary
in paper production. In addition, bleaching technologies are changing rapidly, reducing the
amount of chlorine required to produce comparable products.
From a technical perspective, it is possible to make printing/writing paper, tissue, and
solid bleached paperboard without molecular chlorine (CL^. Many products can also be
successfully produced by a TCF sequence. The highest brightness levels (GE 90 and above),
however, currently require molecular chlorine bleaching. The amount of bleaching and the
bleaching chemicals are a function of both the type of pulping process and the intended end-use
of the pulp. For example, mechanical pulps are usually unbleached and, when bleached, usually
do not use chlorine. Chemical pulps, especially kraft, are usually bleached with chlorine.
Several alternatives to chlorine are currently being used in place of, or in conjunction with,
chlorine. These alternatives, however, can have the following drawbacks (Clement Associates,
1989):
• more costly (e.g., chlorine dioxide, hydrogen peroxide, and
oxygen),
• reduced pulp yield (e.g., ozone),
• reduced pulp strength (e.g., oxygen),
• potential sources of other pollutants (e.g., hypochlorite, which may
produce chloroform).
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An EPA report (U.S. EPA, 1990) details the range of available and emerging
technologies for the control of chlorinated organics in the pulp and paper industry.1 As these
alternatives develop, some may prove to be more successful than currently available alternatives
in terms of both effectiveness and cost. Many of the new technologies, however, continue to
require some use of chlorine.
Information collected by EPA in the 1990 Section 308 National Census indicates that
many pulp mills have recently taken or plan to take actions to reduce the amount of
polychlorinated dioxins (PCCDs) and furans (PCDFs) generated by chlorine bleaching of pulp
(U.S. EPA, 1991). Based on a preliminary summary of industry response to the Census, 64
mills (out of the 105 mills that perform chlorine bleaching of chemically produced pulps)
indicated that they have made substantial changes in their bleach plant operations since 1988.2
The pulping and bleaching technologies used at a mill depend to some degree on site-specific
parameters. According to the EPA preliminary summary, significant trends in bleach plant
operations are:
• Elimination of defoamers with dioxin precursors;
• Increased substitution of chlorine dioxide (ClO^ for chlorine in the
chlorination stage of the bleaching process;
• Modernization and improvement in controlling chlorine bleaching;
• Increased use of peroxide to enhance the extraction stages of the
bleaching process;
'Pulping technologies that reduce the use of chlorine include: extended delignification,
oxygen delignification, polysulfide cooking, improved pulp washing, pretreatment with
nitrogen dioxide, demethylation, anthraquinone catalysis, ozone delignification, and peroxide
delignification. Bleaching technologies that reduce chlorine use include: chlorine dioxide
substitution, oxygen extraction, peroxide extraction, MONOX-L substitution, control of
chemical dosage, improved mixing, split chlorine addition/pH control, monitoring of chlorine
multiple, sic extraction process, and closed cycle technology.
'The status of chlorine bleaching in 1988 and 1990 was determined from two EPA
studies. In 1988, the EPA and the U.S. paper industry characterized the practices of U.S.
mills that practiced chlorine bleaching of chemically produced pulps. This study is
commonly called "The 104 Mill Study" (although it was later revised to include 105 mills).
In 1990, EPA conducted a national census of pulp, paper, and paperboard manufacturing
facilities under the authority of Section 308 of the Clean Water Act (referred to in this report
as "the Section 308 National Census"). Only a preliminary summary of industry's response
to the Census was available for this report.
*•
Vll
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• Anticipated increase in the number of mills using oxygen
delignification;
• Anticipated decrease in the use of hypochlorite in bleaching and
extraction stages; and
• Anticipated expansion of chlorine dioxide generation capacity,
currently a significant factor inhibiting chlorine reduction, at 30
percent of facilities.
The number of mills reporting current and planned activities to reduce their use of
chlorine in the bleaching process is summarized in Table 1. "Current" activities include those
implemented after July 1988 and prior to December 1989. "Planned" activities include those
reported in 1990 and those planned (generally January 1990 through December 1993, but a few
as late as November 1997). The number of mills represented in Table 1 exceeds the total of 64
mills reporting changes because many mills are implementing several chlorine reduction
activities.
The current and planned chlorine reduction activities listed demonstrate a continuing
effort by industry to implement process modifications that: (1) increase chlorine dioxide
substitution, and (2) increase peroxide use. The table also indicates an anticipated increase in
the number of mills that will use oxygen delignification. Nearly one third of the mills will be
replacing or updating their bleach lines to include more efficient chemical addition and mixing,
better chemical use controls and flow meters, and improved bleach plant washing.
According to the preliminary summary, process changes to reduce formation of PCDDs
and PCDFs have been implemented at mills producing a wide variety of pulp and paper
products. The industry has placed major emphasis on those mills producing bleached pulp used
in food grade and personal care products. While process changes have also been implemented
at many market pulp bleached kraft mills (e.g., those producing bleached pulp for sale on the
open market, or for sale overseas), such changes have not been uniformly made across that
segment of the industry.
One very recent development in industry bleaching processes, that was not reflected in
the Section 308 National Census, concerns the plans for a Louisiana-Pacific Corporation mill
in Samoa, California, to convert its operations to TCP production. This conversion plan, which
will be completed in 1995, was developed by Louisiana-Pacific in concert with EPA, the
Department of Justice, the State of California, and the Surfriders Foundation. The plan formed
the basis of a modified consent decree signed by these parties. Once the mill is converted, it
will be the first U.S. facility completely dedicated to production of TCP pulp.
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Current and Planned Activities to Reduce Chldrine
Niiiniber of Mills
TCP Pulp Production 0 1
Implement/Increase Chlorine Dioxide Substitution 33 39
General Bleach Plant Replacement/Modernization/ 17 36
Modification
Improve Brownstock Washing 11 21
Install Oxygen Delignification 8 17
Implement Hydrogen Peroxide Bleaching/Extraction 15 16
Eliminate/Reduce Use of OC1 8 12
Implement O2 Enhanced Extraction 5 7
Eliminate Dioxin Precursor Defoamers 7 8
Use Extended Delignification 2 3
Source: 1990 National Census of Pulp, Paper, and Paperboard Manufacturing Facilities:
Preliminary Summary Report of Questionnaire Responses for Mills that Bleach Chemical
Pulps, Revised October 31, 1991, Commodities Branch, Engineering and Analysis
Division, Office of Science and Technology, Office of Water, U.S. EPA. Table 4.
Markets for Molecular Chlorine-free (MCF) Products are Developing
As of early 1992, a wide variety of unbleached or alternatively bleached paper products
were available in the U.S. market, and many were in the categories of paper that have
traditionally been chlorine bleached. Based on information assembled about these products,
several conclusions can be drawn:
• There are unbleached or alternatively bleached products in each of the three paper
categories currently using large amounts of bleached virgin kraft pulp.
• These products are being produced domestically, as well as in Canada and
Europe.
• Reduced molecular chlorine use in pulp bleaching is being achieved by:
Using recycled fibers without rebleaching,
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Using recycled fibers and bleaching with reduced amounts of chemicals,
Bleaching with a chlorine compound (e.g. sodium hypochlorite); and
Bleaching with a chlorine alternative (e.g. hydrogen peroxide, oxygen,
ozone).
Paper markets can usefully be divided in terms of two main consumer types: personal and
commercial. Both markets have a group who are particularly concerned about, or see a
competitive advantage from, protecting the environment. These groups are actively seeking and
are willing to pay a premium for TCP paper. The majority of purchasers, however, do not
appear to be making purchasing decisions based on the issue of chlorine.
There is a distinct difference between the demand for unbleached and alternatively
bleached paper products. While some environmental and non-profit groups will only buy
unbleached paper, paper products bleached with an alternative process have a much wider appeal
to the general public.
Both in terms of production and market acceptance, alternatively bleached and unbleached
paper is much more common in Europe than in the United States. This is particularly true in
Germany (a country that imports large amount of pulp) and Sweden (a country that exports large
amounts of pulp).
While the pulp and paper industry has made strides in reducing chlorine usage, several
technological as well as financial constraints limit the amount and rate of change. Since many
mills are substituting chlorine compounds for molecular chlorine, the potential environmental
trade-offs of these substitutes should be examined to assure industry and the public that the
appropriate changes are being made, and to avoid potentially more costly changes in the future.
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Executive Summary References
Clement Associates, Inc., (1989). "Dioxin Production in the Pulp/Paper Industry, Revised,
Draft Report", Prepared for the Regulatory Impacts Branch, Office of Toxics Substances, U.S.
EPA. October 31.
U.S. EPA, (1990). "Summary of Technologies for the Control and Reduction of Chlorinated
Organicsfrom the Bleaching Chemical Pulping Subcategories of the Pulp and Paper Industry".
April 27.
U.S. EPA, (1991). "1990 National Census of Pulp, Paper, and Paperboard Manufacturing
Facilities: Preliminary Summary Report of Questionnaire Responses for Mills that Bleach
Chemical Pulps". Office of Science and Technology, Office of Water. October 31.
XI
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CHAPTER 1: INTRODUCTION
This document is a revised version of a February 1991 draft U.S. Environmental
Protection Agency report entitled Unbleached and Non/Low-CMorine Bleached Paper Market
Study. The revisions were made in response to comments from representatives of the pulp and
paper industry and environmental groups. While this revised report includes some new
information, changes concentrated on clarifying the presentation, not on collecting and presenting
additional data. In particular, the Executive Summary and Chapters 1 and 4 were revised.
Chapter 2 and 3 were not revised since they serve the purpose of this report and provide a
background to pulping and bleaching technology.
This chapter describes the circumstance under which the study was originally undertaken
and the purpose of the report. Definitions for terms used in the study are provided in a glossary
at the beginning of the report. This chapter ends with a section suggesting areas for additional
research that were outside the scope of this project.
1.1 Background
During the summer and fall of 1990 the EPA conducted a review of readily available
sources of information on alternative approaches to reducing or eliminating the formation of
chlorinated organics by the pulp and paper industry. Certain chlorinated organics are considered
to be highly toxic based on laboratory animal experiments and have been linked to malignancies,
birth defects, and physical deterioration in animals. While there is some controversy about the
human health effects of chlorinated organics, the EPA has classified one isomer, 2,3,7,8-tetra-
chlorodibenzo-p-dioxin (TCDD), as a "probable human carcinogen". Dioxins1 can be formed
during the manufacture of bleached wood pulp if chlorine is used as a bleaching agent. Studies
by the paper industry and by government agencies in North America and Europe (including the
U.S. EPA) have confirmed that detectable amounts of TCDD are produced and released into the
environment at many bleached kraft pulp mills.
The investigation summarized in this report sought to identify opportunities to reduce the
amounts of chlorinated organics released to the environment. This reduction would be a function
of changes in (1) the processes used to produce pulp and paper, and (2) the demand for chlorine
bleached products. The investigation also examined some of the technological, social, and
economic impediments to these changes.
'The term "dioxin" is commonly used to refer to a family of chemicals that includes
polychlorinated dibenzo-para-dioxins (PCDDs) and polychlorinated dibenzofurans (PCDFs).
There are 75 PCDD and 135 PCDF isomers. The majority of experiments, however, have dealt
with the 2,3,7,8-tetra-chlorodibenzo-p-dioxin (TCDD) isomer.
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This report was written to support the activities of the Pulp and Paper Cluster, a
workgroup established by EPA to coordinate activities across the agency affecting the pulp and
paper industry. The intent of the report was to review and summarize information readily
available to help Agency staff prepare for cluster activities. The report was not intended to be
all-inclusive or to present one particular viewpoint. It was intended to educate the staff about
pulp and paper production and/or marketing.
Since completion of the draft report in the fall of 1990, additional information has
become available, including that collected by the EPA's Offices of Water, Air, and Solid Waste
as part of the development of effluent guidelines (Section 308 data), maximum achievable control
(MACT) standards, and sludge disposal regulations. Some of the new data has been
incorporated into this revision in response to comments. In August 1992, EPA sponsored an
"International Symposium on Pollution Prevention in the Manufacture of Pulp and Paper". Over
300 people attended the symposium, which provided a forum to discuss new and emerging
pulping and bleaching technologies and the demand for unbleached, molecular chlorine-free
(MCF), and totally chlorine-free (TCP) paper products. The Agency intends to sponsor other
projects and forums for assembling and disseminating information on these topics.
This report has three principle goals:
• An identification of the paper and paperboard grades in which the
majority of chlorine-bleached pulp is used. Changes in the
production of and demand for these grades are of primary concern
to the EPA, since they will have the greatest effect on dioxin
generation by the pulp and paper industry. The results of this
identification analysis are presented in Chapter 2.
• An analysis of the attributes of paper and paperboard that are
directly dependent upon chlorine bleaching and the ability of
bleaching substitutes to meet specifications. This will illuminate
some of the technical constraints on changing bleaching processes.
Technical constraints and attributes of bleached paper and
paperboard are discussed in Chapter 3.
• A characterization of markets that currently exist for unbleached
and alternatively bleached paper products. This part of the
analysis investigates the degree to which these unbleached and
alternatively bleached products have been accepted by consumers,
both commercial and individual. The findings are presented in
Chapter 4.
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1.2 Areas for Future Research
While providing an overview of the possibilities for and limitations to the production of
unbleached and alternatively bleached paper products, the report also raises several questions
outside the scope of this analysis. For example, the report does not attempt to analyze the
economic impact of reduced chlorine use by the pulp and paper industry. This information
would be critical in evaluating the effects of a proposed regulation. Furthermore, the size of
the identified markets for unbleached and alternatively bleached paper were not quantified; the
report indicates only whether a market is known to exist.
Useful research might also be conducted to determine the public's criteria for purchasing
paper products. This research could help the EPA anticipate the public response to unbleached,
as compared with alternatively bleached, products. The research could also be used to establish
whiteness standards for printing/writing paper that meet individual and commercial needs.
Research is also needed to evaluate risks associated with chlorinated organics other than 2,3,7,8-
TCDD and 2,3,7,8-TCDF. The production of chlorinated organic pollutants resulting from the
use of chlorine compounds in the bleaching process should also be examined.
Finally, increased paper recycling can reduce chlorine use by reusing bleached fibers.
In particular, research to support the establishment of an infrastructure for the collection of high-
grade office papers would be valuable.
1.3 Overview of the Report
In addition to this Introduction, the report contains three chapters. Chapter 2 provides
an overview of the pulp and paper industry, including the number and size of mills, and defines
product grades of interest for this analysis by estimating the amounts of bleached pulp used by
each grade. Chapter 3 discusses the technical factors affecting the amount and type of bleaching
undertaken, and relates these factors to product attributes. Chapter 4 identifies a variety of
products currently available in unbleached and alternatively bleached forms in both North
America and Europe. Based on literature reviews, anecdotal information gathered from
interviews, and the results of consumer surveys previously undertaken, Chapter 4 examines the
factors that encourage or impede the market for unbleached and alternatively bleached products.
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CHAPTER 2: BLEACHED PULP AND PAPER MARKETS
This chapter presents an analysis of products made from bleached kraft pulps and the
companies and mills which produce them. Bleached kraft pulp is produced by the sulfate
bleaching process, and is used to manufacture a wide range of paper and paperboard products
for consumer, commercial, and industrial use. The chapter has two main sections. The first
section provides an overview of the pulp and paper market. The second section estimates the
quantity of various grades of paper and paperboard that is bleached.
Two primary sources of information are used in this report. For data on product
shipments, the American Paper Institute's (API, 1989) most recent statistical report was used.
The report generally provides consistent data series for most product categories over the last 10-
15 years. The other major source used is the Lockwood-Post's Directory of the Pulp, Paper,
and Allied Trades (Lockwood-Post, 1989 and 1990). This source profiles establishments
engaged in pulp and paper making and paper converting in the United States, and includes
information on the types (and often volumes) of products produced and the processes utilized.
Additional data from the Bureau of the Census (1989) was also used, particularly for presenting
information on value of product shipments.
In addition to these published sources, this report develops original estimates of aggregate
fiber content and pulp composition of major grades of paper and paperboard through discussions
with industry observers and experts. These sources are discussed in the appropriate sections of
the report.
2.1 Introduction to Pulp and Paper Markets
2.1.1 Industry Structure
The pulp and paper industry can be categorized into three primary segments,
corresponding to the three basic operations in paper production:
1. Pulp production converts wood or other fibrous material into a liquid slurry
suitable for paper manufacture. Wood is the primary fiber source for the pulp
and paper industry; however, recycled fiber accounts for approximately one-
fourth of all fiber converted to pulp. Some non-wood natural fibers, such as
cotton, are also used for specialty papers.
2. Paper production converts pulp to one of several dozen grades of paper suitable
for manufacture of finished paper products. Coating and some surface finishing
operations may be part of the paper production process.
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3. Paper conversion includes operations such as cutting, coating, folding, printing,
and other finishing processes, and results in production of paper products for
consumer, commercial, and industrial markets.
This analysis focuses on pulp and paper producers. Paper converters, which purchase
paper from mills, are numerous and highly differentiated. An analysis of this segment of the
industry is outside of the scope of this study. Further, it is expected that pulp mills and paper
mills will be more greatly affected by changing bleaching processes than will converters.
The information presented in this section is derived primarily from self-reported industry
statistics compiled in the 1989 Lockwood-Post's Directory of the Pulp, Paper, and Allied Trades
(Lockwood-Post, 1989). This information, current through 1988, has not been independently
verified. Of the potential sources of inaccuracy in these statistics, two should be noted
specifically: (1) some firms did not provide capacity and/or production statistics for all pulp and
paper mills under their control, with the result that capacity may be underestimated both in the
aggregate and for individual firms and regions; (2) corporate parentage has been determined as
accurately as possible from information presented in Lockwood-Post's, but may not completely
reflect the centralization of ownership and control in the industry. Merger and acquisition
activity since 1988, such as the recent merger of Georgia Pacific and Great Northern Nekoosa,
is also not reflected in these statistics.
Approximately 265 firms produce pulp and/or paper in the United States. Of these, 115
are vertically integrated, producing both pulp and paper; 140 produce paper only, and 10
produce pulp only. These firms operate a total of approximately 310 pulp mills and 640 paper
mills. Nearly all pulp mills (approximately 275) are integrated with an on-site paper mill; over
half of all paper mills, however, are stand-alone operations not associated with a pulp mill
located on the same site.
Pulp Production
The 310 U.S. pulp mills include some 370 separate pulp production lines, with a total
capacity of approximately 177,000 short tons per day (tpd), or 65,000,000 tons per year. These
mills produce pulp by a variety of methods: about 80% of pulp is produced by chemical
methods, 9% is produced by mechanical methods, 7% by semi-chemical methods, and 4% by
other methods (U.S. Bureau of Census, 1989). In 1988, U.S. EPA reported that 104 of these
mills produce chlorine bleached chemical pulps (U.S. EPA, 1990). .
Geographically, the industry is heavily concentrated. By census region, the South
Atlantic states include some 20% of all pulp production lines in the U.S., and over 32% of all
pulp capacity. The South Central states include an additional 24% of all production lines and
32% of capacity. The Southeastern U.S., therefore, includes nearly 45% of all U.S. pulp
production lines, and nearly 65% of U.S. pulp capacity. An additional 15% of production lines
and 15% of pulp capacity are located in the Pacific States, primarily in Oregon and Washington.
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New England and the Middle Atlantic States include over 17% of all U.S. pulp production lines,
but less than 9% of pulp capacity.
The pulp industry is dominated by relatively large firms. Of the approximately 125 firms
active in the industry, the top five firms2 control over 32% of U.S. pulp capacity. The top ten
firms control 52% of all capacity, and the top twenty firms control over 70% of all capacity.
Some 60% of all firms in the industry operate only a single pulp mill, and nearly 90% operate
5 or fewer mills.
Although, as previously stated, the vast majority of all pulp mills are integrated with an
on-site paper mill, a large number of these pulp mills sell some of their output as market pulp
in addition to what they use themselves in paper manufacturing. Of all U.S. pulp production,
approximately 60% is consumed by paper mills integrated with a pulping operation; the
remaining 40% is sold as market pulp to stand-alone paper plants.3
Paper Production
Total U.S. papermaking capacity is approximately 220,000 tpd (80,000,000 tons per
year) at some 640 establishments. In terms of capacity, the papermaking industry exhibits a
regional concentration similar to that of the pulp industry. Twenty-five percent of U.S.
papermaking capacity is located in the South Atlantic States, and an additional 26% of U.S.
capacity is located in the remaining Southeastern and South Central States. The Pacific States
account for an additional 14% of U.S. papermaking capacity. Expressed in terms of number
of establishments, however, the regional concentration is very different. New England and the
Middle Atlantic States contain over 220 mills, or nearly 35% of all U.S. establishments, and the
East North Central States include an additional 140 mills, or 22% of all U.S. mills. The South
Atlantic and South Central States include only some 28% of all papermaking establishments,
while 11% are located in the Pacific States.
The papermaking industry includes approximately 255 firms, over twice as many as the
pulp industry. Of these, 140 firms operate paper mills only, and 115 firms operate both paper
and pulp mills. Nearly 70% of all papermaking firms operate only a single establishment, and
over 90% operate five or fewer establishments. Of the firms that operate only paper mills, over
80% operate only a single mill, and 98% operate five or fewer mills. Among firms that operate
both pulp and papermaking establishments, 50% operate only one paper mill, 33% operate two
to five mills, and 17% operate six or more mills.
top five firms based on pulping capacity are: International Paper, Stone Container,
Georgia-Pacific, Weyerhaeuser, and Great Northern Nekoosa
'Appendix 2.A provides data on bleached and unbleached pulp production volumes for 99
of the 104 mills in the EPA study group.
2-3
-------
Like pulpmaking capacity, U.S. paper capacity is heavily concentrated among the largest
firms in the industry. The top five firms* control approximately 27% of capacity, the top 10
firms control 46% of capacity, and the top twenty firms control 65% of capacity. Capacity is
also significantly concentrated among the integrated pulp and papermaking firms; the 115
integrated firms control 90% of U.S. paper capacity, while the 140 firms that produce only
paper control only 10% of capacity.
Paper Conversion
There are approximately 3,200 paper converting establishments in the United States.
Nearly 30% of all converting establishments are located in New England and the Middle Atlantic
States, and an additional 25% are located in the East North Central States. Fifteen percent are
located in the South Atlantic States, approximately 12% in the South Central States, and
approximately 11 % in the Pacific States.
Distinction Between Paper and Paperboard Grades
Before proceeding to a description of the major paper and paperboard categories, the
distinction between paper and paperboard should be made. The distinction between the two,
while not sharp, lies in the heavier weight of the board grades. Paperboard is heavier, stiffer,
and thicker than most paper. In general, any sheets greater than 0.012 inches in thickness are
classified as paperboard.
2.2 Major Paper Product Categories
The paper products segment of the pulp and paper industry consists of four major product
categories. These are: (1) newsprint, (2) printing, writing and related papers, (3) tissue, and
(4) packaging and industrial papers. Within each of these there are various sub-categories or
grades of products. An overview of each of the major categories and sub-categories is provided
below, followed by historical and current data on the volume and value of product shipments.5
Explanations of the pulping processes mentioned below (e.g., mechanical, chemical, sulfate,
sulfite) can be found in Chapter 3.
4The top five firms based on papermaking capacity are: International Paper, Stone
Container, Georgia-Pacific, Champion International, and Weyerhaeuser.
5Appendix 2.B provides a comprehensive listing of 99 mill outputs for all paper and
paperboard grades.
2-4
-------
2.2.1 Description of Major Paper Product Groups
Newsprint. Newsprint is a light, inexpensive grade of paper made largely from
mechanical pulps. Some unbleached sulfite or other chemical pulps may also be incorporated.
A typical pulp mix for newsprint is 75 percent mechanical pulp and 25 percent bleached kraft
pulp. The primary use of newsprint in the U.S. (75%) is for daily newspapers; weeklies, comic
books, and low-cost advertising and printing account for the remainder. Imports, primarily from
Canada, account for over 60 percent of U.S. consumption.
Printing, Writing & Related Papers. This large category includes a wide variety of
coated and uncoated papers utilized by business, consumer, and commercial users. The main
sub-categories are listed below.
Uncoated groundwood paper. A grade higher than newsprint, uncoated ground wood is
widely used in newspaper inserts, catalogs, paperback books, and directories. Compared with
newsprint, it is both smoother and brighter. Under industry consensus definitions, groundwood
grades contain more than 10 percent groundwood or other mechanical pulps in their furnish, but
common furnishes include up to 50 or 100 percent groundwood. Magazine stock is commonly
produced with 60-70 percent mechanical and 30-40 percent chemical pulp. Imports account for
approximately 50 percent of U.S. consumption of uncoated groundwood paper.
Coated groundwood paper. Papers with a wide variety of coatings are produced for
different end uses. The most common, however, uses a clay coating based on aluminum silicate
(kaolin). Coated groundwood papers accounted for 56 percent of all coated papers in 1989.
Lower grades of coated groundwood compete with uncoated groundwood, while higher grades
may compete with coated free sheet. End uses for these papers include advertising, magazines,
Sunday newspaper supplements, and catalogs.
Uncoated free sheet. By definition, free sheet contains no more than 10 percent
mechanical pulps. Until recently, most papers sold as free sheet met that standard.
Considerable advancement has been made recently, however, that allows a higher percentage of
mechanical pulp to be used without degrading the quality of the paper. Thus, industry observers
believe that papers containing 20 or even 30 percent mechanical pulps are being commonly sold
as free sheet. Uncoated free sheet represents the largest single category of paper, accounting
for about 30 percent of all paper products shipments. The category encompasses most grades
of business paper, including forms, bond, stationary, tablet, envelope, xerox and computer
paper, as well as cover and text grades used in printing. Several of these grades are now being
made with a recycled stock component, using both pre- and post-consumer waste. U.S.
producers account for over 95 percent of U.S. uncoated free sheet consumption.
Coated free sheet. Coated free sheet encompasses several types of surface finishes,
including gloss, dull, matte, and embossed. Gloss accounts for approximately 85 percent of
production, and is used for catalogs, advertising materials, and high quality magazines and
books.
2-5
-------
Bleached bristols. Bristols are high quality cardboards used for products such as index
tags, cards, file folders, and postcards.
Cotton fiber writing paper and thin paper. Papers in which cotton or other non-wood
fibers comprise 25 percent or more of the total. Also referred to as rag content paper.
Tissue. Tissue is a class of light, fairly transparent paper characterized by its gauze-like
texture. It is widely used in sanitary products such as bathroom tissue, facial tissue, napkins,
and toweling. The industry also produces several non-sanitary tissue grades, such as waxing,
wrapping, and wadding tissue. About 60 percent of tissue is purchased by end-use consumers
in grocery stores, with the remainder bought for commercial, industrial, and institutional uses.
Bleached kraft and sulfite pulps are most common, although all pulp types are used to some
extent. Tissue accounts for approximately 13.5 percent of total paper shipments. The
percentage of recycled fibers used in tissue production has increased in recent years, to the
extent that recycled stock comprises an average of 30 to 40 percent of production of some
grades. Particular brands of tissue may be produced with 100 percent recycled fibers.
Packaging & Industrial Converting Paper. This category includes various types of
paper used for industrial or commercial purposes. The largest product classes are wrapping
papers and bag and sack stock. Also included are specialty papers such as butcher paper and
grease-proof and glassine paper. The products in this category may be from either bleached or
unbleached kraft pulp. Overall, this category accounts for approximately 12-13 percent of total
U.S. paper shipments.
2.2.2 Current and Historical Production Volumes
Shipments of paper products in the U.S. totalled 38.3 million tons in 1988. Printing and
writing papers accounted for 56 percent of this total, followed by newsprint (16%), tissue
(14%), and packaging and industrial papers (13%). The single largest paper product category,
uncoated free sheet, had shipments totaling 11.2 million tons in 1988. This represented 51
percent of the printing and writing total, and 29 percent of all paper products.
Table 2.1 and Figure 2.1 present data on shipments of the major paper grades at 5-year
intervals over the period 1963-88. Figure 2.2 shows a breakdown for subcategories of the
largest main group, printing and writing papers. Because consistent data for paperboard
products is available only for the period 1973-88, the comparisons for both groups will focus
on this most recent 15-year period. As seen in the last column of the table, between 1973 and
1988 shipments of paper products grew from 26.8 million to 38.3 million tons, for an increase
of 43 percent. In comparison, the U.S. gross national product (GNP), measured in constant
dollars, increased by 47 percent during the same time period. Hence, paper product growth
from 1973 to the present has kept pace with overall growth of the U.S. economy.
2-6
-------
Table 2.1
U.S. Paper Products Shipments 1963-B8
Select 6d Years
f 000 Tons)
AH Paper Grades
Newsprint
Priming/writing papers
Uncoaied groundwood
Coated papers
Uncoated tree sheet
Thin papers
Cotton fiber paper*
Bleached brlstols
Packaging/industrial papers
Unbleached kralt papers
Bleached packaging papers
Qlasslne. greaseproof. &
vegetable parchment
Special Industrial papers
Tissue Paper
Toilet tissue
Facial tissue stock
Napkin stock
Towelling
Wiper stock
Other unitary tissue
AH other tissues
REAL U.S. GNP (1982 Sblllions)
1963
17.320
2.218
8.185
956
2.42S
3.634
179
119
870
4.342
3.051
782
1B3
314
2.578
1.055
278
261
663
33
50
236
1.873
% change
1963-68
28.1%
37.3%
28.1*
14.0%
27.8%
31.7%
46.4%
4.4%
28.4%
19.7%
18.1%
20.6%
7.5%
41.8%
34.1%
20.7%
25.6%
43.4%
62.6%
52.0%
83.0%
1.1% .
26.3%
1968
22.181
3.045
10.482
1.090
3.101
4.788
262
124
1.117
5.199
3.603
943
208
446
3.456
1.273
350
375
1.078
SO
92
239
2.366
% change
1968-73
20.8%
22.6%
27.6%
8.3%
21.9%
39.4%
36.9%
-0.2%
12.4%
8.7%
8.3%
-8.0%
11.0%
45.6%
16.9%
13.1%
3.4%
19.5%
18.4%
21.9%
101.2%
11.9%
16.0%
1973
26.797
3.738
13.371
1.181
3.779
6.674
358
124
1.256
5,649
3,902
867
231
650
4.039
1.441
362
448
1.276
61
184
267
2.744
% change
1973-78
5.7%
0.8%
8.8%
14.7%
16.4%
7.9%
-1.8%
-7.5%
-10.3%
2.5%
-1.0%
28.6%
12.4%
-15.2%
4.4%
14.1%
-9.1%
10.1%
3.2%
-26.9%
3.0%
-26.1%
13.5%
1978
28.320
3.768
14.549
1.354
4.400
7.202
352
114
1.126
5.789
3.863
1.115
259
551
4.215
1.643
329
493
1.318
45
190
197
3.115
% change
1978-83
15.9%
37.1%
19.4%
13.0%
29.9%
21.2%
-16.9%
16.0%
-14.1%
-5.1%
-9.3%
-61.5%
96.1%
91.1%
13.6%
11.7%
18.3%
8.0%
19.7%
-
460%
-10.1%
19.7%
1983
32.816
5.167
17.365
1.531
5,716
8.726
292
133
967
5.495
3.505
429
508
1.053
4.789
1.835
389
533
1,577
NA
277
177
3.729
% change
1983-88
16.7%
15.8%
25.5%
6.1%
28.7%
29.2%
-26.0%
25.8%
18.8%
-8.2%
-20.1%
8.3%
17.4%
12.6%
14.4%
10.7%
-9.7%
30.9%
18.1%
-
22.1%
9.2%
7.9%
1988
38.298
5.982
21.793
1.624
7.359
11.277
217
167
1.150
5.047
2.600
465
596
1.186
5.476
2.032
351
697
1.863
NA
338
194
4.024
% change
1963-88
121.1%
169.7%
166.3%
69.8%
203.4%
210.3%
21.2%
40.6%
32.1%
16.2%
-8.2%
-40.5%
208.6%
277.2%
112.5%
92.7%
26.2%
166.9%
181.1%
-
576.0%
-17.9%
114.8%
% change
1973-68
42.9%
60.0%
63.0%
37.5%
94.7%
69.0%
-396%
35.0%
-8.5%
-10.7%
-282%
-46.4%
158.7%
82.4%
35.6%
41.1%
-2.9%
55.6%
46.0%
-
83.6%
-27.5%
46.7%
Source: 1989 API Statistics ol Paper. Paperboard. & Wood Pulp.
Note: Totals may not add due to rounding.
-------
£
Figure 2.1
Shipments of Main Paper Products Groups
1963-1988
Million Tons
Grade of paper:
•I- Printing/Writing
Packaging/Industrial
Tissue
Newsprint
'63 '68 '73 78 '83 !88
Source: API 1989 Statistics of Paper, Board, & Wood Pulp.
-------
Figure 2.2
Shipments of Printing/Writing Papers
1963-1988
Million Tons
Grade of paper:
—*— Uncoated groundwood
-f Coated papers
Uncoated free sheet
Thin papers
-X- Cotton fiber
-Q- Bleached bristols
'63 '68 '73 '78 '83 '88
Source: API 1989 Statistics of Paper, Board, & Wood Pulp.
-------
Within the major product categories, however, there has been considerable variation in
growth rates, with newsprint and printing/writing papers experiencing considerably higher
growth. In the period 1973-1988 growth rates for the main product groups were as follows:
• Newsprint (60%)
• Printing, writing & related papers (63%)
• Packaging & industrial papers (-11%)
• Tissue (36%)
Shipments of uncoated free sheet grew from 6.7 million to 11.3 million tons over this
period, an increase of 69 percent.
2.2.3 Current Value of Production
To provide an estimate of the current value of paper shipments, this analysis relied on
the 1989 Current Industrial Report on Pulp, Paper and Board from the U.S. Bureau of the
Census. This report provides Census estimates of both the volume and value of shipments in
the current and previous year. The American Paper Institute's reports present estimates of the
volume but not the value of shipments. While the shipment volume estimates differ slightly
between the two sources, due to differences in the coverage and estimation methods, value per
ton figures calculated from the Census sources can be applied to the appropriate API categories
to obtain an estimated value of shipments. In Table 2.2, the Census value per ton figures are
applied to the 1988 API shipment volumes to obtain an estimate of current year volume and
value of production.
As seen in the table, the 38.3 million tons of paper products shipped in 1988 had an
estimated value of $32.2 billion. Average value per ton for all paper was $843. Higher valued
grades include: cotton fiber papers ($2,401 per ton), thin papers ($1,811 per ton), other sanitary
tissue ($1,504 per ton), and special industrial papers ($1,532 per ton). Uncoated free sheet, the
largest single volume category, had an average value per ton of $863. At $528 per ton,
newsprint represents the lowest value grade.
2.2.4 Current value of imports and exports
U.S. imports and exports of paper products are shown in Table 2.3. In general, export
volumes of paper products are minor, amounting to only 3 percent of shipments in 1988. Two
product categories merit additional note. In 1988 the U.S. exported some 427,000 tons of
newsprint (or 7% of shipments) and 185,000 tons of special industrial papers (16% of
shipments). According to Census Bureau figures, exports of all paper and paperboard products
increased from $2.2 billion in 1987 to an estimated $3.3 billion in 1990, an increase of 48
percent.
In total, the U.S. imported 12.0 million tons of paper products, which represents 24.4
percent of domestic consumption. The U.S. reliance on Canadian newsprint is the most
prominent feature. Imports of newsprint exceeded 8.8 million tons in 1988, compared to total
2-10
-------
TABLE 2.2
Volume of U.S. Paper Shipments.
Value per Ton, and Estimated Shipments Value
(1988)
Product Category
All Paper
Newsprint
Volume of
Shipments
(Thousand
Tons)
38,298
5,982
Value
Per Ton [a]
$
842.8
527.8
Estimated
Value of
Shipments
(SMillions)
32.278
3,157
Printing/writing papers
Uncoated groundwood
Coated papers
Uncoated free sheet
Thin papers
Cotton fiber papers
Bleached bristols
Packaging/industrial papers
Unbleached kraft papers
Bleached packaging papers
Glassine, greaseproof, &
vegetable parchment
Special industrial papers
Tissue Paper
Toilet tissue
Facial tissue stock
Napkin stock
Towelling
Other sanitary tissue
All other tissues
21,793
1,624
7,359
11.277
217
167
1.150
5,047
2,800
465
596
1,186
5,476
2,032
351
697
1,863
338
194
689.0
680.3
931.0
862.9
1,810.6
2,400.5
777.6
847.9
499.3
590.2
1,326.5
1.531.5
998.4
940.8
1,298.5
1,014.0
893.2
1,504.3
1,131.6
19.373
1.105
6.851
9.731
392
401
894
4,279
1.398
274
791
1.816
5,467
1,912
456
707
1.664
508
219
Source: 1989 API Statistics of Paper, Paperboard, & Wood Pulp.
la] Value per ton figures at the most detailed product category level are from corresponding product categories
in Bureau of the Census (1989). For higher level categories, the value per ton is calculated as the sum of
shipment values for all sub-categories divided by the sum of shipments.
2-11
-------
Table 2.3
U.S. Imports. Exports, and Apparent Domestic Consumption
of Paper Products, by Grade. 1988
f'OOO Tons)
Exports
Imports
Apparent
N>
Shipments
All Paper Grades
Newsprint
Printing/writing papers
Uncoated groundwood
Coated papers
Uncoated free sheet
Cotton fiber/Thin Papers
Bleached bristols
Packaging/industrial papers
Unbleached kraft papers
Bleached packaging papers
Glassine, greaseproof, &
vegetable parchment
Special industrial papers
Tissue Paper
38,298
5,982
21,793
1,624
7,359
11,277
384
1,150
5,047
2,800
465
596
1,186
5,476
'000 Tons
1,102
427
287
70
97
83
34
3
347
135
20
32
185
41
% Shipments
2.9%
7.1%
1.3%
4.3%
1 .3%
0.7%
8.9%
0.2%
6.9%
4.8%
4.2%
5.4%
15.6%
0.8%
'000 Tons
12,017
8,802
2,812
1,363
798
592
56
4
343
162
146
24
11
60
Domestic
% Shipments Consumption [a]
31.4%
147.10/0
12.9%
83.9%
10.8%
5.2%
14.5%
0.4%
6.8%
5.8%
31 .4%
4.1%
0.9%
1.1%
49,212
14,356
24,318
2,916
8,059
1 1 ,786
406
1,151
5,044
2.827
591
588
1,012
5,494
Source: 1989 API Statistics of Paper, Paperboard, & Wood Pulp.
[a] Apparent Domestic Consumption is equal to shipments plus imports less exports.
-------
domestic production of 6.0 million tons. Close to 1.4 million tons of uncoated groundwood
were also imported; this compares to domestic production of 1.6 million tons. Imports of
bleached packaging papers, at 146,000 tons, represented over 30 percent of domestic shipments.
Between 1987 and 1990, the value of all paper and paperboard product imports rose from $5.9
to $7.9 billion dollars. This represented an increase of 32.6 percent (U.S. Department of
Commerce, 1990).
Apparent domestic consumption of paper products can be calculated by adding net
imports to domestic shipments. In 1988, apparent domestic consumption of paper products was
49.2 million tons. Of this, printing and writing papers accounted for 49 percent and newsprint
for 29 percent.
2.3 Major Paperboard Product Grades
Paperboard is the second major subdivision of the paper industry. Unlike the various
paper grades, the paperboard product categories are broken down first according to the primary
pulp type used and second according to type of product. Hence, there is a list of products under
each of the following: (1) unbleached kraft paperboard; (2) solid bleached kraft paperboard; (3)
semichemical paperboard; and (4) recycled paperboard. Most of the overlap is in products
which are produced from both bleached and unbleached pulps, e.g. linerboard. Other products
are made predominantly with a single pulp type, e.g. milk carton board. An overview of these
product divisions is provided below, followed by current and historical data on the volume and
value of paperboard product shipments.
2.3.1 Description of Major Paperboard Product Groups
Unbleached paperboard. Unbleached paperboard can be divided into the three
categories described below.
Unbleached kraft linerboard. Unbleached kraft linerboard, a subset of containerboard,
is used for facing materials in the production of corrugated containers, and accounts for 41
percent of all paperboard output.
Tube, can, and drum board. Includes any unbleached board stock used for lining fibre
or composite cans, tubes, cores, and drums. Tubes and cores are of similar construction, but
have different end uses. Tubes are used as rolls for shipping items such as calendars and
posters, while cores are used as rolls onto which products such as carpets and paper are wound
to provide support and ease of handling. The main use of fibre drums is to ship dry bulk
products.
Other unbleached packaging and industrial converting kraft paperboard. This residual
category includes corrugating medium and folding carton type board made from unbleached kraft
pulps.
2-13
-------
Solid bleached kraft paperboard. This paperboard category is also known as solid
bleached sulfate, or SBS. SBS is used mainly for folding carton and milk carton packaging.
Industry consensus is that this grade is produced using a minimum of 80 percent virgin bleached
wood stock, though in practice a somewhat lower percentage may be used. Most bleached kraft
board is coated with either clay or polyethylene.
Bleached kraft linerboard. Compared to unbleached board, only a small percentage of
linerboard production is from bleached kraft pulp (127,000 out of 11.3 million tons). The main
end use is in facings for corrugated boxes and containers.
Folding carton type board. A subset of boxboard, used in the manufacture of "folding
type" containers. These are boxes which are formed, filled, and closed by the user (as
distinguished from "setup type" boxes, which are rigid). Folding type board accounts for about
half of all bleached paperboard.
Milk carton board. A special grade of bleached boxboard capable of being converted into
containers for milk, cream, and other beverages (e.g. aseptic juice containers). Milk cartons
account for 40 percent of SBS production.
Cup and nested container board. A bleached paperboard used in the manufacture of cups
and other nested cylindrical containers. Used for hot and cold drinks and in the packaging of
moist, liquid, and oily foods.
Semichemical paperboard. Semichemical pulps are those produced by a mild chemical
treatment of the raw materials followed by a mechanical defiberizing operation. The most
common Semichemical process is known as the neutral sulfite process, which produces neutral
sulfite Semichemical (NSSC) pulp. Nearly all of Semichemical paperboard production is used
for corrugating medium, which forms the inner, fluted layer of cardboard and corrugated
containers. Approximately 75 percent of all corrugating medium is from Semichemical pulp
(which normally contains 20 percent recycled fiber), while the remainder is from scrap paper
stock.
Recycled paperboard. Recycled board is made from a combination of recycled fibers
from various grades of paper stock. Major uses include: folding boxboard, core/can/tube
grades, corrugating medium, and gypsum linerboard.
2.3.2 Current and Historical Production Volumes
Shipments of paperboard products totalled 38.1 million tons in 1988, representing SO
percent of all paper and paperboard shipments. Table 2.4 and Figure 2.3 present data on
shipments by product grade. By combining data from Tables 2.1 and 2.4, it shows that the
paperboard share of the overall paper and board market has fallen very slightly over time, from
52.4 percent in 1973, to 51.6 percent in 1978, to 49.5 percent in 1983 and 49.9 percent in 1988.
Between 1973 and 1988, however, paperboard shipments have increased by only 29 percent in
2-14
-------
TABLE 2.4
U.S. Paperboard Products Shipments by Grade
Selected Years 1973-1988
('000 Tons)
Grade
All Paperboard
Containerboard
LJnerboard
Unbleached kraft
Solid bleached
Recycled
Corrugating material
Unbleached kraft
Semichemical
Recycled
Container chip & filler
Unbleached kraft
Recycled
Boxboard
Folding
Unbleached kraft
Solid bleached
Recycled
Set-up
Recycled
Milk carton & food service
Solid bleached
Recycled
Other
Gypsum wallboard lacing
Recycled
Tube. can. & drum
Unbleached kraft
Semichemical
Recycled
AllOther
Unbleached kraft
Solid bleached
Semichemical
Recycled
Exporta
Unbleached Kraft
Solid bleached
Semichemical
Recycled
REAL U.S. GNP (1882 SbUlions)
1973
29,549
16.690
11.356
10.939
128
289
5.255
2
4.124
1.129
69
10
69
6.742
4.682
455
1.706
2.522
465
465
1.594
1.594
-
4.102
1.050
1.050
1.145
226
18
901
1.007
333
134
10
1.430
2015
1597
280
107
31
2,744
% change
1973-78
2.4%
6.0%
6.9%
7.5%
-9.4%
-11.3%
4.7%
-
4.4%
6.1%
-27.5%
77.5%
-53.2%
-4.2%
0.1%
35.8%
2.0%
-7.9%
-28.5%
-28.5%
-9.3%
-9.3%
-
-0.9%
4.2%
4.2%
1.5%
10.8%
-20.2%
-0.3%
-5.1%
-22.5%
65.2%
-98.1%
-6.9%
1.2%
-8.2%
54.6%
11.2%
-29.0%
13.5%
1978
30,251
17.687
12.134
11.762
116
256
5.503
-
4.305
1.198
50
18
32
6.457
4.688
618
1,740
2.321
333
333
1.446
1.446
-
4.067
1.094
1.094
1.163
251
15
898
1.810
258
221
0
1.331
2040
1466
433
119
22
3.115
% change
1978-83
6.3%
7.4%
8.2%
8.2%
-O.6%
12.8%
6.1%
-
5.3%
9.0%
-26.3%
-
15.3%
-3.5%
-1.5%
15.0%
-2.6%
-4.7%
-23.0%
-23.0%
-«.1%
-6.1%
-
-4.0%
-3.7%
-3.7%
4.1%
-18.5%
-
12.1%
-«.4%
-20.0%
-3.4%
2450.0%
-8.7%
47.6%
55.6%
18.7%
62.2%
0.1%
10.7%
1983
32.146
19.000
13.125
12.722
115
289
5.838
-
4.533
1.305
37
-
37
6.230
4.615
710
1.694
2511
256
256
1.359
1.359
-
3.904
1.054
1.054
1.211
204
-
1.007
1.639
207
213
5
1.215
3012
2281
514
193
24
3.729
% change
1983-88
18.5%
24.0%
23.3%
22.6%
47.7%
40.6%
25.9%
-
22.0%
39.7%
-5.4%
-
-5.4%
12.6%
14.7%
30.1%
19.0%
6.4%
8.7%
8.7%
6.2%
6.2%
-
12.6%
12.1%
12.1%
16.6%
-23.9%
-
21.8%
10.0%
-20.2%
19.7%
-
13.9%
4.0%
0.7%
22.0%
-29.5%
200.0%
7.9%
1988
38.104
23.563
16.177
15.601
170
407
7.351
-
5.528
1.823
35
-
35
7.014
5.292
924
2.016
2.352
279
279
,443
.443
-
.396
.182
.182
.411
155
-
1.226
1.804
165
255
-
1.384
3131
2296
627
136
72
4.024
% change
1973-88
29.0%
41.2%
42.5%
42.6%
33.0%
40.7%
39.9%
-
34.0%
61.6%
-49.4%
-
-49.0%
4.0%
13.0%
103.1%
18.2%
-6.7%
-40.1%
-40.1%
-9.5%
-9.5%
-
7.2%
12.5%
12.5%
23.2%
-31.3%
-
36.1%
-5.4%
-50.5%
90.9%
-
-3.2%
55.4%
43.8%
123.9%
27.1%
132.3%
46.7%
Source: 1080 API Statistics of Paper. Paperboard. & Wood Pulp.
Note: Totals may not add due to rounding.
2-15
-------
Figure 2.3
Shipments of Main Paperboard
Products Groups 1973-1988
Million Tons
20
10
Grade of board:
+ Linerboard
~^~ Corrugating material
-B- Folding box
Set-up box
Milk carton/food
other board
Container chip
'73 '78 '83 '88
Source: API 1989 Statistics of Paper, Board, & Wood Pulp.
-------
comparison to 42.9 percent for paper products and 46.7 percent for the economy as a whole (as
measured by real GNP).
Within paperboard, the major grades and their share of production are: containerboard
(62%), boxboard (18%), and other types of board (20%). The lower growth rate of paperboard
compared to paper is due primarily to slow growth in the boxboard and "other" board segments.
The containerboard category, which encompasses linerboard and corrugating material,
grew by 41 percent, from 16.7 million to 23.6 million tons. Boxboard shipments, on the other
hand, grew by only 4 percent overall, from 6.7 million to 7.0 million tons. This resulted from
a decline in setup board shipments of 40 percent and a near 10 percent decrease in milk carton
and food service board (e.g., cups, dishes).
In Table 2.5, the same data has been recategorized and is presented according to type of
fiber utilized in each product category. Figure 2.4 also provides a fiber-based perspective of
the data. Overall in 1988, unbleached kraft accounted for 50 percent of all paperboard
shipments, of which 82 percent is linerboard. Solid bleached board comprised 12 percent of the
total. About 45 percent of this was folding boxboard, and another 32 percent was milk carton
and food service products. Semichemical pulps, which accounted for 15 percent of all
paperboard, was almost entirely used for corrugating materials. Recycled fibers, meanwhile,
comprised 23 percent of all paperboard. A variety of end products in multiple categories are
made from recycled fiber.
2.3.3 Current Value of Production
In 1988, paperboard product shipments were valued at $15.3 billion (see Table 2.6).
Average value per ton for all paperboard products is estimated at $401.8, which is considerably
less than the average value ($842.8) for paper products (see Table 2.2). The lower value per
ton is illustrated by the fact that in 1988 paperboard accounted for approximately 50 percent of
shipment volume but only 30 percent of value. Solid bleached board product grades are among
the highest in value. For example, milk carton and food service board had an average value of
$638.7 per ton. Solid bleached folding boxboard had a similar value of $616.7 per ton.
Recycled and unbleached kraft board have values in the range of $300-400 per ton.
2.3.4 Current Value of Imports and Exports
As shown in Table 2.7, in the paperboard categories, exports represent approximately
10 percent of domestic U.S. shipments volume, while imports are less than 1 percent of
shipments. The largest export category is unbleached kraft board. In 1988, the U.S. shipped
2.5 million tons of unbleached kraft board overseas, an amount that represents 13 percent of
domestic production. Greater than 20 percent of bleached kraft board production, or 924,000
tons in total, were also exported. Linerboard contributes more to U.S. exports than
containerboard because of its relative ease of transportation. The primary markets for U.S.
linerboard are the Pacific Rim, Europe, Latin America, and Australia. Mexico and Canada
purchased the majority of the U.S. corrugated box exports, which were valued at $197 million
in 1989. Exports of folding cartons and set-up boxes amounted to only $88 and $23 million
respectively in 1989. The majority of these shipments also went to nearby Canada and Mexico.
2-17
-------
TABLE 2.5
U.S. Paperboard Products Shipments bv Type of Fiber
Selected Years 1973-1988
('000 Tons)
Grade
All Paperboard
Unbleached kraft
Containerboard
Linerboard
Corrugating material
Container chip & filler
Boxboard
Folding
Other
Tube, can, & drum
All other
Export
Solid bleached
Containerboard
Linerboard
Boxboard
Folding
Milk carton & food service
Other
AllOther
Export
Semichemical
Containerboard
Corrugating material
Other
Tube, can, & drum
AllOther
Export
Recycled
Containerboard
Linerboard
Corrugating material
Container chip & filler
Boxboard
Folding
Set-up
Milk carton & food service
Other
Gypsum wallboard facing
Tube. can. & drum
AllOther
Exports
REAL U.S. GNP (1082 Sbilliont)
1973
29.549
13.563
10.952
10,939
2
10
455
455
559
226
333
1597
3,842
128
128
3.300
1.706
1.594
134
134
280
4.260
4.124
4.124
29
18
10
107
7,885
1.486
289
1.129
69
2.987
2.522
465
-
3.381
1.050
901
1.430
31
2.744
% change
1973-78
2.4%
7.9%
7.6%
7.5%
-
77.5%
35.8%
35.8%
-9.0%
10.8%
-22.5%
-8.2%
-1.1%
-9.4%
-9.4%
-3.5%
2.0%
-9.3%
65.2%
65.2%
54.6%
4.0%
4.4%
4.4%
-48.3%
-20.2%
-98.1%
11.2%
-5.0%
0.0%
-11.3%
6.1%
-53.2%
-11.1%
-7.9%
-28.5%
-
-1.7%
4.2%
-0.3%
-6.9%
-29.0%
13.5%
1978
30.251
14,373
11.780
11.762
-
18
618
618
509
251
258
1466
3,955
116
116
3.186
1.740
1.446
221
221
433
4.439
4.305
4.305
15
15
0
119
7.485
1.486
256
1.198
32
2.654
2.321
333
-
3.323
1.094
898
1.331
22
3,115
% change
1978-83
6.3%
7.2%
8.0%
8.2%
-
-
15.0%
15.0%
-19.3%
-18.5%
-20.0%
55.6%
-4.0%
-0.6%
-0.6%
-4.2%
-2.6%
-6.1%
-3.4%
-3.4%
18.7%
5.0%
5.3%
5.3%
-66.2%
-
-
62.2%
-1.2%
9.8%
12.8%
9.0%
15.3%
-7.0%
-4.7%
-23.0%
-
-1.4%
-3.7%
12.1%
-8.7%
9.1%
19.7%
1983
32.146
16.122
12.721
12,722
-
-
710
710
411
204
207
2281
3.895
115
115
3.052
1.694
1.359
213
213
514
4.730
4.533
4.533
5
-
5
193
7.398
1.632
289
1.305
37
2.468
2.211
256
-
3.275
1.054
1.007
1.215
24
3.729
% change
1983-88
18.5%
21.7%
22.6%
22.6%
-
-
30.1%
30.1%
-22.1%
-23.9%
-20.2%
0.7%
14.9%
47.7%
47.7%
13.3%
19.0%
6.2%
19.7%
19.7%
22.0%
21.8%
22.0%
22.0%
-
-
-
-29.5%
18.2%
38.8%
40.6%
39.7%
-5.4%
6.6%
6.4%
8.7%
-
15.8%
12.1%
21.8%
13.9%
200.0%
7.9%
1988
38.105
19.140
15.601
15.601
-
-
924
924
320
155
165
2296
4.511
170
170
3.459
2.016
1.443
255
255
627
5.664
5.528
5.528
-
-
-
136
8.789
2.265
407
1,823
35
2.631
2.352
279
-
3.791
1,182
1.226
1.384
72
4.024
% change
1973-88
29.0%
40.8%
42.5%
42.6%
-
-
103.1%
103.1%
-42.8%
-31.3%
-50.5%
43.8%
9.1%
33.0%
33.0%
4.8%
18.2%
-9.5%
90.9%
90.9%
123.9%
33.1%
34.0%
34.0%
-
-
-
27.1%
11.0%
52.4%
40.7%
61.6%
-49.0%
-11.9%
-6.7%
-40.1%
-
12.1%
12.5%
36.1%
-3.2%
132.3%
46.7%
Source: 1989 API Statistics of Paper. Paperboard. & Wood Pulp.
Note: Totals may not add due to rounding.
2-18
-------
Figure 2.4
Shipments of Main Paperboard
Product Groups 1973-1988
Million Tons
NO
10 -
5 -
73 18 '83 '88
Unbl. kraft
73 78
Soli
'88
73 78 '83 '88"
Semichem.
73 78 '83 '88
Recycled
Source: API 1989 Statistics of Paper, Board, & Wood Pulp.
-------
Table 2.6
Volume of U.S. Paperboard Shipments.
Value per Ton, and Estimated Shipments Value
(1988)
Product Category
Volume of
Shipments
(Thousand
Tons)
Value
Per Ton [a]
Estimated
Value of
Shipments
(SMillions)
All Paperboard
38,105
401.8
15.309
Containerboard
Linerboard
Unbleached kraft
Solid bleached
Recycled
Corrugating material
Semichemical
Recycled
Container chip & filler
Recycled
Boxboard
Folding
Unbleached kraft
Solid bleached
Recycled
Set-up
Recycled
Milk carton & food service
Solid bleached
Other
Gypsum wallboard facing
Tube, can, & drum
Other
Exports
Unbleached kraft
Solid bleached
Semichemical
Recycled
23,563
16.177
15,601
170
407
7.351
5,528
1.823
35
35
7.014
5.292
924
2.016
2.352
279
279
1.443
1.443
4,396
1.182
1.411
1.804
3,131
2,296
627
136
72
373.1
380.5
379.5
496.3
368.7
357.0
358.2
353.5
316.8
316.8
511.7
483.4
449.5
616.7
382.4
391.4
391.4
638.7
638.7
353.5
322.7
302.0
413.9
439.4
375.7
671.7
426.4
470.7
8.790
6,155
5.921
84
150
2.625
1,980
645
11
11
3.589
2.558
415
1.243
900
109
109
921
921
1,554
381
426
747
1,376
863
421
58
34
Source: 1989 API Statistics of Paper, Paperboard. & Wood Pulp.
[a] Value per ton figures at the most detailed product category level are from corresponding product categories
in Bureau of the Census (1989). For higher level categories, the value per ton is calculated as the sum of
shipment values for all sub-categories divided by the sum of shipments.
2-20
-------
Table 2.7
U.S. Imports. Exports, and Apparent Domestic Consumption
of Paoerboard Products. bvTvoe of Fiber, 1988
('000
Tons)
Exports
Product Category
All Paperboard
Unbleached Kraft
Semichemical
Bleached Kraft
Recycled
Wet Machine Board
Shipments
(a|
38,105
19,140
5,664
4,511
8,789
120
('000 Tons)
[b]
3,793
2,532
42
924
283
12
as % of
Shipments
10.0%
13.2%
0.7%
20.5%
3.2%
9.70/o
Imports
('000 Tons)
IbJ
345
86
142
11
101
4
as % of
Shipments
0.9%
0.4%
2.5%
0.3%
1.2%
3.5%
Apparent
Domestic
Consumption
Icl
34.657
16,694
5,764
3,598
8,607
113
[a] Source: 1989 API Statistics of Paper, Paperboard, & Wood Pulp.
[b] Source: 1989 Bureau of the Census, Current Industrial Reports; Pulp, Paper, and Board.
(c] Apparent Domestic Consumption represents Shipments plus Net Imports.
-------
Apparent domestic consumption of all paperboard products, defined as domestic shipments plus
net imports, totalled 34.7 million tons (U.S. Department of Commerce, 1990).
2.4 Overview of the Major Pulp, Paper, and Paperboard Producers
The types of pulp produced by the 20 largest U.S. pulp producers and the grades of paper
and paperboard produced by the largest 25 paper and paperboard producers are described below.
Information on the processes used at each mill operated by the 20 largest U.S. pulp producers
was collected using the 1989 Lockwood-Post Directory and through industry consultants. In
Table 2.8, production capacity by pulping process is presented for each company.
As seen in the table, the 20 largest U.S. producers own 74 bleached kraft mills. The
kraft process is the dominant process in the industry, representing 77 percent of the capacity of
the 20 largest U.S. pulp producers. This capacity is split relatively evenly between bleached
(50,255 tpd) and unbleached (45,801 tpd) kraft processes. Overall, 38 percent of the capacity
of these 20 producers is bleached kraft and 35 percent is unbleached kraft.6 The next largest
processes are semichemical (5.3% of capacity), unbleached mechanical (4.8%), defibrated
(4.1%), bleached sulfite (3.4%), and bleached mechanical (3.2%).
International Paper (IP) has the greatest capacity to pulp, at 14,938 tons per day. IP
operates eleven bleached kraft mills with capacity of 8,438 tpd (56.5 percent of their total
capacity) and five unbleached kraft mills with capacity of 3,888 tpd. Georgia-Pacific has the
second greatest capacity, at 12,705 tpd. Georgia-Pacific operates five bleached kraft mills with
capacity of 6,090 tpd (48% of total capacity) and three unbleached kraft mills with capacity of
3,600 tpd. Champion International has the sixth largest total pulping capacity, but the third
largest in terms of bleached kraft capacity (5,465 tpd or 64 % of total capacity).
The third largest U.S. pulp producer, Stone Container, has total pulp capacity of 11,615
tpd. Of this, only 7.5 percent (875 tpd) is bleached kraft, while 81 percent is unbleached kraft.
The only producer in the top 20 with no bleached kraft production is U.S. Gypsum, which uses
the exploded, defibrated process to produce hardboard. Although alternatives to bleached kraft
exist, Table 2.8 illustrates that, to date, the 20 largest U.S. pulp producers have not dedicated
a significant percentage of their capacity to non-kraft bleached pulp..
Table 2.9 presents capacity by major product groupings of the 25 largest U.S. producers
of paper and paperboard products. This information was compiled using the 1989
Lockwood-Post Directory of the Pulp, Paper and Allied Trades and the monthly grade reports
6For 5 percent of kraft capacity it was not possible to determine whether the capacity was
for bleached or unbleached pulp.
2-22
-------
Table 2.8
1988 Pulp Mill Capacity bv Type of Mill - TOD 20 U.S. Producers
(Tons Per Day)
Kraft
No. of
No. Bleached
of Total Kraft % Total
Company MID. Capacity MID. Id) Bleached Cap Unbleached
1 International Paper la) 23 14.938
2 Georgia-Pacific Ibl 18 12.706
3 Stone Container 13 11.816
4 WeyarheeuMr Co. 17 9.606
6 GNN |ol 13 10.828
8 Champion Corp. 14 8.680
7 Union Camp 4 7.770
8 Jamea River Corp. 16 8,288
9 Waatvaco Corp. B 6,802
10 Bolee Caarade If! fj 010
11 Jeff SmurflUCCA 9 6.610
12 TampMnland B 6.370
13 Bowater B 3.884
14 Scott Paper Co. 1O 3.836
16 USD 8 3.896
18 Mead 7 3.226
17 ITTRayonlar 4 3.226
18 Federal Paper Board 3 3,200
18 Shnpaen Papar 7 2,876
20 Willamette 6 2.806
Total 209 131.222
Percent of Total 100.0%
11
6
3
8
4
8
2
8
3
8
1
O
2
6
0
3
4
2
4
1
74
8.438 68.6%
8.090 47.9%
876 7.6%
2,816 28.8%
3,184 28.4%
6,486 83.9%
1,960 26.1%
3,238 61.8%
3.202 66.2%
1.790 31.8%
460 8.2%
1,620 28.3%
1,360 34.1%
1,460 38.8%
0 O.0%
1.200 37.2%
1.726 63.6%
3.200 1OO.O
1.816 68.2%
700 28.9%
60.266
38.3%
3,888
3,800
8,410
3,190
3.3OO
1m70O
6.20
1OO
2.6OO
1,863
3,810
2.960
760
0
0
1.0OO
O
0
1.200
1.430
46.801
34.9%
(al Indudaa Hammarmm
Ibl Indudaa Brunewlek Pulp ft Papar
(el . Include. Leaf River Foreat Product.
Id) Theae mm. uaa chlorine In the production of bleached kraft pulp, according to U.S.
l«l TtttmMm |M» kraft Inriuri* k*a*e]tv frw milt* that rfld rMt iMfflefta th« •mttutt of bleac
SuHlte Mechanical
Total |al Bleached Unbleached Semlchem Bleached Ur
13.948 - - 162 ISO
8.890 8OO - 6OO
10.286 - - 1.160
8.O06 860 - 970 1,820
6,484 236 666 2,1 OO
7.166 - - 386
7.770 - -
4,841 810 - 280 320
6.802 - -
3.843 - - 220 460
4.060 - - 2OO
4.470 - - 4OO
2,100 - 1,084
2,860 836 -
0 - -
2.20O - - 676 200
1,726 1,600 - -
3.200 - -
2,816 - -
2,130 - - 476
101,181 4,430 666 7.0O2 4,199
77.1% 3.4% 0.4% 6.3% 3.2%
EPA. Tht 1O4 MOl Study, April 13, 1990.
hed vemja unblaaehad eanaeltv.
ibleached De-Inked De-Flbrated Other
- - - 680O
626 280 1.010
ISO -
260
1.470 -
1,010 -
_ _ _
- 236 -
1.186 160
960 300
600
800 -
- 260 -
136 - 3.68O
- - - 260
- - - -
_
- 60 - -
_ _
8.336 1,276 6.33O 930
4.8% 1.0% 4.1% 0.7%
Source: lodtwood-Ptmt't Dlnctory of the Pulp, Ptper tmf Altled Trmdta. 1989, and ERG Induatry eMlm*te>.
-------
Table 2.9
Production Capacity of Largest U.S. Paper and Paoerboard Products 1988
Rank
(al
(bl
1
2
3
4
6
8
7
8
8
10
11
12
13
14
16
16
17
18
19
20
21
22
23
24
26
s
Company Name
International Paper Co.
Georgia-Pacific Corp.
Stone Container
Weyerhaauaor Co.
Champion Corp.
GNNekooM
Jeff Smurfit/CCA Corp.
Jama* River Corp.
Botee Ceacade Corp.
Union Camp Corp.
Weatvaeo Corp.
Mead Corp.
Scott Paper Co.
Templfrlntand
Bowater
P40 Buckeye CeHutoee
Klmbertay-Clark
Willamette
Packaging Corp. '
AWtlbhPrlce Inc.
Slmpeon Paper
Federal Paper Board
Potlatch Corp.
U.S. Gypeum
Fort Howard
(000 Tons)
Paper Grade
Coated Uncoated Bleached Coated Uncoated Kraft Kraft Recycled Chem Mkt Corrugating
Free Sheet Free Sheet Paperboard Groundwood Groundwood Tlnue Paper Urwrboard Paperboard Pulp Newsprint Medium
(al
2.1OO
936 646
1.970 3380
lal
180
286
-
-
262
270 Ibl
-
680
380
900
-
-
- '
-
-
-
102
290
(a)
300
-
-
I.I
807
1.114
714
-
872
810
800
200
620
(al
-
-
-
80
180
-
460
•
-
-
-
-
220
247 689
lal
186
236 Ibl 316
390
140
620
336
-
367
330
-
-
-
-
-
-
631
664
-
-
260 1,860
637 366 1,376 - 1
773 2.760
- - 1,630
239 - 196 240
288 - - 1,260
- - 1.460 1,330
lal 1,111 160 223
270 36 |*| 23 Ibl
360 1,360
- - 800
- - 398
1,060 -
- - 1.236
-
9OO - -
680 -
- 70 800
- - - 800 210
626 180
lal |a|
-
70
Ibl 632 332
860 - -
820
.116
260 286
660 604
270 868
617 331
680
110 Ibl
246 677
-
108
108
108
lal
266 1.039
870
240 419
262
-
386
420
460
-
-
-
370
276
860
69O
-
980
390
-
110
-
lei
39O
-
210
-
-
-
-
280
-
-
-
-
-
-
Total*
6.980
6.987
4,928
4,481
4,137
4,080
3,936
3,268
2.831
2.640
2.308
2.129
2,068
1,802
1.624
1,670
1,419
1,302
1,290
1,192
1.160
1.O91
924
864
860
Production Indicated, but quantity not apedfM.
Additional mill* Indicated production, but did not apedfy quantity.
no production volume reported.
Note:
Source:
Ranking* were made by ERG according to production volumea reported In the aoureea lltaed. Addition*,
unreported production may exltt which would affect total volume* and ranking*.
A/fc A P*ptr MfffntM. Auguat 1888 to July 1890.
fjMftMMMMtAM*'* nfr**#nn/ «/ th» Ptita- Pmo& mntl Anted TemAtm 1989.
-------
in Pulp & Paper Magazine from August 1989 through July 1990. Rankings were made
according to capacity reported in the sources noted above.7
Each month, Pulp & Paper Magazine (1989, 1990) publishes a grade profile listing the
top 10 U.S. producers for a specific grade of paper or paperboard. This data was compiled for
each of the 12 major paper and paperboard grades and used to rank companies in order of their
total capacity, i.e. across all 12 grade categories. The capacity figures from Pulp and Paper
were supplemented with information from Lockwood-Post's Directory to fill in additional
capacity information for these companies. It must be noted, however, that Lockwood-Post's
listings for mills operated by these companies often indicate the products which are produced
without providing information on volumes. The rankings by total volume in Table 2.9 are based
only on capacity volumes which could be identified through these two sources.
This compilation of capacity data, as seen in Table 2.9, indicates that IP has potential to
be the largest overall producer, with significant production of bleached paperboard, coated
groundwood, uncoated free-sheet, kraft linerboard, kraft paper, corrugating medium, and paper
grade chemical market pulp. IP's total reported capacity was 7.0 million tons in 1988.
According to the 1989 Lockwood-Post's directory, IP operates 23 pulp and paper mills in the
U.S. The other large producers include Georgia-Pacific (6.0 million tons; 25 mills), Stone
Container (4.9 million tons; 13 mills), Weyerhaeuser (4.5 million tons; 17 mills), and Champion
Corporation (4.1 million tons; 14 mills).
2.5 Bleached Paper Products
This section addresses the amount of bleached pulp utilized in the manufacture of various
grades of paper and paperboard. It first provides an overview of the fibrous and non-fibrous
materials which go into making paper and paperboard, then addresses the issue of recycled fiber
utilization in the paper and board making process. Estimates of the bleached pulp content of
paper and paperboard grades are then presented.
2.5.1 Fibrous and Nonfibrous Materials Used in Paper and Paperboard Making
Paper and paperboard products are generally made from a mix of both fibrous and
non-fibrous materials. Collectively, the materials which are blended to produce a grade of paper
or paperboard are referred to as the "furnish". In addition to fibrous material (pulp or a mix
of pulps), the furnish may contain any of the following: nonfibrous fillers such as clay, used to
improve the smoothness and brightness of the paper; sizing agents, which affect surface
characteristics such as creasability or abrasion resistance; wet-strength or .other additives; and
'According to these sources, unreported production exists in some cases which affects total
volumes and rankings.
2-25
-------
dyes. These non-fibrous additives may constitute up to 40 percent of the furnish weight; in most
grades additives average less than 10-15 percent.
The fibrous component of the furnish generally consists of wood pulp or a mix of wood
pulps, as well as secondary or recycled fibers, if they are used. Most grades utilize a mix of
pulps in order to obtain the desired properties of the paper or board. Typical pulps for
newsprint, for example, consist of 75 percent mechanical and 25 percent chemical fibers.
Scrap paper (i.e., any paper that could be reprocessed), has become an important source
of fiber for some grades of paper. The amount of scrap paper used in the manufacture of a
grade of paper, as a percent of total production of that grade, is referred to as the scrap paper
utilization rate. This rate varies depending upon the grade of paper or board. The highest rates
are for recycled paperboard (100%), tissue (44%), and newsprint (23%), while rates for most
printing and writing papers are below 10 percent. When blended with virgin palp, recycled
materials are processed separately using mechanical means to separate the fibers and filter out
foreign materials. For most tissue and writing papers, the recycled fibers also go through a
de-inking process. (In addition to removing ink from the fibers, the term "de-inking" covers
other cleaning and purifying processes that may be required). Recycled fibers may also go
through a bleaching or coloring process, depending upon (1) whether they are originally from
bleached paper or board grades, and (2) the degree of whiteness desired in the final product.
In general, however, recycled fibers are not subjected to the chlorine bleaching processes used
for virgin fibers.
Paper manufacturers tend to utilize scrap paper which is similar in furnish to the final
products they are making. (Mixed paper is generally used to manufacture the lowest grade of
paper in the mix.) Thus, corrugated scrap paper is recycled into corrugating medium, scrap
business paper is used in producing recycled printing and writing paper, and old newspapers are
recycled into newsprint. The secondary fibers used in paper and boardmaking can be expected,
therefore, to have approximately the same furnish as the virgin fibers with which they are being
blended. An investigation of the bleached pulp content of various grades of paper and
paperboard based only on virgin fibers might understate, therefore, the amount of bleached
fibers contained in the final product. To the extent possible, information on the amount of
bleached secondary fibers present in the various grades of paper and board has been incorporated
in the analysis which follows.
2.5.2 Pulp Types Used in Various Grades of Paper and Paperboard
This analysis develops estimates of the total fiber content of a variety of paper and
paperboard grades, as well as the percent of all fiber which is from virgin bleached pulp. Data
came partially from the 1987 risk assessment for bleached kraft paper products completed for
EPA (Arthur D. Little, 1987), with the remainder from Eastern Research Group (ERG). ERG
2-26
-------
developed their estimates based on discussions with industry specialists from the U.S. Forest
Service, Department of Commerce, and academia.8
Table 2.10 presents the analysis of the fiber and bleached pulp components of a number of paper
and paperboard grades. The grades shown are those for which estimates were available or could
be accurately developed. While estimates at a more detailed product level would be desirable,
this data is not currently available.
Columns in the table present a variety of data items and estimates. From left to right,
these are:
(a) 1988 shipment volumes for paper and paperboard categories.
(b) The amount of fiber contained in the overall furnish. This indicates the
percentage of the final blend of slurried materials which is processed into paper
by pulp and paper mills that is fiber, as opposed to other materials such as fillers,
agents, dyes, etc. These percentages were largely developed for this analysis
from published sources and discussions with industry observers.
(c) The amount of total fiber (in thousands of tons) which is assumed to be contained
in the final product. This is the product of the shipment volume of a particular
grade of paper or board and the percent of the furnish which is estimated to be
fiber. Fiber and furnish quantities are often expressed on an oven-dry basis (zero
water content), and this is the assumption made here. Hence a ton of paper or
board is assumed to be produced from a ton of furnish.
(d) Bleached virgin kraft pulp as a percent of total fiber. This represents the estimate
of the percent of all fiber which goes into the furnish which is from bleached
virgin kraft pulp. Some of these estimates, as noted, are from the 1987 risk
assessment for bleached kraft paper products (Arthur D. Little, 1987), while the
remainder were developed for this report.
(e) The amount of virgin bleached fiber which is assumed to be contained in the final
product. This is the product of the estimated fiber usage (column c) and >the
estimate of the percent of that fiber which is from bleached virgin pulp.
'It should be noted that the American Paper Institute (API) has conducted surveys as recently
as 1986 which would provide more complete data on this subject. API declined to make these
survey results available since they felt they were out of date. In mid 1990, API reported that
they intended to conduct another survey in late 1990 and that they will make the data from that
survey available to the public.
2-27
-------
Grade |a|
1988
Table 2.10
Estimates e>( Bleached Kraft Pulp and Other Fiber Usage
tor Various Paper and Paperboard Grades
Recycled
Implicit Bleached
Bleached Bleached Kraft Fiber
Implicit Virgin Kraft Virgin Kraft as a Percent
Percent Fiber Pulp as a Pulp ol Total Fiber
Source of
Percent
Shipments Fiber in Usage |c| % ol Total Usage (c) (maximum) Bleached Kraft
'000 tons Furnish |b| '000 tons Fiber
'000 tons
[dlle]
Estimate |l|[g||h| Other Fibers |i|
Newsprint
Uncoated groundwood
Coated groundwood
Coated free sheet
Uncoated free sheet
Bond & writing
Form bond
Ledger
Mimeograph
Duplicating
Papaterie & wedding
Carbonless
Cover & text papers
M.F..E.F..& supercalendered
Offset
White wove envelope
Tablet
Thin papers
Cotton fiber
Bleached bristols
Tabulating index
Tag
File folder
Index bristol
Printing bristol
Coated bristol
5.982
1.624
4,262
3.349
11.277
2953
2127
41
28
45
40
684
349
86
2918
942
379
217
167
1.150
40
185
214
153
67
488
100.046
90.0%
60.046
70.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
100.0%
90.0%
90.0%
90.0%
90.0%
90.0%
90.0%
90.0%
90.0%
5.982
1.461
2.557
2.344
9.022
2.362
1.702
33
22
36
32
547
279
69
2.334
754
303
217
150
1.035
36
167
193
138
60
439
20.0%
20.0%
50.0%
90.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
80.0%
90.0%
30.0%
90.0%
90.0%
90.0%
90.0%
90.0%
90.0%
90.0%
1,196
292
1,279
2,110
7.217
1.890
1.361
26
18
29
26
438
223
55
1.868
603
243
195
45
931
32
150
173
124
54
395
4.8%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
63%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
6.3%
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ADL/ERG
ADL/ERG
ADL/ERG
ADL/ERG
ADL/ERG
ADL/ERG
ADL/ERG
TMP (30%). Groundwood (25%). Other recycled (20%)
Groundwood (45%). TMP. Sulfite
Groundwood (20%). TMP
none
Sullilo (5%)
Siillito (5%)
Sullite (5%)
Sullite (5%)
Sulfite (5%)
Sulfite (5%)
Sulfite (5%)
Sulfite (5%)
Sulfite (5%)
Sulfite (5%)
Sulfite (5%)
Siillito (5%)
Sulfite (5%)
Unbleached kraft
Sulfite
Sullite. Semichemical
Sulfite. Semichemical
Sulfite. Semichemical
Sulfite, Semichemical
Sulfite, Semichemical
Sulfite, Semichemical
Sulfite. Semichemical
-------
1988
TABLE 2.10 (Cont.)
Estimates of Bleached Kraft Pulp and Other Fiber Usage
for Various Paper and Paperboard Grades
Recycled
Implicit Bleached
Bleached Bleached Kraft Fiber
Implicit Virgin Kraft Virgin Kraft as a Percent
Percent Fiber Pulp as a Pulp of Total Fiber
Source of
Percent
Shipment*. Fiber In Usage |cj % ot Total Usage |c| (maximum) Bleached Kraft
Grade [a]
'000 tons Furnish |b| '000 tons
Fiber
'000 tons
|dl|8| Estimate [f||g)[h| Other Fibers |i|
Unbleached kraft packaging
& Industrial papers
Bleached packaging papers |j|
Wrapping
Bag and sack
Shipping sack
Other converting
Specialty packaging
Special Industrial papers
Tissue
Toilet
Facial
Napkins
Towelling
Other sanitary tissue
All other tissue
Unbleached kraft paperboard
Solid bleached paperboard
Unerboard
Folding carton type board
Milk carton & food service
Other
Exports
Semlchemlcal paperboard
Recycled paperboard
3.861
465
24
262
111
69
596
1.186
5.476
2.032
351
697
1.863
383
194
19.140
4.511
170
2.016
1.443
255
627
5.664
8.789
100.0%
95.0%
95.0%
95.0%
95.0%
95.0%
95.0%
95.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
90.0%
90.0%
90.0%
90.0%
90.0%
90.0%
100.0%
95.0%
3.861
442
23
248
105
66
566
1.127
5.476
2.032
351
697
1.863
383
194
19.140
4.060
153
1.815
1.298
229
565
5.664
8.350
0.0%
90.0%
90.0%
90.0%
90.0%
90.0%
90.0%
50.0%
50.0%
50.0%
50.0%
50.0%
50.0%
50.0%
50.0%
0.0%
80.0%
90.0%
80.0%
75.0%
80.0%
80.0%
0.0%
0.0%
0
398
21
224
95
59
510
563
2.738
1.016
176
349
932
192
97
0
3.248
138
1.452
974
184
452
0
0
0.6%
3.0%
3.0%
3.0%
3.0%
3.0%
3.0%
3.0%
31.1%
31.1%
31.1%
31.1%
31.1%
31.1%
31.1%
0.6%
0.6%
0.6%
0.6%
0.6%
0.6%
0.6%
1.6%
26.5%
ERG
ADL/ERG
AOL/ERG
ADL/ERG
ADL/ERG
ADL/ERG
ADL/ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ERG
ADL/ERG
ADL/ERG
ADL/ERG
ADL/ERG
. ADL/ERG
ADL/ERG
ERG
ERG
Unbleached kraft (90%)
Sullite. Unbleached kraft
Sullile. Unbleached kraft
Sullite, Unbleached kraft
Sullile, Unbleached kraft
Sullite, Unbleached kraft
Sulfite. Unbleached kraft
Sullite, Groundwood, TMP
Sulfite (10%). Unbleached draft. TMP
Sullite (10%). Unbleached kraft, TMP
Sullite (10%). Unbleached kraft, TMP
Sulfite (10%). Unbleached kraft. TMP
Sulfite (10%). Unbleached kraft. TMP
Sulfite (10%). Unbleached kraft. TMP
Sullite (10%), Unbleached kraft. TMP
Other recycled (10%), Semichemical
Recycled. Groundwood
Recycled. Groundwood
Recycled, Groundwood
Groundwood
Recycled. Groundwood
Recycled, Groundwood
Semichemical (70%), Other recycled (25%). Unbleached kraft
Recycled (70%)
-------
Notes to Table 2,10
(a) These are grades tor which estimates of fiber and bleached pulp content are available. This list Is not comprehensive and Is not designed to account (or all
bleached pulp produced or consumed In the United States.
(b] The term 'furnish* refers to the blend of fibrous and nonfibrous materials which are used In the papermaking process. In addition to fiber (pulp), some grades of paper may contain substantial
quantities of fillers, additives, dyes. etc.
|c| Tons are as measured on an oven-dry basis (zero water content).
|d| Includes the following grades of waetepaper: high grade delnklng. mixed grades, and pulp substitutes. Excludes newspaper and corrugated grades. The grades Included are those which
potentially would have gone through chlorine bleaching. Secondary fibers, from both bleached and unbleached stock, may also be bleached (or re-bleached) prior to blending with virgin fibers.
Data describing treatment of secondary fibers Is not readily available, however bleaching processes for secondary fibers generally do not Involve chlorine.
|e] Utilization rates are available for the following end-use categories only: newsprint; printing, writing, & related; packaging & industrial converting paper; tissue; unbleached & bleached krafl
paperboard; semlchemlcal paperboard; and recycled paperboard.
|f| Some of the AOL estimates give a range for bleached pulp content; the midpoint Is presented here.
|g] AOL estimates are based on 1987 fiber furnish estimates.
|hj ERG estimates are based on 1089 fiber furnish estimates. ERG subtracted the percent of bleached recycled fiber from the AOL estimates where this was appropriate.
|i) Where no percentages are given, percent Is estimated at below 5.
U| Includes semibleached packaging.
Sources:
American Paper Institute. 1980 Statistics of Paper, Paperboard. & Wood Pulp.
American Paper Institute. Paper Recycling Committee. 1989 Annual Statistical Summary of Waste Paper Utilization.
^ A.D. Little. Inc. Exposure and Risk Assess, of Dloxln In Bleached Kraft Paper Products. U.S. EPA Contract 68-01-6951. June 25.1987.
O ERG estimates, based upon Industry consultants and other Industry sources.
-------
(f) Estimate of the percent of total fiber in the furnish which is from recycled
bleached sources. Many grades of paper and paperboard are manufactured with
significant quantities of recycled or secondary fibers. The use of scrap paper can
be an additional source of bleached fibers for these grades if the fibers are either
from bleached scrap paper products or if they are bleached (or re-bleached) prior
to being mixed in with the virgin fiber in the pulp. While the percent of total
fiber which was from bleached scrap paper products was estimated for this
analysis, it was not possible to estimate the amount which is bleached or
re-bleached prior to use.
The table indicates that the estimate of recycled bleached fiber is a maximum.
As indicated in footnote [d], the estimate is based on the combined percentage of
fiber which is from high grade deinking, mixed grades, and pulp substitute grades
of scrap paper. These grades may be assumed to contain varying amounts of
bleached paper or board.
(g) The source of the estimate of the percent of total fiber which is from virgin
bleached kraft pulps. These estimates are based partly on the 1987 risk
assessment for bleached kraft paper products and partly upon original
investigations performed for this report.
(h) Additional fiber types used in the manufacture of each grade of paper. The
percentages, where given, indicate the percent of total fiber represented by each
fiber type. Where no percentages are given, the percentages are estimated at
below 5 percent.
2.5.3 Percentage of Bleached Pulp in Various Paper and Paperboard Grades
As seen below, the various grades of paper and paperboard can be classified into three
groups according to their bleached pulp content. These are:
High bleached pulp content (75-90 percent of total fiber)
• Coated and uncoated free sheet
• Thin papers
• Bleached bristols
• Various grades of bleached packaging papers
• Various grades of solid bleached paperboard
Medium bleached pulp content (30-75 percent of total fiber)
• Coated groundwood
' • Special industrial papers
• All grades of tissue (an additional 30-40 percent is from recycled bleached fiber)
2-31
-------
Low bleached pulp content (0-30 percent of total fiber)
• Newsprint
• Cotton fiber papers
• Unbleached kraft packaging paper
• Unbleached kraft paperboard
• Semichemical paperboard
• Recycled paperboard
In the sections below, paper and board grades classified in either the high or medium pulp
content categories are examined in detail.9
2.5.4 Paper and Paperboard Grades with High Bleached Pulp Content.
Among the paper and paperboard grades shown above to be formulated with a high
percentage of virgin bleached pulp fibers, some categories include high volume, everyday use
products, while others represent relatively specialized product groups. Each of the high bleached
pulp content grades is examined below.
Uncoated and coated free sheet. Uncoated free sheet represents the highest volume
category classified as having a high bleached virgin pulp content. In the aggregate, this category
is estimated to contain approximately 80 percent fiber, of which 80 percent is bleached virgin
pulp. A large number of common business, commercial, and consumer papers are classified as
uncoated free sheet. Examples include, in order of 1988 shipment volume (see Table 2.11):
• Bond and writing paper (26% of all uncoated free sheet);
• Paper used in offset printing (25%);
• Form bond, used for printed business forms (19%);
• White wove envelope (8%);
• Carbonless paper, also used for business forms (6%)
• Tablet paper (3%).
The table shows data on shipments volume for the different categories of uncoated free
sheet over the period 1963-88. As before, comparisons will be made between grades over the
1973-88 period, since consistent data for paperboard products back to 1963 has not been
developed. During 1973-88, shipments of all uncoated freesheet grades increased from 6.7
million to 11.3 million tons, an increase of 69 percent. Shipments of bond and writing paper
and form bond paper grew at considerably higher rates, 175 and 90 percent respectively. Offset
grade, the other large category of uncoated free sheet, grew by 57 percent. Shipments of several
other grades, including ledger, mimeo, duplicating, manifold, papeterie and wedding, machine
finish, English finish, and supercalendar, decreased over this period.
'Appendix 2.C presents additional data on the number of mills which produce in the high
and medium bleached pulp content product categories.
2-32
-------
Table 2.11
Shipments of Uncoated and Coaled Free Sheet Grades 1963-1988
to
Selected Years
('000 Tons)
Grade
Uncoaled free sheet
Bond & writing
Form bond
Ledger
Mimeograph
Duplicating
Manifold
Papeterle & wedding
Carbonless
Opaque circular
Other
Cover & text papers
M.F., E.F., & supercalendered
Offset
White wove envelope
Tablet
Kraft envelope papers
Brown kraft (est.)
Bleached kraft (est.)
Other
Coated Free Sheet |a)
1963
3.634.1
470.0
375.0
45.1
110.9
116.0
17.4
42.9
NA
27.3
247.6
155.4
264.1
862.3
318.8
281.5
175.2
65.0
90.2
124.6
1,115.6
% change
1963-68
31.7%
33.4%
52.2%
21.1%
21.6%
38.7%
-19.5%
30.5%
-
-14.7%
-
24.1%
-25.0%
50.2%
44.2%
11.2%
6.5%
7.5%
5.5%
261.5%
27.8%
1968
4.787.7
627.1
570.9
54.6
134.9
160.9
14.0
56.0
50.0
23.3
NA
192.8
198.2
1.295.4
459.6
313.0
186.6
91.4
95.2
450.4
1.426.2
% change
1968-73
39.4%
71.4%
96.2%
13.6%
6.2%
13.4%
-9.3%
2.3%
140.0%
44.2%
-
13.8%
-22.0%
43.8%
24.2%
-2.4%
14.7%
16.7%
12.7%
20.0%
21.9%
1973
6.673.6
1.075.0
1.119.9
62.0
143.3
182.4
12.7
57.3
120.0
33.6
NA
219.5
154.6
1,862.5
570.9
305.5
214.0
106.7
107.3
540.4
1,738.4
% change
1973-78
7.9%
32.5%
18.8%
-6.9%
-35.9%
-18.0%
-4.7%
-14.1%
108.3%
17.9%
-
-3.4%
-55.0%
3.1%
3.7%
14.7%
7.6%
13.5%
1.7%
-21.9%
16.4%
1978
7.202.0
1.424.7
1.330.5
57.7
91.9
149.5
12.1
49.2
250.0
39.6
NA
212.1
69.5
1,920.2
592.3
350.4
230.2
121.1
109.1
422.1
2.024.0
% change
1978-83
21.2%
44.4%
26.8%
-10.9%
-39.2%
-11.6%
-76.0%
-21.3%
60.0%
-
-
30.1%
25.9%
15.1%
20.7%
15.9%
0.2%
-5.7%
6.8%
-11.2%
29.9%
1983
8,725.7
2.057.3
1.687.5
51.4
55.9
132.1
2.9
38.7
400.0
NA
NA
276.0
87.5
2.209.8
715.1
406.1
230.7
114.2
116.5
374.7
2.629.3
% change
1983-88
29.2%
43.5%
26.1%
-19.3%
-49.4%
-65.9%
-55.2%
2.8%
71.1%
-
-
26.3%
-1.7%
32.0%
31.8%
-6.8%
16.6%
26.4%
7.0%
10.4%
31.9%
1988
11.277.0
2.953.1
2.127.3
41.5
28.3
45.0
1.3
39.8
684.4
NA
NA
348.6
B6.0
2,917.9
942.5
378.6
268.9
144.3
124.6
413.8
3.467.9
% change
1963-88
210.3%
528.3%
467.3%
-8.0%
-74.5%
-61 .2%
-92.5%
-7.2%
-
-
-
124.3%
-67.4%
238.4%
195.6%
34.5%
53.5%
69.8%
38.1%
232.1%
210.9%
% change
1973-88
69.0%
174.7%
90.0%
-33.1%
-80.3%
-75.3%
-89.8%
-30.5%
470.3%
-
-
58.8%
-44.4%
56.7%
65.1%
23.9%
25.7%
35.2%
16.1%
-23.4%
99.5%
Note |a| API reports figures for all coated papers only. Census data Indicates that In 1988 free sheet accounted lor 46% of all coated paper. This percentage has been used
to estimate shipments of coated free sheet for 1963-88. ERG will develop further estimates of shipments of coated free sheet (or its final report.
Source: 1989 API Statistics of Paper, Paperboard. & Wood Pulp.
-------
Coated free sheet is generally reported as a single category of paper. In fact, the API
data on which most of this analysis is based does not differentiate between coated free sheet and
coated groundwood papers; a single figure for "coated papers" is reported. This distinction is
made, however, in the Bureau of the Census Report on Pulp, Paper, and Board (1989). In the
most recent report, free sheet accounts for approximately 46 percent of all coated paper
shipments. Shipments of coated free sheet have increased from 1.7 million to 3.5 million tons
over the period 1973-88. This amounts to a near doubling in volume, compared to a 69 percent
increase for uncoated free sheet over the same period. As previously indicated, coated free sheet
is used mainly in commercial printing for high quality advertising, brochures, magazines, and
books. Coated free sheet is estimated to contain 70 percent fiber, of which 90 percent is
estimated to be virgin bleached wood pulp fiber.
The increase in demand for printing/writing papers has been largely a function of the
surge in paper used by businesses, primarily for office copying and duplicating. Writing papers
are also consumed in business forms and computer print-outs. While it was anticipated that the
age of electronic data processing would decrease the demand for paper, the expanded quantity
of data that is analyzed has resulted in more paper use.
Thin papers. Thin papers include lightweight papers such as carbon paper, cigarette
paper, condenser paper, and paper used in printing Bibles. Tissue paper is not included in this
category. These papers are estimated to contain close to 100 percent fiber, of which 90 percent
is virgin wood pulp fiber.
Shipments data are generally reported only for the entire category of thin papers; data
for particular product categories described above are not available. Between 1973 and 1988,
shipments of thin papers decreased, falling from 358 thousand to 216 thousand tons. This
represented a decrease of close to 40 percent (see Table 2.12). Undoubtedly this decline is
related to the reduced demand for carbon paper in the office market as well as a reduced smoker
demand for cigarette papers.
Bleached Bristols. Solid bleached bristols are estimated to contain an average of 90
percent fiber, of which 90 percent is virgin bleached fiber. Compared with uncoated free sheet
or even particular grades such as bond and writing, form bond, or offset, bristols are a relatively
low volume category of product. In 1988, shipments of all bristol grades totaled 1.1 million
tons. This represented only 3 percent of all paper products shipments. Examples of bleached
bristol grades, in order of 1988 shipments volume, are:
Coated bristol, used for poster board and postcards (42 % of all bleached bristols);
File folder, used in manila and other types of folders (19%);
Tag stock, used for making tags of all types (13%);
Printing bristol, used for printing purposes (6%);
Tabulating index, used for computer cards, but declining rapidly in significance
(3%).
As seen in Table 2.13, shipments of all bristols grew from 870 thousand tons in 1963 to
1.25 million tons in 1973, but have since fallen to 1.1 million tons in 1988, the most recent year
for which data are available. Nevertheless, the two largest volume bristol grades, coated bristol
2-34
-------
Table 2.12
Shipments of Thin Paper Grades. 1963-1988
Selected Years
('000 Tons)
Year
1963
1968
1973
1978
1983
1988
Shipments
178.7
261.6
358.2
351.7
292.4
216.5
Period
1963-68
1968-73
1973-78
1978-83
1983-88
1963-88
1973-88
% change
46.4%
36.9%
-1.8%
-16.9%
-26.0%
21.2%
-39.6%
Source: AP11989 Statistics of Paper, Paperboard, & Wood Pulp.
2-35
-------
to
Table 2.13
Shipments o( Bleached Bristol Grades 1963-1988
Selected Years
('000 Tons)
Grade
Bleached bristols
Tabulating Index
Tag
File (older
Index brlstol
Printing brlstol
Postcard
Coated brlstol
1963
870.3
395.5
164.7
58.9
98.0
22.3
13.7
117.2
% change
1963-68
28.4%
35.2%
23.7%
32.1%
6.5%
7.6%
-62.0%
43.1%
1968
1.117.4
534.6
203.7
77.8
104.4
24.0
5.2
167.7
% change
1968-73
12.4%
-8.1%
8.1%
12.0%
25.4%
95.4%
-40.4%
64.7%
1973
1,255.7
491.2
220.3
87.1
130.9
46.9
3.1
276.2
% change
1973-78
-10.3%
-36.8%
-5.7%
28.9%
9.5%
9.4%
-80.6%
8.8%
1978
1.126.3
310.6
207.7
112.3
143.4
51.3
0.6
300.4
% change
1978-83
-14.1%
-65.6%
-8.1%
28.9%
-1.7%
8.0%
216.7%
8.8%
1983
967.3
106.7
190.9
144.8
140.9
55.4
1.9
326.7
% change
1983-88
18.8%
-62.5%
-3.0%
47.4%
8.4%
21.7%
68.4%
49.3%
1988
1.149.5
40.0
185.1
213.5
152.7
67.4
3.2
487.6
% change
1963-88
32.1%
-89.9%
12.4%
262.5%
55.8%
202.2%
-76.6%
316.0%
% change
1973-88
-8.5%
-91.9%
-16.0%
145.1%
16.7%
43.7%
3.2%
76.5%
Source: AP11989 Statistics of Paper, Paperboard, & Wood Pulp.
-------
and file folder, have increased in volume since 1973. Shipments of coated bristols increased
from 276 thousand tons in 1973 to 488 thousand tons in 1988, an increase of 77 percent, while
file folder grades increased from 87 thousand to 214 thousand tons for an increase of 145
percent. The most dramatic decrease has been, as mentioned, in the tabulating index grade.
In 1973 shipments of this grade totalled 491 thousand tons and accounted for 39 percent of all
bleached bristols. In 1988, only 40 thousand tons, representing 3.5 percent of all bristols, were
produced.
Bleached Packaging Papers. The bleached packaging paper category includes a list of
products which is analogous to that for unbleached packaging, i.e., wrapping, bag and sack,
shipping sack, and other converting. While unbleached products dominate these categories,
about 17 percent of total production is from bleached pulps. These are generally more expensive
than their unbleached counterparts and are used to enhance the appearance of the final product.
In Table 2.14, shipments of all bleached packaging papers are seen to have increased
from 782 thousand tons in 1963 to 1,115 thousand tons in 1978, but the volume had declined
to 465 thousand tons by 1988. It should be noted, however, that API revised several of these
data series in 1981. Apparent reductions in shipments may be more a result of this
reclassification than of actual industry conditions. However, it is likely that paper packaging
will face continued strong competition from plastic, as well as from the growth of bulk shipping
requiring no bags or containers.
Bleached Paperboard. As seen in Table 2.15, shipments of bleached paperboard grades
totaled 3.8 million tons. This represented 10 percent of all paperboard shipments. Bleached
paperboard products fall into one of four main subcategories. Listed in order of 1988 shipment
volume, these are:
Folding boxboard. These are boxes which are set up, filled, and closed by the
end user. Examples include gift boxes utilized by department and specialty
stores. In 1988, these accounted for 52 percent of all bleached paperboard
product shipments;
Milk carton and food service. Includes board used for milk carton and other
liquid beverages as well as board used for other food items such as butter and ice
cream. These grades accounted for 37 percent of bleached paperboard shipments
in 1988;
Other bleached paperboard grades (7%);
Linerboard, used as the facing material in corrugated or solid fiber shipping
containers (4%).
Shipments of bleached paperboard products have increased only slightly over 1973-88,
from 3.5 million to 3.8 million tons. Highest growth has been in the miscellaneous category,
2-37
-------
Table 2.14
Shipments of Bleached Packaging Papers 19631-1988
Selected Years
('000 Tons)
to
k
00
TYPE OF PRODUCT
Bleached packaging papers
Wrapping
Bag & sack
(exc. shipping sack)
Shipping sack
Other converting
1963
782.0
191.4
130.4
67.0
393.2
% change
1963-68
20.6%
10.0%
59.4%
32.4%
10.8%
1968
942.9
210.5
207.8
88.7
435.8
% change
1968-73
-8.0%
-24.9%
22.3%
17.7%
-19.6%
1973
867.0
158.1
254.2
104.4
350.4
% change
1973-78
28.6%
-2.5%
8.9%
-12.3%
69.1%
1978
1.115.2
154.2
276.7
91.6
592.7
% change
1978-83
-61.5%
-79.8%
-14.9%
-3.4%
-87.5%
1983
429.3
31.1
235.6
88.5
74.1
% change
1983-88
8.3%
-22.5%
11.0%
25.0%
-7.2%
% change % change
1988
465.0
24.1
261.5
110.6
68.8
1963-88
-40.5%
-87.4%
100.5%
65.1%
-82.5%
1973-88
-46.4%
-84.8%
2.9%
5.9%
-80.4%
Source: AP11989 Statistics of Paper, Paperboard, & Wood Pulp.
-------
VO
Table 2.15
Shipments ol Bleached Paperboard Grades. 1973-1988
Selected Years
('000 Tons)
Grade
Bleached paperboard
Llnerboard
Folding boxboard
Milk carton & food service
Other
1973
3,561
128
1.706
1.594
134
% change
1973-78
-1.1%
-9.4%
2.0%
-9.3%
65.2%
1978
3.522
116
1.740
1.446
221
% change
1978-83
-4.0%
-0.6%
-2.6%
-6.1%
-3.4%
1983
3.380
115
1.694
1.359
213
% change
1983-88
14.9%
47.7%
19.0%
6.2%
19.7%
1988
3.884
170
2.016
1.443
255
% change
1973-88
9.1%
33.0%
18.2%
-9.5%
90.9%
Source: 1989 API Statistics of Paper. Paperboard, & Wood Pulp.
-------
which has increased from 134 thousand to 255 thousand tons over this period. The largest
volume category, folding boxboard, increased from 1.7 million to 2.0 million tons, for an
increase of 18 percent. The moderate growth rate of folding boxboard may be due to the
saturation of supermarket packaging and, also, to increased competition from plastic containers
and flexible packaging. Similarly, milk cartons/food service board must compete with plastic
and glass alternatives.
2.5.5 Paper and Paperboard Grades with Medium Bleached Pulp Content
The following paper and paperboard grades are estimated to contain a medium range of
virgin bleached pulp content (30-50 percent of total fiber).
Coated groundwood. As indicated above, API data sources report shipments for all
coated papers together, regardless of type. In this report, it is assumed that 46 percent of all
coated paper is coated free sheet and that the remainder (54 percent) is coated groundwood
paper.
Coated groundwood is commonly used for printing magazines, directories, and
advertising materials; demand for coated groundwood therefore depends on the circulation of
these materials. Shipments of these papers have grown from 2.0 million to 3.9 million tons over
the period 1973-88, for an increase of 95 percent (see Table 2.16). Coated groundwood is
estimated to contain approximately 60 percent fiber, of which 50 percent is virgin bleached pulp.
Special Industrial Papers. Industrial papers are described in the Dictionary of Paper
(API, 1980) as "Papers intended for industrial uses, as opposed to those for cultural or sanitary
purposes'1. Although a range of paper types is likely to be represented here, shipments data is
reported only for the main category. As was the case for bleached packaging paper, API revised
their definitions for this category in 1981, with the result that shipments trends reported in the
data are related only partly to actual industry occurrences.
According to available data, shipments in 1973 were 650 thousand tons. By 1988, over
1.1 million tons of papers classified in this group were shipped (see Table 2.17).
Tissue. Tissue papers as a class contain close to 100 percent fiber, of which
approximately 50 percent is estimated to be from virgin bleached wood pulp. An additional
30-40 percent, however, is from bleached scrap paper sources, hence the bleached fiber content
of tissue is actually closer to 90 percent.
In 1988, shipments of all tissue grades totalled 5.5 million tons (see Table 2.18),
representing 14 percent of all paper products. Over 95 percent of tissue is used in
manufacturing sanitary products. The non-sanitary grades include wrapping, waxing, and
creped. The main tissue products groups, in order of 1988 shipments volume, are:
2-40
-------
Table 2.16
Shipments o( Coated Groundwood Grades. 1963-1988
Selected Years
('000 Tons)
Year
1963
1968
1973
1978
1983
1988
Shipments [a]
1,310
1,674
2,041
2.376
3,087
3,974
Period
1963-68
1968-73
1973-78
1978-83
1983-88
1963-88
1973-88
% change
27.8%
21.9%
16.4%
29.9%
28.7%
203.4%
94.7%
Note: [a] Based on assumed 54% of all coated paper shipments.
Source: AP11989 Statistics of Paper, Paperboard, & Wood Pulp.
241
-------
Table 2.17
Shipments of Special Industrial Paper Grades. 1963-1988
Selected Years
('000 Tons)
Year
1963
1968
1973
1978
1983
1988
Shipments
314.4
445.8
650.1
551.0
1.052.7
1.185.8
Period
1963-68
1968-73
1973-78
1978-83
1983-88
1963-88
1973-88
% change
41.8%
45.8%
-15.2%
91.1%
12.6%
277.2%
82.4%
Source: AP11989 Statistics of Paper, Paperboard. & Wood Pulp.
2-42
-------
Table 2.18
Shipments ot Tissue Grades 1963-1988
Selected Years
('000 Tons)
Grade
Tissue papers
Sanitary tissue stock
Toilet tissue
Facial tissue stock
Napkin stock
Towelling
Wiper stock
Other sanitary tissue
All other tissues
% change
1963 1963-68
2.576.4
2.340.4
1.054.6
278.4
261.3
662.9
33.1
50.0
236.0
34.1
-------
Toilet tissue (37% of all tissue);
Toweling, including roll and fan-folded paper towels for consumer, commercial,
and industrial uses (34%);
Napkin stock, also for consumer and commercial use (13%);
Facial tissue (6%).
As seen in Table 2.18, tissue shipments have increased over the period 1973-88 from 4.0
million to 5.5 million tons. This represents an increase of 35.6 percent. Toilet tissue, toweling,
and napkin stock have increased by somewhat higher percentages, while remaining grades,
particularly facial and non-sanitary grades, have experienced declines.
In contrast to most papers, sanitary paper products are sold by highly sophisticated and
aggressive advertising programs. In 1980, sanitary paper products accounted for over 70 percent
of all traceable media expenditures of the entire paper industry (Kline & Co., 1980). These
highly developed media techniques contribute to growth in demand by emphasizing the
convenience of products inexpensive enough to discard after one use. In addition, tissue
products are continually improved, developing more expensive grades and therefore higher sales
dollar volumes. Possibly countering this growth is the market saturation of such products as
toilet tissue and an increasing environmental awareness that may lead the consumer to switch
from paper to cloth for some products such as towels.
2.5.6 Bureau of the Census Data
Further data on the percent of paper and board grades that are bleached was obtained
from a special tabulation by the U.S. Bureau of the Census from its Pulp, Paper, and Board
Survey (MA26A). The survey covers all pulp and paper mills in the U.S., and is designed to
collect information on aggregate U.S.shipments of pulp, paper, and paperboard products. The
survey data indicates the minimum quantity and percentage of paper and board grades which are
produced in an unbleached form.
According to the survey, a minimum of about 44% of all paper and board is unbleached.
Specific grades with a relatively high minimum percentage of unbleached shipments include:
construction paper and board (minimum of 97% unbleached), recycled paperboard (89%), solid
wood pulp furnish paperboard (68%), packaging and industrial converting paper (44%), tissue
paper excluding sanitary and thin (28%), newsprint (24%), uncoated groundwood paper (8%),
and sanitary tissue (8%). This information is consistent with the estimates of bleached virgin
pulp content by product that was presented in Table 2.10. For more information regarding the
Bureau of the Census survey, see Appendix 2.D.
2.6 Conclusions
The product segments of greatest interest for this analysis are those that consume the
most chlorine-bleached pulp. Both virgin paper and recycled fibers can be bleached. To
2-44
-------
identify the products that compel the initial use of bleached fibers, this analysis focuses on
products which use bleached virgin pulp rather than bleached recycled pulp.
Estimates of chlorine-bleached virgin pulp usage by product type are, however, not
readily available. In the absence of this data, this report identifies product segments of interest
based on usage of bleached virgin kraft pulp; that is, the sole pulping method considered is the
kraft process and the bleaching method is not restricted to chlorine. Since kraft pulping is the
predominant pulping process and chlorine bleaching is the major bleaching method used for kraft
pulp, the results of the analysis should be representative of all chlorine-bleached virgin pulp.
The estimates of bleached kraft pulp usage, as calculated from Table 2.10, are shown in Table
2.19.
As can be seen from Table 2.19, three market segments use over 85% percent of
bleached virgin kraft pulp. These are: (1) printing/writing papers (58% of total bleached virgin
kraft pulp), (2) solid bleached paperboard (16%), and (3) tissue (13%). Figure 2.5 displays
these percentages graphically. Within printing and writing papers, free sheets use 45 percent
of total kraft bleached pulp - 35 percent is used in uncoated free sheets and 10 percent in coated
free sheets. Within solid bleached paperboard, boxboard uses 12 percent of total kraft bleached
pulp.
The percentages of bleached virgin pulp in a product will not, however, exactly reflect
the percentage of the pulp that is bleached with chlorine. It is likely, for example, that
mechanical pulps will not be bleached with a chlorine process; sodium hydrosulfite and hydrogen
peroxide are generally used for bleaching lignin-rich mechanical pulps (Office of Technology
Assessment, 1989). Therefore, products made from bleached mechanical pulp are likely to have
used less chlorine than products made from bleached chemical pulp.
Both bleached free sheets and bleached boxboard are likely to have been bleached with
chlorine since they are manufactured largely from chemical pulp. By definition, free sheets
contain less than 10% mechanical pulp (though, with recent advancements, mechanical pulp
content may be somewhat higher). Kraft pulp is also the major fiber used in producing bleached
boxboard for the packaging industry (Office of Technology Assessment, 1989). Tissue products
are also manufactured mostly from bleached kraft and sulfite pulps, though all pulp types are
used to some extent. Therefore, the bleaching agent for all three types of paper is likely to be
chlorine. The determination of precise quantities of chlorine-bleached pulp used in these
products requires research beyond the scope of this project. Given the available information,
printing/writing paper (with particular attention to free sheets), tissue, and boxboard will be the
focus of the remainder of the analysis.
2-45
-------
Bleached
PAPER
Newsprint
Printine/Writine Paper
uncoated groundwood
coated groundwood
coated free sheet
uncoated free sheet
thin papers
cotton fiber
bleached bristols
Packaging/Industrial Papers
unbleached kraft
bleached packaging
wrapping
bag and sack
shipping sack
other converting
specialty packaging
special industrial papers
Tissue
toilet
facial
napkins
toweling
other sanitary tissue
all other tissue
PAPERBOARD
Unbleached kraft
Solid bleached
linerboard
boxboard (folding carton and milk
carton & food service)
other
exports
Semichemical papcrboard
Recycled papcrboard
TOTAL
Table 2.19
Virgin Pulp Content by Product
Use of Bleached Virgin
Pulp ('000 tons)
17474
1196
12069
292
1279
2110
7217
195
45
931
1471
0
398
21
224
95
59
510
563
2738
1016
176
349
932
192
97
3248
0
3248
138
2426
184
452
0
0
20722
Type
Percent of Total Bleached
Kraft Virgin Pulp Use
84%
6%
58%
7%
13%
16%
0%
16%
0%
0%
100%
1%
6%
10%
35%
1%
0%
4%
0%
2%
0%
1%
0%
0%
2%
3%
5%
1%
2%
4%
1%
0%
1%
12%
1%
2%
5purce- See Table 2.10.
Ati
-------
Figure 2.5
Bleached Kraft Pulp Consumption bv Type of Product
(Percentage of Total U.S. Bleached Kraft Pulp Consumption bv Weight. 1988)
16%
(3,248,000 tons)
13%
(2,738,000 tons)
13%
(2,667,00 tons)
58%
(12,069,000 tons)
Printing and Writing • Tissue Paper
Paper
Solid Bleached
Paperboard
Other Paper and
Paperboard
Source: American Paper Institute. 1989 Statistics of Paper, Paper Board, and Wood Pulp. Arthur D.
Little, Inc., Exposure and Risk Assessment of Dioxin in Bleached Kraft Paper Products. U.S.
EPA Contract No. 68-01-6951. June 25,1987 Eastern Research Group, Inc. Estimates.
2-47
-------
Chapter 2 References
American Paper Institute, (1989). "1989 Statistics of Paper, Paperboard, and Wood Pulp".
Economic and Financial Service Branch, NY.
American Paper Institute, (1980). The Dictionary of Paper. 4th .Edition. New York: API.
Arthur D. Little, Inc., (1987). "Exposure and Risk Assessment ofDioxin in Bleached Kraft
Paper products". U.S. EPA contract no. 68-01-6951. June 25.
Bureau of the Census, (1989). Current Industrial Report on Pulp, Paper and Board. Survey #
MA26A. November.
Kline & Co., Inc., (1980). "The Kline Guide to the Paper Industry", Fairfield, NJ, Fourth
Edition.
Lockwood-Post, (1989, 1990). "Directory of the Pulp, Paper, and Allied Trades". Miller
Freeman Publications. San Francisco.
Office of Technology Assessment, (1989), "Technologies for Reducing Dioxin in the
Manufacture of Bleached Wood Pulp", OTA-BP-O-54 (Washington, DC: U.S. Government
Printing Office, May).
Pulp and Paper, (1989-1990). Monthly grade reports. Miller Freeman Publications. San
Francisco.
U.S. Department of Commerce, (1990). "1990 U.S. Industrial Outlook", Washington D.C.,
Jan. ISBN 0-934213-10-0.
U.S. EPA, (1990). "Paper Industry Cooperative Dioxin Study, 'The 104 Mill Study', Statistical
Findings and Analyses", Office of Water Regulations and Standards, July 13.
2-48
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CHAPTER 3: CHARACTERISTICS OF BLEACHED PAPER
There are many steps in the process of converting wooo and other cellulose-containing
materials into paper and paperboard products, and each step has some influence on both the
subsequent steps and the final product. The basic steps include pulping, bleaching (if desired),
and papermaking. This chapter discusses pulping and bleaching and describes the technical
requirements that influence whether pulp is bleached, and the specific types of bleaching that
would be appropriate.1
3.1 Factors Affecting Paper Attributes
The characteristics of paper and paperboard (such as weight, color, strength, ability to
absorb or resist water, surface texture, and permanency) depend on a myriad of factors
including:
• the source of the cellulose (hardwood or softwood, virgin or
recycled fibers, and wood or non-wood fibers such as cotton or
grasses),
• the type of pulping and bleaching processes and the chemicals used
in the pulping/bleaching processes and/or added to the pulp,
• the type of paper-making process and the substances added during
this process.
3.1.1 Source of Cellulose
The papermaking process starts with the separation of the cellulosic fibers (usually wood
fibers) from which paper is formed. The source of cellulose has more influence on the strength
of the paper than on the extent of bleaching and brightening; softwoods tend to have longer
fibers than hardwoods and thus produce a stronger paper. The amount and type of
bleaching/brightening undertaken is more a function of the pulping process than of the type of
wood.
In many cases, secondary or recycled fibers that have previously been bleached need little
or no bleaching. It may be necessary, however, to deink the pulp. High-quality recycled office
or white paper needs little deinking and recycled pre-consumer paper may need no deinking.
There is some question, however, as to the number of times fiber can be recycled, as continued
repulping will result in increasingly shorter fibers and therefore a reduction in the fiber strength.
'Appendix 3.A contains further information on pulping.
3-1
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According to current estimates, a paper fiber can be reused six to eight times. For many types
of uses, therefore, a mixture of secondary and virgin fibers is used, and the virgin fiber may be
bleached even when the secondary fiber is not. To the extent that the production of high-quality
white recycled papers depends on the use of bleached office papers as the source of secondary
fibers, recycling may reduce but not eliminate bleaching.
3.1.2 Pulping Processes and Bleaching/Brightening Pulps
The types of chemicals used to bleach, and the extent of the bleaching, varies with the
type of pulping process and the intended use of the pulp. Table 3.1. lists the major wood
pulping techniques and typical end-product uses for the pulp.
The two major pulping processes are chemical pulping and mechanical pulping.
Mechanical pulping uses abrasion of the wood in a grinder or refiner to physically tear the fibers
apart. Mechanical processes tend to produce high yields but pulps of low strength (the fibers
are chopped indiscriminately). The chemical pulping process involves the use of chemicals,
heat, and pressure in a digester to dissolve the lignin (i.e., delignify). Lignin is the
noncarbohydrate portion of the plant cell wall and is responsible for cementing and strengthening
the wood fibers and the coloration of the wood. Removal and bleaching of the lignin is
necessary to allow flexibility of the fibers and reduce discoloration of the paper with age.
Chemical processes tend to produce pulps of high strength because the fibers are
chemically separated, not ground. However, chemical pulping processes have low yields due
to removal of the lignin. The two main types of chemical pulping processes are the sulfate or
kraft process and the sulfite process. These differ in that the kraft process produces a very
strong brown pulp, while the sulfite process produces a less strong but lighter colored pulp.
Bleaching Related to Types of Pulping
Most of the pulp and paper industry's chlorinated organic contaminants, including dioxin,
originate in the bleaching processes. A wide range of bleaching and caustic washing sequences
may be used to bleach and brighten pulp. The choice of which bleaching agents, and in what
sequence, is generally determined by the pulp characteristics desired, such as brightness and
strength, balanced against capital and operating costs. Molecular chlorine has become the
preferred bleaching agent because of its relatively low cost and high effectiveness.
Bleaching is used to purify and whiten pulp by chemically altering the coloring matter
or by removing the lignin. The less lignin retained, the brighter the paper and the longer the
paper will last without yellowing and becoming brittle. The whiteness of pulps is generally
measured in terms of the amount of a nearly monochromatic light it reflects; the higher the
number, the more light reflected. Since one of the most commonly used meters for measuring
brightness is made by General Electric, one common brightness measure is referred to as the
GE number. Unbleached pulps generally exhibit the following GE brightness levels:
3-2
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Table 3.1
Major Wood Pulping Technologies
Pulp Grades
Wood Type
End-Use Product
Chemical Pulps
Sulfite Pulp
Kraft Sulfate Pulp
Dissolving Pulp
Softwoods and Hardwoods
Softwoods and Hardwoods
Softwoods and Hardwoods
Fine and Printing Papers
Bleached - Printing and
Writing Papers, Paperboard
Unbleached - Heavy
Packaging papers,
Paperboard
Viscose Rayon, Cellophane,
Acetate Fibers, Film
Semichemical Pulps
Cold-Caustic Process
Neutral Sulfite Process
Softwoods and Hardwoods
Hardwoods
Newsprint and Groundwood
Printing Papers
Newsprint and Groundwood
Printing Papers
Mechanical Pulps
Stone Groundwood Softwoods
Refiner Mechanical Pulp Softwoods
Thermomechanical Pulp Softwoods
Corrugating medium
Newsprint and Groundwood
Printing Papers
Newsprint and Groundwood
Printing Papers
Source: Technologies for Reducing Dioxin in the Manufacture of Bleached Wood
Pulp: Background Paper, Congress of the United States, office of
Technology Assessment, May 1989, p. 18.
3-3
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Sulfite up to 65
Groundwood 40 to 60
Kraft, Semichemical 25 to 35
It is interesting to note that the two chemical pulping processes produce the pulps with
the highest and the lowest brightness levels. Sulfite pulps are used predominately in fine writing
and printing papers, so the initial high brightness levels are very desirable. The sulfite process
is not more widely used, however, because it is limited in terms of the types of wood that can
be used and because there are greater environmental controls on the by-products of this process
than on kraft processes. In particular, the sulfite process produces significant amount of sulphur
dioxide. Some kraft pulp is used for printing and writing papers, and the amount has grown as
kraft bleaching processes have advanced.
There are two basic methods to increase the brightness of pulp. The first method is to
use bleaching agents that destroy at least a portion of the colored compounds without
significantly reacting with the lignin. This method is used to brighten pulps with high lignin
content, such as groundwood and semichemical. In these cases, significant delignification is not
desirable since high yields are desired from these pulping methods. However, brightness values
above GE 70 are difficult to achieve without delignification. Substitution of bleached mechanical
pulps for bleached chemical pulps on a large scale, therefore, is not likely for uses which require
a high brightness level. In the past, much of the mechanical pulp was not bleached, but the
bleaching of groundwood has increased and improved technology now enables bleached
groundwood pulp to be used for printing papers, tissue and toweling. Chemicals used to destroy
coloring impurities include: sodium bisulfite, calcium or sodium hypochlorite, and hydrogen or
sodium peroxide.
The second method includes complete or near-complete removal of the lignin remaining
after chemical pulping, followed by further bleaching of the pulp to a desired degree of
brightness. Conventional bleaching of kraft and sulfite pulps involves three principal types of
reactions:
• Chlorination under acid conditions (pH 2-4),
• Alkaline extraction, to remove the dissolved lignin (pH 10-11.5),
• Further brightening using hypochlorites, chlorine dioxide, and/or
hydrogen peroxide.
Brightness values of 80 and higher may be attained without adverse impacts on pulp
strength using hypochlorites for final bleaching. Selective use of chlorine dioxide in place of
hypochlorites permits brightness of 90 and above.
3-4
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Bleaching Impacts on the Quality of Pulp
While high brightness is a valued characteristic of bleached pulp, strength is another
important papermaking characteristic that can be adversely affected by the amount and type of
bleaching. Additional papermaking characteristics that can be affected by bleaching are: density,
viscosity, and freeness. Density is a measure of the weight per given volume, viscosity
measures the degree to which a solution of the pulp resists flowing, and freeness measures the
rate at which water drains from the pulp in the papermaking process.
A critical determinant in choosing a bleaching chemical is the "selectivity" of the agent.
Selectivity refers to the capacity of the chemical to attack lignin while doing minimal damage
to the cellulose fibers. A selective chemical will increase brightness while not reducing the
strength of the pulp. Unbleached kraft pulp (brown stock) contains relatively high levels of
lignin in the initial stages of bleaching, and therefore less selective chemicals (e.g. oxygen and
chlorine) can be used at this stage of the bleach cycle. As delignification occurs, however, a
greater proportion of the non-selective chemical is available to react with the cellulose, adversely
affecting the strength of the pulp.
Since the 1930s, molecular chlorine has been the predominant chemical used for the
delignification of pulp. It is both effective and economical to use. If used improperly, however,
it can result in loss of pulp strength. Hypochlorite is another bleaching chemical that is easy to
make and use but which can result in loss of pulp strength if used improperly. Oxygen
deliginification requires expensive equipment and also can result in loss of pulp strength. On
the other hand, chlorine dioxide and hydrogen peroxide are highly selective; they react rapidly
with lignin but affect cellulose very little, thus affecting pulp strength minimally. Both
chemicals, however, are expensive, and chlorine dioxide must be made at the mill site (Clement
Associates, 1989).
Bleaching Sequence
The impact of these chemicals on pulp strength and brightness varies, depending on when
in the bleaching sequence and with which other chemicals they are used. There are two phases
to bleaching chemical pulp: delignification and extraction, which are carried out in alternating
acid and alkaline stages. Between adding the acidic bleaching chemicals, which continue the
delignification process begun in the digester, alkaline chemicals are added to extract the
dissolved lignin from the fibers. The first delignification and extraction stages of a normal
bleach sequence constitute pre-bleaching and all subsequent states are referred to as the final
bleach (U.S. EPA, 1990).
The standard abbreviations used to describe the different bleaching chemicals and types
of types of bleaching stages in a bleach plant are:
3-5
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Bleach Stage • Description
O Oxygen delignification. Oxygen is applied in an alkaline environment
under pressure prior to chlorine bleaching for partial delignification.
Linked with the pulping chemical recovery system.
C Chlorine or C-Stage. Chlorine Dioxide (D) may be added in the C-Stage.
E Caustic extraction or E-Stage. Oxygen (O), Sodium Hypochlorite (H), or
Hydrogen Peroxide (P) may also be used in the E-Stage.
H Hypochlorite or H-Stage.
D Chlorine Dioxide or D-Stage.
P Hydrogen Peroxide or P-Stage
Z Ozone or Z-Stage.
Conventional bleaching sequences are typically CEHED or CEDED, where molecular
chlorine is applied in the first bleaching stage, followed by caustic extraction, hypochlorite or
chlorine dioxide bleaching, a second extraction stage, and a final bleaching stage. The more
recent trend has been toward short sequence bleaching with chlorine dioxide substitution for
some portion of the chlorine in the C-Stage, and use of oxygen in the E-Stage, or (CD)(EO)D.
(When more than one chemical is applied in one bleaching stage, the chemical with the highest
usage is listed first.) A mill that uses oxygen delignification prior to bleaching would be
characterized as O(CD)(EO)D or, O(DC)(EO)D, depending upon the degree of chlorine dioxide
substitution (Amendola, 1990b).
Prebleach - Delignification
The first bleaching stage(s) are designed to remove most of the lignin (delignification)
and involves little improvement in the brightness of the pulp. Removing the bulk of the lignin
minimizes the volume of more expensive bleaching chemicals (e.g. chlorine dioxide,
hypochlorite, and hydrogen peroxide) needed in the later stages. Molecular chlorine has been
the preferred chemical for the prebleaching process. Chlorine reacts selectively with lignin,
under normal bleaching conditions does little harm to cellulose fibers, and is relatively
inexpensive.
There is a trend toward modifying the first chlorination stage by including other
bleaching agents (e.g. chlorine dioxide either mixed with, or in sequence with, the chlorine).
Inclusion of these chemicals can reduce cellulose degradation, improve pulp strength, and reduce
environmental releases. While chlorine dioxide can be used to completely replace molecular
chlorine in the prebleaching stage, it has two significant drawbacks. First, it is more expensive
3-6
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than molecular chlorine. Second, it can not achieve pulp brightness equivalent to that produced
by molecular chlorine.
An additional modification is to use oxygen as a delignifier prior to the chlorination
stage. Oxygen is an effective delignifier and reduces the amount of bleaching chemicals needed
in subsequent stages. Another variant is to use hydrogen peroxide with oxygen. Peroxide acts
as a good delignifier and significantly reduces the amounts of chlorine, chlorine dioxide and/or
hydrogen peroxide needed in subsequent stages.
Extractive Stages
Between each bleaching stage the pulp is washed with an alkali extraction solution to
remove the dissolved lignin. Oxygen gas added to the sodium hydroxide in the extraction stage
decreases the kappa number (amount of lignin), conserves chemicals in subsequent bleaching
stages (reducing the number of bleaching stages in some cases), and reduces the loss in pulp
strength.
Adding peroxide to the extraction in addition to oxygen further increases the lignin
removal: using oxygen alone in the extraction stage results in 10 to 15 percent delignification,
while adding peroxide (0.3-0.4%) to this stage results in 30 to 35 percent delignification.
Peroxide is most effective when used with ozone, oxygen and/or chlorine.
Final Bleach Delignification for Brightening Stages)
Chlorine dioxide is very selective and produces high brightness pulp. Chlorine dioxide
is generated as a gas at the mill and dissolved in cold water. Because of its high cost, it is
commonly used at or near the end of the bleaching sequences, in addition to its use in
conjunction with chlorine in the first stage.
Peroxide is a very effective cellulose-preserving bleaching agent and is well suited for
improving the brightness of highly lignified pulps, such as mechanical groundwood and chemi-
mechanical pulps, without significantly reducing yields. It is used in the intermediate stages of
the bleaching sequence as a replacement for hypochlorite or chlorine dioxide, and it is frequently
used as the last stage in the bleaching sequence where it can add a few points of brightness to
the pulp and improve its brightness stability. Peroxide alone is a relatively ineffective means
for bleaching kraft pulp. However, when used in sequences with chlorine-based bleaching
agents, peroxide is an efficient delignifier and brightener.
Hypochlorite was used for bleaching before the development of chlorine bleaching
technologies, and about 40 percent of North American mills still use at least one hypochlorite
stage in their bleach sequence. It is most appropriate for sulfite mills; kraft pulps are more
difficult to bleach and require a chlorine and alkaline extraction stage to be added to the
sequence. Until chlorine dioxide and peroxide processes became available in the 1940s, kraft
pulps of 85 brightness were the brightest that could be produced with hypochlorite bleaching
3-7
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while maintaining acceptable pulp strength. These pulps, however, had poor brightness stability.
One possibly significant drawback to the use of hypochlorite is its apparent link to the production
of chloroform. The specific conditions and reactions contributing to the production of
chloroform are not well known, however, and more research is needed to establish causation.
Ozone is a very powerful bleaching and oxidizing agent. The decomposition of ozone
into oxygen after bleaching produces neither a residue nor undesirable inorganic by-products.
In a bleaching sequence with hydrogen peroxide, ozone can produce high-brightness pulps. In
conjunction with preliminary oxygen delignification, ozone may reduce the amount of chlorine
and hypochlorite used in the bleaching sequence. Ozone bleaching is particularly well suited to
bleaching sulfite pulps because of their low residual lignin content. High-brightness, high-
quality, hardwood kraft pulps can be produced by using ozone in the first stage of the bleaching
sequence. The first commercial ozone-based pulp bleaching process has been announced by
Union Camp for its Isle of Wight, Virginia paper plant. According to company officials, this
unit will completely eliminate the use of molecular chlorine. With the Union Camp OZED
sequence, ozone (Z) will be used in place of chlorine and chlorine dioxide in the first bleaching
stage to bleach southern pine. The company plans to use chlorine dioxide for final bleaching.
The line is scheduled to be placed in operation in 1992. In addition, Union Camp expects to
license the process to other paper companies on a royalty basis and has received inquiries from
several groups (Chemicalweek, 9/5/90).
Distinctions Between Using Reduced Levels of Chlorine, Molecular Chlorine-free
(MCF) Bleaching, and Totally Chlorine-Free (TCF) Bleaching
As indicated by data in the Section 308 National Census, many mills are reducing their
use of chlorine through increased substitution of chlorine dioxide, oxygen delignification, or
other methods (see Table 1 in the Executive Summary). For example, adding an oxygen
delignification stage (e.g., an O-C-E-D sequence) could reduce the quantity of chlorine needed
in comparison to a traditional chlorine sequence. The feasibility of reducing levels of chlorine
often depends on the fiber source, pulping process and pre-bleaching pulp treatment. For
example, many secondary fiber mills conduct mild bleaching using chlorine or hypochlorites at
rates substantially less than necessary for bleaching virgin kraft pulps. Also, the amount of
chlorine used to bleach sulfite pulps is often less than the amount used to bleach kraft pulps.
Finally, there are differences in chlorine application rates for bleaching kraft hardwood vs. kraft
softwood pulps, and for bleaching oxygen delignified kraft pulps vs. conventional kraft pulps.
Hence, it is important to consider relative use of chlorine in the context of the fiber source,
pulping process and pulp treatment prior to bleaching with chlorine.
Buckeye Cellulose in Oglethorpe, Georgia, is an example of one mill implementing
complete substitution of chlorine with chlorine dioxide. The resulting pulp, therefore, is MCF.
An example of an MCF bleach sequence is OD(EO)D, using oxygen delignification to minimize
chlorine dioxide consumption. Note, however, that while molecular chlorine is not directly
3-8
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applied, a chlorine compound in the form of chlorine dioxide (D) is used in the first bleaching
stage as well as in a subsequent bleaching stage. Therefore the pulp is MCF, not TCP.2
A TCP bleaching sequence would most likely require some form of extended
delignification in the pulping process followed by oxygen delignification prior to bleaching.
Many, if not most, U.S. mills would require major pulping and bleach plant modifications to
accommodate such changes on a retrofit basis. Currently, no U.S. mills are known to be
bleaching TCP kraft pulps. There were no such mills when the 104 Mill Study was conducted
in 1988. Recently, the Louisiana-Pacific mill in Samoa, California adopted plans to begin
production of TCP kraft pulp as part of a settlement agreement with the EPA, the Department
of Justice, the State of California, and the Surfriders Foundation.
3.1.3 Paper-making
Bleached and unbleached pulps are further processed to obtain desired qualities in
finished paper, such as proper surface, opacity, strength, and feel. Pulp is prepared for
formation into paper by mechanical treatments, called beating and refining. Generally, beating
and refining make the finished paper stronger, more uniform, more dense, more opaque, and
less porous.
About 70 percent of the paper produced is sized to resist penetration of liquids, either
internally as the paper is being made on the paper machine, or externally after the paper sheer
is formed. Rosin, rosin size, emulsified waxes, fortified sizes, bituminous emulsions, latex,
silicones are examples of paper sizes used. They are usually applied with various precipitants
including alum, sodium aluminate and others in specific proportions to impart the desired degree
of sizing.
Fillers are added to most papers to improve texture, print quality, opacity, brightness and
to affect certain physical properties such as pore size (for filterability), porosity, burning rate
(for cigarette papers), and formability. Fillers can also have adverse effects on finished paper
quality including increase in softness, loss of strength, reduction in pick resistance (a printing
quality), or two-sidedness, which is a difference in paper qualities on opposite sides of a sheet.
Fillers commonly used include clays, silicas, talc, and certain inorganic chemicals - calcium
sulfate, barium sulfate, zinc sulfide and titanium dioxide.
Many papers are colored through the addition of inorganic and organic dyes and
pigments. Shade control of the paper product can be affected of addition of dyes and pigments,
pH control, mechanical adjustments in beating and refining, the use of fillers, the type of pulp
used, and other mill procedures. Dyes and pigments are added before the paper is formed for
most products.
Depending upon the method of manufacture of chlorine dioxide, some molecular chlorine
may also be present.
3-9
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For many types of paper, the grade of the paper depends in part on its brightness level.
For example, according to standards published in Walden's Handbook, premium bond paper has
brightness levels between 90 and 92, while number 5 bond paper has brightness levels from 79
to 82. As shown in Table 3.2, the brightness level of paper varies across grades. Generally,
groundwood papers have lower brightness levels than free sheets and are not considered to be
high quality papers. It is the brightness standards established for the highest grades that
chlorine-free paper may be unable to meet.
3.2 Summary
As described above, several production processes impact the performance qualities of
paper. Table 3.3 summarizes the manufacturing processes that correspond to specified paper
performance qualities. The manufacturing processes listed in the table are those which generally
correspond to listed paper characteristics; however, the most effective process will vary with the
specific end product. Further, the listed individual manufacturing processes may not be optimal
when integrated.
From the table it can be seen that to maximize paper strength a softwood furnish is
desirable as is a kraft bleaching process. In particular, it is interesting to note that while
chlorine bleaching improves permanence and brightness, it is detrimental to paper strength.
Also, bleaching, whether chlorine based or not, adds to the production costs of the paper.
Building on Table 3.3, Table 3.4 presents performance requirements for major paper
products as well as the preferred production processes given these requirements. While the
preferred processes are not always those actually used in the production of these products, they
are most likely to be used based on the product performance requirements.
Since there is no single relationship between the use of chlorine and the type of paper
products produced, there are no simple responses to the question of whether or not chlorine is
needed in making paper. From a technical perspective, it is possible to make any type of paper,
broadly enough described, without molecular chlorine. That is, it is possible to produce some
form of tissue, printing/writing paper, boxboard, etc. without chlorine. However, whether the
products produced without chlorine would meet the quality demanded by the market at an
acceptable price is less clear. To further complicate the issue, the use of chlorine by the paper
industry is in a very fluid situation at the moment. As the concern over the generation of dioxin
has increased, new technologies that reduce the use of chlorine are being developed. The
current situation can be described in terms of the major findings of this chapter.
• The extent of bleaching, and the bleaching chemicals used, are a
function of the type of pulping process and the intended end-use of
the pulp. To a lesser degree, bleaching depends on the type of
wood used.
3-10
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Table 3.2
Paper Brightness Levels
Grade Levels
White Business Papers (All 20#)
Bond
Premium
Number 5
Mimeo
Number 1
Number 5
Duplicator
Number 1
Number 5
Groundwood
Xerographic
Number 1
Number 4
Roll-Copy
Number 1
Number 4
White, Coated Web Offset Papers (All 80#)
Glossy Finish
Premium Double
No. 4 Single
Dull Finish
Premium Double
No. 4 Single
Matte Finish
Premium
No. 5
Brightness
(GE)
90-92
79-82
85-89
79-81
85-89
79-81
75-78
89-90
83-84
89-90
83-84
93
73-78
93
73-78
93
72-below
Opacity
84
88
88
89
88
86
91
88-89
91-92
88-89
91-92
96
95
96
95
96
94
3-11
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Table 3.2, cont.
Paper Brightness Levels
Grade Levels
White, Coated Offset Paper
Glossy Finish (70#)
Premium Double
No. 5 Single
DuU Finish (70#)
Premium Double
No. 5 Single
Matte Finish (80#)
Premium
No. 5
White, Uncoated Offset Paper (60#)
Premium
No. 2-Opaque
No. 1-Offset
No. 5-Offset
Groundwood
White, Coated Letterpress Paper
Glossy Finish
No. 1 (70#)
No. 4 (60#)
No. 5 (40#)
Groundwood No. 1 (40#)
Groundwood No. 3 (40#)
White, Coated Gravure Paper
No. 5
Brightness
(GE)
86-91
72-lower
86-91
72-lower
93-94
72-below
95-97
87-89
85-87
80-82
69-72
85
71
69-70
72-74
64-67
70#
70-71
Opacity
95
92
90
96
94
94
94
93
92
96
95
95
90
88
86
80#
95
Source: Walden's Handbook, Second Edition; Walden-Mott Corporation, Oradell,
New Jersey; Copyright, 1981.
3-12
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Table 3.3
Relationship of Selected Pulp and Paper Performance Qualities to Manufacturing Processes
Quality Performance
Requirements Preferred Furnish1
Preferred Pulping
Process
Preferred Bleaching
Process
Preferred Coatings & Preferred Beating &
Sizings Refining
MECHANICAL CHARACTERISTICS
Strength Softwood
Tensile
Bursting
Tearing Resistance
Folding Endurance
Chemical
Kraft
Unbleached
West str. Resins,
rosin size, Increased
Starch Increased
Decreased
Increased
APPEARANCE PROPERTIES
Brightness HW/SW'
Opacity HW/SW
Gloss HW/SW
Chemical
Sulfite
Mechanical
NSSC2
Chemical
Kraft
Sulfite
See opacity, dependent
upon product
Chlorine-based
CEHED
(CD)(EO)D
O(CD)(ED)D
0(DC)(EOP)D
Others
See brightness,
dependent upon
products
See brightness,
dependent upon
product
TiOj No effect
Dyes
Fillers, Decreased
Dyes
Fillers No effect
Coatings
BARRIER AND RESISTANCE PROPERTIES
Moisture Resistance HW/SW
Chemical
Kraft
Sulfite
No effect
Internal sizing No effect
(rosin size-alum, wax
emulsions, synthetics)
External sizing
(starches, gums,
glues, polyvinyl
alcohol)
Polyethylene,
Polyvinylidine
1. HW/SW indicates either hardwood or softwood.
2. Neutral Sulfite Semi-Chemical.
-------
Table 3.3, cont.
Relationship of Selected Pulp and Paper Performance Qualities to Manufacturing Processes
Quality Performance
Requirements
Permanence
Absorbency
Economy
Sources:
Preferred Furnish1
HW/SW
HW/SW
Preferred Pulping
Process
Chemical
Kraft
Chemical
Kraft
Sec. Fiber: Hydro-pulping
high grade deinking,
boxboard
Virgin Fiber:
SW
Mechanical
groundwood
Preferred Bleaching
Process
Chlorine-based,
See above
Sulfite
No effect
Single stage (Ca.
hypochl.)
Unbleached
Unbleached
Preferred Coatings
Sizings
Alkaline or neutral
sizes and fillers
Wetting agents
None
None
(1) Smook, G.A., Handbook for Pulp and Paper Technologists, Joint Textbook Committee of the Paper Industry, TAPPI,
Atlanta, Georgia, 1982.
(2) Scott, S.E. and Trosset, S., Properties of Paper: An Introduction, TAPPI, Technology Park/Atlanta, Atlanta, Georgia,
(3) Walden's Paper Catalog, Walden-Mott Corporation, Oradell, New Jersey, Spring 1990.
(4) Walden's Handbook, Walden-Mott Corporation, Oradell, New Jersey, Second Edition, 1981.
(5) Tappi Proceedings - 1989 Papermakers Conference, TAPPI Press, Technology Park/ Atlanta, Atlanta, Georgia, 1989.
& Preferred Beating &
Refining
Decreased
Decreased
None
None
Technology Park/ Atlanta,
1989 (ISBN 0-89852-052-5)
I
£
indicates either hardwood or softwood.
Sulfite Semi-Chemical.
-------
I
H^
Ul
Table 3.4
Performance Requirements and Preferred Production Methods by Major Grade
Product
Performance
Requirements Preferred Furnish'
Preferred Pulping
Process
Preferred Bleaching Preferred Coatings &
Process Sizings
PRINTING GRADES
Newsprint
Publication
Bond,
Ledger
Stationery
Runnability, HW/SW
Printability,
Appearance
Brightness (68-72)
Cleanliness
Opacity
Moderate Strength
See Newsprint HW/SW
Brightness (72-88)
See Newsprint HW/SW,
Brightness (79-92) Rag
Appearance HW/SW
Brightness Rag
Opacity
Strength
Stiffness
Erasability
Ink Resistance
Surface Texture
Permanence
Mechanical &
Chemical
Sulfite
Kraft SW
Mechanical &
Chemical
Chemical
Kraft
Sulfite
Chemical
Sulfite
Kraft
None Variable
None
Semi-Bleached
None or Semi-Bl. TiO2, clay, synthetics
Semi-Bleach to Fully
Bleached
Fully Bleached Variable
Fully Bleached Internal Size
Top size
Fillers
1. HW/SW indicates either Hardwood or Softwood.
-------
Product
Bleached Bags,
Wrapping, Food
Packaging
Greaseproof,
Glassine
Performance Requirements and
Table 3.4, cont.
Preferred Production Methods by Major Grade
Performance Preferred Pulping
Requirements Preferred Furnish1 Process
Strength HW/SW
Stiffness
Brightness
Cleanliness
Grease Resistance HW/SW
Water Resistance
Kraft
Sulfite
Preferred Bleaching
Process
Fully Bleached
Unbleached
Preferred Coatings &
Sizings
Variable
Variable
PAPERBOARD
Corrugating
Medium
Linerboard
Boxboard
Stiffness Hardwood
Economy
High Strength Southern Pine
Appearance
Printability
(one surface)
See Linerboard Southern Pine
Semi-chemical
Kraft
Kraft
Unbleached
Unbleached
Unbleached to Fully
Bleached
Variable
Variable,
Wet Strength
Variable,
Wet Strength
1. HW/SW indicates either Hardwood or Softwood.
-------
Table 3.4, cont.
Performance Requirements and Preferred Production Methods by Major Grade
Product
Performance
Requirements
Preferred Furnish1
Preferred Pulping
Process
Preferred Bleaching
Process
Preferred Coatings &
Si zings
I
H^
•vj
Toweling
Absorbency
Water-Holding
Capacity
Bulk
Strength - Wet
Formation
Appearance
Softness
HW/SW
Sec. Fiber
Sulfite
Kraft
Mechanical
Unbleached to Fully
Bleached
Wetting Agents
Creped Wadding
See Toweling
HW/SW
Sec. Fiber
Sulfite
Kraft
Unbleached to Fully
Bleached
Variable, Wetting
Agents
Sources:
(1) Smook, G.A., Handbook for Pulp and Paper Technologists, Joint Textbook Committee of the Paper Industry, TAPPI, Technology Park/Atlanta,
Atlanta, Georgia, 1982.
(2) Scott, S.E. and Trosset, S., Properties of Paper: An Introduction, TAPPI, Technology Park/Atlanta, Atlanta, Georgia, 1989 (ISBN 0-89852-052-5)
(3) Walden's Paper Catalog, Walden-Mott Corporation, Oradell, New Jersey, Spring 1990.
(4) Walden's Handbook, Walden-Mott Corporation, Oradell, New Jersey, Second Edition, 1981.
(5) Tappi Proceedings • 1989 Papermakers Conference, TAPPI Press, Technology Park/Atlanta, Atlanta, Georgia, 1989.
1. HW/SW indicates either Hardwood or Softwood.
-------
Mechanical pulps tend to not be bleached; when
bleached, chlorine is seldom used as the agent.
Due to their high lignin content, which is both an
advantage (high yields) and a disadvantage (low
brightness, rapid yellowing, and low durability),
mechanical pulps tend to be used for printing papers
which do not require good quality color
reproduction nor durability, such as newspapers and
catalogs.
Chemical pulping processes produce strong pulps,
containing little lignin. They are often bleached;
the sulfite pulps need less bleaching than the kraft
pulps.
• There currently are alternatives to chlorine, but they tend to have
drawbacks in terms of being: -
more costly (e.g., chlorine dioxide and hydrogen
peroxide),
less effective (e.g., hypochlorite), and/or
potential sources of other pollutants (e.g.,
hypochlorite may produce chloroform).
• New technologies are being developed in North America and
Europe that may result in cost-effective alternatives to the use of
chlorine. An example is the new Union Camp mill that will rely
on the use of ozone.
• All of the non-selective bleaching elements (e.g., chlorine and
oxygen) may weaken the pulp by destroying cellulose if used
improperly.
• The movement towards the use of secondary fibers has reduced the
amount of bleaching necessary, especially when high-quality office
or white paper is recycled.
• A major industry response to the relationship between the use of
chlorine and the generation of dioxin has been to substitute
chlorine dioxide for chlorine. Since chlorine derivations may still
produce chlorinated organic pollutants, more research is needed to
determine if this shift is desirable.
3-18
-------
There are at least 19 processes that can reduce the use of chlorine:
12 of these technologies are available, with the remaining 7
emerging as viable technologies. Nine of the technologies are
changes in pulping processes, and ten are bleaching process
changes (U.S. EPA, 1990).
3-19
-------
Chapter 3 References
Amendola, Inc., (1990a). "Preliminary Report: A Paper Market Study, Characteristics of
Bleached Pulp". Draft, prepared for the Regulatory Impacts Branch, Office of Toxic
Substances, U.S. EPA, August 17.
Amendola, Inc., (1990b). "Paper Market Study, Characteristics of Bleached Pulp: Response
to EPA Questions". September 10.
Chemicalweek, (1990). "Doing with Less Chlorine", September 5, page 15.
Clement Associates, Inc., (1989). "Dioxin Production in the Pulp/Paper Industry, Revised,
Draft Report", prepared for the Regulatory Impacts Branch, Office of Toxic Substances, U.S.
EPA, October 31.
Office of Technology Assessment, (1989). "Technologies for Reducing Dioxin in the
Manufacture of Bleached Wood Pulp: Background Paper", May.
U.S. EPA, (1990). "Summary of Technologies For The Control And Reduction Of Chlorinated
Organics From The Bleached Pulping Subcategories Of The Pulp and Paper Industry", Office
of Water Regulations and Standards and Office of Water Enforcement and Permits, April 27.
Walden's Handbook, (1981). Walden-Mott Corporation, Oradell, New Jersey, Second Edition.
3-20
-------
CHAPTER 4: CHARACTERIZATION OF MARKETS FOR UNBLEACHED
AND ALTERNATIVELY BLEACHED PAPER PRODUCTS
This chapter characterizes the United States markets for products made from unbleached
and alternatively bleached paper and paperboard. For comparison purposes, information on
European markets is also presented. A variety of sources were used, including contacts with
approximately 10 industry experts and environmental groups.
The chapter is arranged into six major sections. The first describes a variety of
unbleached and alternatively bleached products currently available on the market, with emphasis
on three product groups: printing and writing, tissue, and bleached paperboard. Together, these
groups consume over 85 percent of the bleached pulp used by the paper industry. The second
section characterizes both the personal and commercial consumer groups, and the third section
characterizes markets for unbleached vs. alternatively bleached products. The fourth section
describes the German and Swedish markets. The fifth section describes market, economic, and
technological factors that may inhibit industry's adoption of alternative bleaching processes. The
final section describes future trends.
4.1 Commercially Available Unbleached or Alternatively Bleached Paper Products
Table 4.1 lists examples of unbleached or alternatively bleached paper products
commercially available in the United States, arranged by grade. The products were identified
through a literature review and a series of telephone conversations with mill operators, paper
distributors and retailers, environmental groups, and other industry experts. Further discussion
of the grade categories follow the table.
The paper grades presented are those that use at least one percent of the bleached kraft
pulp produced in the United States. The table lists the desirable qualities of each grade, the
major uses of the paper, examples of commercially available unbleached or alternatively
bleached products, major purchasers of these products, and the production processes. In
addition to the type of bleaching chemicals used, the whiteness/brightness of paper can be
affected by: the pulping process (e.g., sulfite pulps tend to be significantly brighter than kraft
pulps), the furnish used (e.g., type of wood and/or type of recycled paper), and the coatings and
fillers used to make the papers. Several of the products in Table 4.1 have adjusted these other
factors in conjunction with changing and/or eliminating their bleaching agents. All of the
products listed have been produced without the direct use of molecular chlorine.1
Manufacturers of most of the alternatives listed on the table reduced or eliminated the use of
'Although molecular chlorine was likely used to bleach paper contained in recycled paper
feedstocks, mills listed as using recycled paper as feedstocks did not themselves use molecular
chlorine to rebleach the recycled pulp.
4-1
-------
"< fable 4*1 Paper and Baperboard Grades Containing Virgin Bleached Pulp* and Commercially Available Unbleached or
?^^^^£1^&$:?&&?*<&*''"''£* >',**, Alternatively Bleached Products - -
,>*&^<^:j
:%f^£,f^^'
v^% -H^ ,W4-€^V^
^ f s* ^ •• o-X^
;j5JSi^
JJ/.'Ss^vJht '
', ," sfxx/ ,s ^ ,,'
%v.S>;;^t;;v,
•S-V^S X%. t^y»%^. / */»*''« » S '
v-?-<-^-^ ^''k^'A*5- -,
x*" « *> V ? * /• ••
•. 5 ; '
•• % *•
\ %
'
%,'?' ^ ' " ' 'v ' '
Major Uses of fisper
^leadfe*.' - -
Examples of Couunercjalfy
Available Unbleached or.
Alternatively Bleached Products4
Major Purchasers4
Alternative Process
Used**
High Bleached Pulp Content (75 to 90 percent of total fiber)
C^atod Free Sheet
*•» J/ ..-.' 'S^ s , 5 si
^ ",J #'*-;'- '
••"•Is '^ ',/A < ', \
\ \y- *', ,/, *w.
^Wfa^tf^fifajft
s > \ . «. •• ;
5"\^ V % ,
•.s
-------
Tabk
'ape* and Paperboard Grades Containing Vir,
Alternatively
cached Pulff and Commercially Available Unj^fched or
died Products ^^
^,||^?^^1;;
Form Bond
Carbonless
AkMrtft
K&ft^r;
-
7
2
:^;;,^^;;, "-",
|^Cfi:l
good perforating,
folding, punching, and
manifolding properties
able to make legible
reproductions via a
chemical transfer of
pigment due to impact
from typing/writing
,
"*• f *•
Major, ttoes «f Paper v
<3ifaditr - ;
.^
printed business
forms/invoices. Most
common use is carbon
interleaved multi-part
computer printout paper
which is marginally
punched, cross perforated,
and fanfolded
used primarily in producing
typewritten multiple copies
for business forms
s
Examples of Commercially -,
Holman (Sweden)
Cascades, Inc (Montreal, Canada)
Ecofiber (sand and white)
James River (Camas, WA) Natural
Copybond
Rolland Inc. (St Laurent, Quebec)
New Life Dual Purpose
..
Major Purchasers*
commercial -
distributed by
American Paper Sales
(NY, NY) mainly to
environmental
magazines and
universities
commercial,
government -
distributed through
Paper Choice
Recycled Paper Co
(Vancouver)
Alternative Process
virgin pulp bleached
with hydrogen
peroxide
unrebleached
recycled paper
unbleached virgin
paper
hydrogen peroxide
bleached 100%
recycled content
4-3
-------
V Table 4,1 J^apet and Paperboard Grades Containing Virgin Bleached Pulp* and Commercially Available Unbleached or
^ &^vh&'' &L"*± ^LJ. i',.:. . *' * ' •: '> Alternatively Steadied Products - -
%^K«^i
if^l^^B^-
Cover and Text
Paper
:M;|f|;'>
1
& f •> ^x -.^ .. V' ' ^•" * /• ' ^ v
X • ss "'•<$ "" * f'*<: - 't
>'*^>f&kl'A'*
%vMv^?''V-' \ /
^ ^,'^W"/r-r,/ '-/;
5^ ^v%^ ^ V ^ •• •''•> '
3i?46»^%Qtt^Wef> - *, ^
good folding qualities,
printability, and
durability
""--' - .: *
,- < 'r;
-- -f .. , » ,
Major ^«6s «f fttper
^Irad^v., -,'"
covers of books,
magazines, catalogs,
brochures, photomounts,
pamphlets
Examptes of Cmrnaemaliy
Available tlabteached or
Abetoativety BJeacfc&a Product^
Alte Schule photo albums, diaries
Domtar Sandpiper
Simpson (US) Quest
Patriot paper (Hyde Park, MA) -
several lines of paper
Major Purchasers'*
personal - sold
through health food
stores, environmental
catalogs
commercial and
personal - sold retail
to small, medium, and
large businesses and
nonprofits by
Recycled Paper
Company (Boston,
MA), and to
consumers through
catalogs and health
food stores by
Atlantic Recycled
Paper (Baltimore,
MD)
commercial - sold
retail to small,
medium, and large
businesses and
nonprofits by
Recycled Paper
Company
commercial - sold
retail to small,
medium, and large
businesses and
nonprofits by
Recycled Paper
Company
: Alternative Process
1 Used4*
unrebleached, non-
deinked 100%
recycled content
100% postconsumer
non-deinked
hydrogen peroxide
bleached
100% postconsumer
non-deinked non-
chlorine bleached
recycled paper, 10%
postconsumer non-
chlorine cleaning
washing bleaching
system
-------
fable '£' fc>lR'^"^ s,,£ x ." ' ^ '" Alternatively MRfeed Products ^^
'•2 •*'',/&', /* ' '/% '/"
S^^l'-rW
Offset
**&*'**"
&*' /' rf
Vlfcfe'a
j*%$*f,"$' ' *' * %»* * ^ v ' s
* __^ ^ ' •">
''••'•' '* ',
>* <• ''- ^ * "- s>s ''' -
' ^ ^.-> '% w f "^ f S & ^
^W^
*<• ' ' ••
'f ' ""
Mftjor Usos of J^aper
%<3»d^ ,
book papers, magazine, all
kinds of papers suitable for
use with offset lithography
Examples of CommerciaUy
Available Unbteacberf or
Alternatively Bfeaehed Products*
Mohawk Paper
P.M. Gladfelter (Neenah, WI)
Recycle 100
P.H. Gladfelter
Cross Pointe (Miami, OH) uncoated
free sheet
Steinbeiss (Germany) Recyconomic
Domtar
M^of Purclittsers^
personal consumers -
sold through catalogs
and health food stores
by Atlantic Recycled
Paper
personal and very
small businesses -
distributed through
Earth Care (Madison,
Wl)
commercial - used in
outdoor
fashion/equipment
catalogues
commercial -
distributed by
International Paper
(US), and by
Recycled Paper
Company
personal - distributed
by Atlantic Recycled
Paper Co.
>
Alternative Process
Osed**
recycled paper,
either unrebleached
or bleached with
hydrogen peroxide
unrebleached '100%
recycled content
100% pre consumer
recycled content,
bleached with
sodium hypochlorite
60% average
recycled content,
bleached with
sodium hypochlorite
unrebleached or
hydrogen peroxide
bleached non-
deinked 100%
recycled paper.
100% postconsumer
recycled content,
non-deinked,
unrebleached
4-5
-------
Tabte 4 ' ''^ ' - J ; S '
strength, smooth fold,
strength at crease, good
printability, lack of
tendency to curl or
cockle
fairly good writing
surface, uniform caliper,
resistant to erasing
abrasion
"• v f '•
Major tfeo* of Faper
envelopes
writing tablets
carbon paper,
cigarette paper,
condenser paper,
Bible paper,
manifold paper
Bxaraple»of0orainercialiy - :
Available tlabteaehed or : •
Afienuttivery Bleached Product^ i
Holman printing paper
Domtar
Tri-State
Steinbeiss Recyconomic
Diversified Packaging Products
writing tablets
FSC Paper legal pads
/
personal and
commercial - supplied
by American Paper
sales to mainly
nonprofits and
universities for
newsletters,
magazines, etc.
personal - distributed
by Atlantic Recycled
Paper Co.
personal - distributed
by Atlantic Recycled
Paper Co.
personal - distributed
by Atlantic Recycled
Paper Co.
personal consumers -
distributed through
Seventh Generation
(Colchester, VT)
personal - distributed
by Atlantic Recycled
Paper
Alternative Process
ttsed**
Oxygen bleached
virgin paper
100% postconsumer
recycled content,
non-deinked,
unrebleached
100% recycled
content,
unrebleached
100% recycled,
bleached with
hydrogen peroxide
unrebleached
recycled paper
100% postconsumer
recycled paper
unrebleached or
bleached with
hydrogen peroxide
4-6
-------
Table
'aper and Paperboard Grades Containing VI
Alternatively
leached Pulp* and Commercially Available
felled Products
~'?v w, "" *-<"i -'*"',
;>A"~ 'Ml-
/ /"W <"n*s
'Vf^'<* , *'''••
x ?>t?uC"«'
s^V-?''"* V'"'^v '
^^t^M v;>
"•f'V^'"--^^"^-^
?$it*ii'',, --il- '% ^'
Coated Bristol
|f|^m;|^ ^ff|fflff^f^''
.fiiffff!^ ? ••'' * ••••'&
Bag and Sack
Spgeiaitv Paekflautt
^ifflHf ' ''' ' , '
-y^.-^, "".
; ' 'f < ' ' "• ' /
^ * -"' ^^-'
Toilet
|^fea*^i;
fotaj " ,;-
fileaciwf .•>•
-«Wk/^;
-3*^S
;^t|^^
4
1
2
1
2
13
5
Xs JS.-« / < , /
^ -^^,, ->*
S -• ' % K.%
', * •• j J ' ' 0
,- ^- , ; - >-"'
>• ;,:' 3& •:•• "
y. x",:: vU--.< £'/,'"•-..
*<"•. ' ,'/-, '--•• " '
\fc4tflfr*M*tr* ""
durability
softness, absorbency,
cleanliness, adequate
strength
softness, absorbency,
cleanliness, adequate
strength
V
Mejor Uses of Paper
^fade*"' ;' •'
index cards, records, cards,
menus, announcements,
folders, advertising cards
posterboard and postcards
grocery bags.sack paper
toilet paper
Bxorapfes of ConuHerdaify
Avaitebte Uttbleftctte
-------
Table 4.1 Paper and Paperboard Grades Containing Virgin Bleached Pulpa and Commercially Available Unbleached or
Alternatively Bleached Products
£>/',,,/.••• V?;^Y '
"> '"' ,,i '''"';',".,* '/'
' ' !<£ ''„+'-
J*'\ ^, '•''''•• s' ' *ff
,'$/?': f ' ',€-"- ''£,
i
•^ '/" >
«•• ^ ^
.• 5 ^ ^^-^ %
^ % , ' ' ^ ' % ^
«s s'*'' ' s ^^
-'C]^ £ \' V, ' ~,
/I^I^Quafeta^ - \
softness, absorbency,
cleanliness, adequate
strength
, s -
"•
'
y ajo* t/ses of I'aper
<2r«
-------
Table 4^fc?aper and Paperboard Grades Containing Virgj^fceached Pulpa and Commercially Available Unt^fcied or
* AJ.* JKL . * v* „ ; < u»l \ , . . Alternatively Hehed Products ^
.^ % "• v v. ..« y- . ? ••
*
& -5- , , " V» - ,
^" ^-^^-o s?
,<^<&\> -:*;, ,
>s^<^ .v X- S ^ v ^-X %
S $£* \ • '•. \>s^
•4; x--»s ' - « 5 ^ -*
^" ^> '" '%£ ,J%-^ ?fsvtt
$$$$!!*$!$&*£»•
Napkins
V&rtof
Total ^<
':.Btea.cli'^
x - - }? ' ' ^ ' 's %
- ^Jt *% 4 ^"- v/-
„,-- ^ s*>%, ^\A -'-
^^Qiad^e^,?;/ %
softness, absorbency
M ftjor Ifses of Fapef
<3«ad:«^ ;
napkins
Examples of Camroeraally :
AvaUtible Unbleached; or
Alternatively Steadied Brodnct^
Fort Howard Product 100
Fort Howard Envision
Wisconsin Tissue Second Nature and
Seventh Generation dinner napkins
Orchid Paper Co. Caroline*
Major Purdbaseirs?
mainly commercial,
some personal
consumers -
distributed in stores,
catalogs, and to large
companies by
distributors and
brokers
mainly commercial,
some personal
consumers -
distributed in stores,
catalogs, and to large
companies by
distributors and
brokers
personal and
commercial -
distributed by Seventh
Generation, retailed
commercially to
commercial and
industrial users by
WT
personal and
commercial -
distributed by Asdun
Industries and Today's
Choice
Alternative Process
Cteetl**
unrebleached 100%
recycled content
100% recycled
content
bleached with
hypochlorite
hydrogen peroxide
bleached 100%
recycled content
hydrogen peroxide
or unbleached
4-9
-------
Table 4.1 Paper and 1
Toweling
4
3at>erboard Orades Containing Virgin Bleached Pultf and Commercially Available Unbleached or
V% \..\ ,' - Alternatively Bleached Froducts
;-, J^/l'^,; ' ..
fast absorbency, water
holding capacity, tear
resistance, softness,
freedom from lint and
unpleasant odors
Major tfett dac«* ..
Fort Howard Product 100
Fort Howard Envision
Wisconsin Tissue Seventh
Generation
Wisconsin Tissue
Scott Paper
Orchid Paper Co. Caroline'
Major Purchasers4
personal and
commercial
consumers -
distributed in stores,
catalogs, and to large
companies by
distributors and
brokers i.e., Recycled
Products Company
and Atlantic Recycled
Paper
mainly commercial,
some personal
consumers -
distributed in stores,
catalogs, and to large
companies by
distributors and
brokers
personal - distributed
by Seventh Generation
commercial - retailed
by WT to airports,
restaurants, industry
personal and
commercial -
distributed by Asdun
Industries and Today's
Choice
Alternative Process
Used**-
unrebleached 100%
postconsumer
recycled content
unrebleached or
bleached with
hypochlorite 100%
recycled content
unrebleached
recycled paper
bleached with
hydrogen peroxide
recycled paper
hydrogen peroxide
or unrebleached
recycled paper
hydrogen peroxide
or unbleached
-------
laoie 4^praper ana raperooara uraaes containing virgj^peacneu Fuiptt and commercially Available untuned or
<4#^f - ^^7 -f* ,Vfc';*'A* ";> " ''-- Alternatively flKfced Produce ^^
Other Sanitary
Tissue
•pi'
j&Mtfe^'
i
*,%%\, ', - , , JV
-------
«, Table 4 A Paper and Paperboard Grades Containing Virgin Bleached Pulp* and Commercially Available Unbleached or
'/-.,,„,', ,-,,, , ,,< , , , <, , > Alternatively Bleached Products
/'« ''' ' '**',. V--, i
f f f x
IJaperfooArd •;:; "
,§;gK, - ^|t ;
Linerboard
Folding Carton Type
Board
Milk Carton and
Food Service
Other
' •• ^ - , ' 5
•XrVIKM .j,
JnraroiiffjffjBy .• "'
16
1
7
5
1
,. *• .•"•
' •" ~"f "* <•
v i.yfttfjl-ftMj TjltftiH-B^Sr %*'
foldability, appearance,
stiffness
strong, tough,
waterproof, usually
plastic coated, able to be
formed into cartons, taste
Major tfees of l^aper
Orade* ,
used as the facing material
in corrugated or solid fiber
shipping containers
boxes set up, filled, and
used by the end user
cartons for milk and other
liquid beverages, butter, ice
creams
\
Examples of Conunerdally
Available Unbleached or
Alternative^ Bleached JProdtw*^
Total Marketing Co (Pleasant Hill,
CA) sanitary napkins
Universal Health Care Products
(Canada) sanitary napkins
Melitta coffee filters
Mr Coffee coffee filters
Natural Brew (Little Rapids, Little
Rapids, WI) coffee filters
Caroline (Orchid Paper Co., La
Palma, CA) coffee filters
Inland Container Corporation
(Ontario, CA)
Inland Container Corporation
ASSI (Sweden) milk cartons
Glenn Foods (NY) lollipop stick
Major Purchasers*
personal - distributed
by Today's Choice
personal - distributed
by Seventh Generation
personal and
commercial
personal and
commercial
personal and
commercial -
distributed by
Rockline (Sheboygan,
WI)
personal and
commercial -
distributed by Asdun
Industries and Today's
Choice
commercial
commercial
commercial and
personal
personal
Alternative Process
Used**
recycled paper,
bleached with
hydrogen peroxide
recycled paper,
hydrogen peroxide
bleached
unbleached
bleached without
molecular chlorine
unbleached
hydrogen peroxide
or unbleached
Monox-L with virgin
pulp
Monox-L with virgin
pulp
unbleached virgin
pulp
unbleached virgin
-------
Table ^Bpaper and Paperboard Grades Containing Virgj^fceached Pulpa and Commercially Available UnJ^fcted or
£kV*'"-'# TS?T -, *» £ /' ; - ,;y. Alternatively fflKfeed Products ^^
Hi
Exports
#' 'rtftrf'
S5
2
.V' " -
li/^:#^'"
% f
V
MftjoirUseiJofFapef
Examples of Commercially
Available Uflbteacaed or
Altettmtivdy gfeacfced JProdact^
Major Purchasers4
Alternative Process
Used**
Medium Bleached Pulp Content (30 to 74.9 percent of total fiber)
|^|^y^'
'lH '''-$'
y ,. v ^ ^ f f * S*
*JtJfajfa&.'.*
-------
molecular chlorine by using recycled paper as a feedstock and either not rebleaching or
rebleaching with sodium hypochlorite or hydrogen peroxide.
Paper recycling and alternative bleaching are linked for at least two reasons. First,
recycled paper feedstocks that have been bleached once do not require nearly as much bleaching
as virgin feedstocks to achieve the same brightness levels. Mills using recycled paper as a
feedstock can use weaker bleaching chemicals, or smaller amounts of bleaching chemicals, than
would be required to bleach virgin pulp. By using non-deinked recycled pulp as a feedstock,
virtually any pulp and paper mill can produce unbleached pulp or paper without major
conversion costs or time delays (Resource Recycling. May 1990).
Second, consumers demanding unbleached or alternatively bleached paper often also want
recycled paper. So far, the primary consideration for environmental consumers has been
recycled content, with the bleaching process being an important, but secondary, consideration.
Although not exhaustive, Table 4.1 indicates the presence of many unbleached or
alternatively bleached paper products in the United States as of early 1992, many of which exist
in categories of paper that have typically been chlorine bleached.
Conclusions that can be drawn from Table 4.1 include the following:
• There are unbleached or alternatively bleached products in each of the three paper
categories currently using large quantities of bleached virgin kraft pulp.
• Alternative products sold in the United States are being produced domestically,
as well as in Canada and Europe.
• Reduced molecular chlorine use in pulp bleaching is being achieved by:
using recycled fibers without rebleaching;
using recycled fibers and bleaching with fewer chemicals than are required
to bleach virgin fibers;
bleaching with a chlorine compound (e.g., sodium hypochlorite); and
bleaching with a chlorine alternative, (e.g., hydrogen peroxide and
oxygen).
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The following subsections describe only the paper grades listed in the table for which
unbleached or alternatively bleached products were identified.2
4.1.1 Coated Free Sheet
Coated free sheet uses 10 percent of the bleached kraft virgin pulp used in the United
States. Its main use is for printing in high quality advertising, brochures, magazines, and books.
Desired qualities include good printability, color, smoothness, opacity, and a quality surface
(API, 1980). Mohawk Paper Mills is developing an unrebleached or hydrogen peroxide
rebleached coated free sheet from recycled paper.
4.1.2 Uncoated Free Sheet
Uncoated free sheet is the single largest user (35 %) of the bleached kraft virgin pulp used
in the United States. It includes bond and writing, form bond, carbonless, cover and text,
offset, white wove envelope, and tablet papers. Used mainly for printing, writing, and related
applications, historically the desired qualities of uncoated free sheet included printability, color,
smoothness, opacity, quality surface and permanence (API, 1980). With the advent of
widespread computer use, however, much of the uncoated free sheet used by universities,
businesses, and the government is for short term, disposable uses, such as draft reports or
internal memos. These purposes do not require the extremely high brightness or permanence
of high quality papers, and represents a large potential market niche for alternatively bleached
or even unbleached paper (H.A. Simons, 1991).
Current producers and distributors are having varying success in selling alternatively
bleached or unbleached uncoated free sheet. A distributor of printing papers found unbleached
grey paper "really hard to sell" to mainstream commercial businesses. He found, however, that
selling MCF bleached paper was much easier. He felt that "people would love to buy totally
chlorine-free bleached alternatives that gave them the quality they wanted if that was an option".
A spokesman from Earth Care indicated that all of their unbleached or alternatively bleached
paper lines were quite successful among environmental consumers. In fact, their Minimum
Impact paper line (unbleached, 100% post-consumer recycled content) was their top seller, used
mainly by environmentalists and nonprofits for producing their newsletters.7
Bond and Writing Papers
Bond and writing papers comprise nine percent of the bleached kraft virgin pulp used in
the United States. These papers are characterized as having superior strength, performance,
Additional grades for which no products were found are omitted from the discussion;
therefore, percentages may not sum to total usages expressed in Section 4.1 subsections.
7For a more detailed discussion of consumer and commercial markets, see Section 4.2.
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durability, printability, erasability, whiteness, cleanliness, freedom from fuzz, uniform finish,
and good formation (API, 1980). Historically, bond and writing papers were used for legal
documents, bonds, stationery, insurance policies, letterheads, business forms, data sheets,
collection books. Now, however, the bond and writing papers also include office paper such
as copy and printer paper (API, 1980). Manufacturers of alternative products include Alte
Schule, Domtar, Holman, Cascades, Inc., James River, and Holland, Inc. Most of the
alternatively bleached papers are made from recycled paper feedstocks and are either
unbleached, unrebleached, or rebleached with hydrogen peroxide. In addition, Domtar adds
grey or cream dye to its non-deinked unrebleached recycled pulp to obtain a consistent color.
Holman, a Swedish paper company, is one of the few producers found to make paper by using
virgin pulp bleached with hydrogen peroxide. The American distributor of the paper, American
Paper Sales, has reported a substantial increase in demand for the paper in 1990. The main
purchasers of the paper have been environmental magazines and universities.
Seventh Generation, a catalog company selling environmentally friendly products, has
decided to drop its entire line of recycled and alternatively bleached office papers. A
spokeswoman from Seventh Generation felt that the line did poorly not because people were
uninterested in recycled and alternatively bleached papers, but because too many conventional
office suppliers had gotten into the market niche. As she explained, "lots of people sell
environmental lines at this point; it's no longer lucrative for our catalog".
Paper in Motion, a distributor of recycled bleached, unrebleached, and hydrogen peroxide
bleached office papers to large companies, found that large corporations tended to purchase
bleached paper out of habit and a belief that whiter is better. Wholesalers, however, are often
more willing to buy tan or unbleached paper.
j
Cover and Text Paper
Cover and text papers account for one percent of the bleached kraft virgin pulp used in
the United States. Cover papers require good folding qualities, printability, and durability.
They are used for book, magazine, and catalog covers, as well as for brochures, photomounts,
and pamphlets. Text paper requires fine quality and texture for printing, and is used for
advertising, booklets, brochures, announcements, fine books, annual reports, menus, and folders
(API, 1980). Several examples of alternatively bleached cover and text papers contained
recycled paper feedstocks either unrebleached or bleached without chlorine. Two of the sample
manufacturers of the alternatively bleached cover and text paper did not deink the pulp.
As with other writing and printing papers, the success of marketing cover and text papers
depends on the type of purchaser, and whether or not the paper is bleached. A distributor that
targets environmental consumers and sells only recycled and mainly unbleached papers said the
paper lines are "very successful; this is what people are looking for". Even among staunch
environmentalists, however, there is still a desire for white paper. In 1990 Greenpeace, for
example, reported using sodium hypochlorite bleached white paper for their magazine because
they found that color photos did not show up well on off-white paper.
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Offset Paper
Offset paper uses nine percent of the bleached kraft virgin pulp used in the United States.
It is characterized as having good internal bonding, high surface strength, dimensional stability,
lack of curl, and freedom from fuzz and foreign surface material. As the name implies, offset
papers are used in offset lithography to produce books, magazines, and other printed materials
(API, 1980).
The unbleached and alternatively bleached offset papers found were manufactured in
Germany (Steinbeiss), Canada (Domtar), Sweden (Holman), and the United States (P.H.
Gladfelter, Cross Pointe). All papers except Holman's were produced from recycled paper
feedstocks, and were either unrebleached or rebleached with sodium hypochlorite or hydrogen
peroxide.
White Wove Envelope
White wove envelope uses three percent of the bleached kraft virgin pulp used in the
United States. It requires qualities of strength, smooth fold, strength at crease, good printability,
and lack of tendency to curl or cockle. As its name implies, the paper grade is used to make
envelopes. Domtar, Tri-State, and Steinbeiss manufacture alternatively bleached envelopes sold
in the United States. All three make envelopes from unrebleached recycled paper feedstocks;
Steinbeiss also produces a hydrogen peroxide bleached recycled paper line.
Tablet
Tablet paper uses one percent of the bleached kraft virgin pulp used in the United States.
Made into writing tablets, it requires a fairly good writing surface, uniform caliper, and
resistance to erasing abrasion (API, 1980). Two alternatively bleached writing tablets were
found: one made of unrebleached recycled paper, and another with unrebleached or hydrogen
peroxide rebleached dyed recycled paper. Both are sold mainly to environmental consumers
through catalogs; the unrebleached, undyed paper reportedly sold poorly, while the yellow-dyed
paper sold well. Seventh Generation found that their unbleached undyed writing paper, now
discontinued, did not sell well because "it's grey and it soaks up ink. People don't like using
it".
4.1.3 Tissue
Tissue papers use 13 percent of the bleached kraft virgin pulp used in the United States.
Desired qualities include softness, absorbency, cleanliness, and adequate strength. Bleached
tissue is used to make toilet tissue, facial tissue, napkins, paper towels, and other sanitary tissue.
To date, tissue grades have been the most successful grades among the unbleached and
alternatively bleached commercially available products. Alternatively bleached tissues have sold
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particularly well to commercial purchasers and environmentally concerned consumers. Several
companies that target environmental consumers report that their unbleached and hydrogen
peroxide bleached tissues are their top sellers. In addition, Wisconsin Tissue, which produces
hydrogen peroxide rebleached recycled tissue, napkins, and paper towels, reported strong
success selling to commercial and institutional purchasers.
The mainstream retail market, however, still demands bright white tissue. Wisconsin
Tissue uses chlorine bleach for some products they retail because they cannot get products
sufficiently white with hydrogen peroxide and "consumers demand it". Sorg Paper Company
also found that institutional purchasers are more tolerant than retail customers of tissue that is
less bright or white. Sorg produces toilet paper from unrebleached, non-deinked recycled pulp.
As a spokesman from Total Marketing Co. (a tissue manufacturer) explained, "In our
business, clean and sanitary translates to white". Although they have recently introduced a line
of hydrogen peroxide bleached products, they find that most consumers are not concerned with
the difference in bleaching process. "[People] would rather buy the Bounty brand of paper
towels with polyester fibers for strength than buy a lesser performing environmental brand".
In sum, the general public still wants soft, white tissue. For alternatively bleached tissues to
gain a larger market share, manufacturers must either produce products of the same quality as
those produced with molecular chlorine, or they must convince retail consumers to accept off-
white tissue.
Because tissue manufacturing in the United States is highly concentrated, any change in
marketing will depend on the actions of a small number of companies . The top five companies
control 75 percent of the market; the top ten companies control 93 percent of the market
(Canadian Forestry Service, 1988) (see Table 4.2). The top companies have a reputation as "the
world's leaders in tissue paper machine technology, converting technology and innovative
marketing" (Canadian Forestry Service, 1988). If the top 10 tissue producers were to convert
to totally chlorine-free (TCP) bleaching technologies, the tissue market would shift dramatically,
decreasing the use of bleached kraft pulp in the United States by approximately 12 percent.
Several of the top producers, notably Fort Howard and Scott Paper, already produce unbleached
and alternatively bleached tissue lines.
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Table 4.2
Top Ten United States Tissue Producers, 1987
Company Capacity (1000 tpy)* Market Share (%)
Scott Paper
James River
Proctor and
Gamble
Fort Howard
Georgia-Pacific
Kimberly-Clark
Erving Paper Mills
Pope and Talbot
Chesapeake
APL
Total for Top Ten
Source: Canadian Forestry
* tpy = tons per year.
940
916
816
771
490
393
136
134
100
86
4,782
Services, 1988.
18.3
17.9
15.9
15.0
9.6
7.7
2.7
2.6
1.9
1.7
93.3
Table 6.2.
Toilet
Toilet tissue uses five percent of the bleached kraft virgin pulp used in the United States.
Its desired qualities include softness, absorbency, cleanliness, and adequate strength.
Distributors found that mainstream consumers decided unbleached toilet tissue was not soft
enough, nor looked "clean" enough, as defined by its whiteness. As one distributor explained,
"only the diehards buy grey toilet paper". Another distributor who wanted to carry unbleached
toilet tissue was discouraged from doing so by other suppliers who said it did not sell well.
However, as mentioned before, unbleached and alternatively bleached tissues, including toilet
tissue, were top sellers for distributors selling to environmental consumers. The unbleached
toilet tissues found in this investigation were all made from unrebleached recycled paper, and
appear to be sold mainly to environmental and commercial or institutional buyers. Toilet tissues
made from virgin or recycled pulp bleached with hydrogen peroxide or sodium hypochlorite
have entered the mainstream retail market as well.
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Facial
Facial tissue comprises one percent of the kraft bleached virgin pulp used in the United
States. Similar to toilet tissue, its desired qualities include softness, absorbency, cleanliness, and
adequate strength. The issues of whiteness and softness that apply to toilet tissue also apply to
facial tissue, and the purchasers appear to be the same as well. Most of the facial tissues found
were made from recycled pulp, and were either unrebleached, or rebleached with hydrogen
peroxide or sodium hypochlorite. The tissues are being sold to both personal and commercial
purchasers.
Napkins
Napkins make up two percent of the kraft bleached virgin pulp used in the United States.
They require softness and absorbency. The same producers making unbleached or alternatively
bleached toilet and facial tissues also make unbleached or alternatively bleached napkins. The
napkins found were generally sold on the commercial market, with some personal consumers
as well.
Toweling
Paper toweling makes up four percent of the kraft bleached virgin pulp used in the United
States. It requires fast absorbency, water holding capacity, tear resistance, softness, and
freedom from lint and unpleasant odors. Towels are sold in rolls or fanfolded for the personal
and commercial markets. As with napkins, paper towels are made as a part of an unbleached
or alternatively bleached tissue line. Most of the paper towels found used recycled paper
feedstocks and either did not rebleach or rebleached with hydrogen peroxide or sodium
hypochlorite. Wisconsin Tissue noted that the whiteness standards for toweling were lower than
for napkins, stating, "People are more willing to accept a high dirt count in brown paper
toweling than in napkins".
Other Sanitary Tissue
Other sanitary tissues make up one percent of the kraft bleached virgin pulp used in the
United States. Absorbent and bulky, they are used for sanitary, disposable purposes. Products
included in this category include handiwipes, diapers, sanitary napkins, and coffee filters.
Unbleached coffee filters have been particularly successful in mainstream markets. For
example, Melitta began marketing unbleached coffee filters in July, 1989. After only 10 months
on the market, the unbleached filters accounted for IS to 20 percent of all of Melitta's coffee
filter sales, and as much as SO percent in some west coast markets (U.S. EPA, 1990a). A paper
manufacturer said that all coffee filter manufacturers are moving away from molecular chlorine
bleaching processes, mainly to chlorine dioxide.
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4.1.4 Solid Bleached Paperboard
Solid bleached paperboard is another significant use of kraft bleached virgin pulp,
accounting for 16 percent in the United States. This category includes linerboard, folding carton
type board, milk cartons and food service, and miscellaneous paperboard. Several sources have
pointed out that molecular chlorine was not necessary to achieve the desired qualities required
by the market. One paper expert from Resource Recycling states that "there is generally no
reason to use bleached board". The exception to this is for very greasy foods and milk where
the FDA has concerns over contaminant leaching.
Inland Container Corporation is switching to a MCF MONOX-L8 bleaching system for
its entire production of bleached virgin pulp and paperboard. Because they have found no
difference in quality between the products bleached with MONOX-L and those bleached with
molecular chlorine, they find that their MCF products occupy the same market niche as the
molecular chlorine bleached products did. Inland did not feel any impetus to advertise the
change because they found that people were more concerned with recycled content than with
bleaching processes.
Linerboard
Linerboard makes up one percent of the bleached kraft virgin pulp used in the United
States. It is used as the facing material in corrugated or solid fiber shipping containers. Desired
qualities include strength and durability. The percentage of the materials being bleached has
been increasing in order to include advertising print on boxes. Inland Container Corporation
makes virgin bleached linerboard without using molecular chlorine.
Folding Carton Type Board
Folding carton type board makes up seven percent of the bleached kraft virgin pulp use
in the United States. It is used to make boxes that are set up, filled, and used by the end user.
Requirements include foldability, appearance, and stiffness. Inland also makes virgin bleached
folding carton type board without using molecular chlorine.
8MONOX-L is hypochlorous acid (HCLO) plus an additive developed and patented by
Quantum Technologies. Hypochlorous acid (L), the hydrated form of chlorine monoxide, has
been known since the 1930s as an excellent bleach chemical, however, it has not been used as
it is destructive to the pulp. Quantum's developed additive maintains bleaching characteristics
without pulp destruction. In many ways, MONOX-L can be compared to chlorine dioxide due
to its bleaching condition and abilities. The process equipment metallurgy required for
MONOX-L is reported to be the same as that needed for chlorine dioxide (U.S. EPA, 1990b).
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Milk Carton and Food Service
Milk carton and food service paperboard use five percent of the kraft virgin pulp made
in the United States. Usually plastic coated, it is required to be strong, tough, waterproof, able
to be formed into cartons, and flavorless. These cartons are used to hold liquids and foods such
as milk, juices, butter, and ice cream.
Although unbleached milk cartons are produced and used in Sweden, no unbleached or
alternatively bleached milk cartons were found in the United States. Based on conversations
with the Milk Industry Foundation and one dairy, there appears to be a belief that the paper
industry has successfully eliminated risk resulting from dioxin leaching from milk cartons to
milk. Given this understanding, these two sources were not concerned with developing further
changes in the bleaching method used for milk cartons. According to the United States Food
and Drug Administration, the most exposed individual's risk from leached dioxin into milk is
below one in one million cases per lifetime.
Given that mill effluents or sludge may result in increased environmental or health risks,
however, the question remains whether or not molecular chlorine bleached milk or food cartons
are required. According to STFI, a Swedish corporation, milk cartons used in Sweden are no
longer bleached with molecular chlorine; oxygen, chlorine dioxide, and/or hydrogen peroxide
are used to bleach the cartons. Another Swedish company, ASSI, produces milk carton grades
that are completely unbleached. ASSI coats the unbleached cartons with clay to achieve a bright
surface and coats the interior to avoid any imparted taste from the paper. They have
experienced no problems with taste for milk sold in unbleached cartons, a stated concern of
American producers.
In addition to concern about possible taste problems, there is the perception in the
United States that white is clear and pure. As a United States dairy representative commented,
"The whiteness of the carton elaborates on the purity of the milk. White milk from a brown
carton is unappealing". The Swedish experience, however, demonstrates that 1) molecular
chlorine is not needed to produce white cartons, and 2) a consumer market exists that is
receptive to unbleached milk cartons. The acceptability of unbleached milk cartons in the United
States is as yet unknown.
4.1.5 Coated Groundwood
Coated groundwood uses six percent of the kraft virgin pulp made in the United States.
It is characterized as having good printing quality, color, smoothness, opacity, and a quality
surface. This paper is used for commercial printing for high quality advertising, brochures,
magazines, and books. The only alternatively bleached paper in this grade found was a light
magazine grade made by Weyerhaeuser, with chlorine dioxide bleached virgin paper.
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4.1.6 Newsprint
Newsprint uses six percent of the kraft virgin pulp made in the United States. It is
mainly used to print newspapers, flyers, catalogs, and directories. Newsprint has low bleaching
requirements, and is composed of approximately 25 percent bleached pulp and 75 percent
unbleached pulp (see Table 2.10). Because newsprint does not require high brightness, it can
be readily produced without molecular chlorine. Some newspapers, however, such as USA
Today, are starting to use "improved" or "upgraded newsprint" requiring increased brightness
and opacity. The demand for "improved" newsprint is expected to grow as newspapers
increasingly compete with television for an audience (Canadian Forestry Service, 1988). One
source suggested combining thermomechanical pulping with hydrogen peroxide bleaching and
inorganic fillers to achieve the higher standards without using chlorine (Canadian Forestry
Service, 1988).
4.2 Paper Market: Consumer Groups
The paper market can be divided into two main consumer groups: personal and
commercial. The personal market includes papers purchased through retail outlets or catalogs
for home and office use. The commercial market includes all types of paper and paperboard
grades bought wholesale or retail for businesses and institutions. The distinguishing feature
between the two is that the personal market is composed of individual consumers buying small
quantities for personal use, while the commercial market is characterized by professional
procurers buying large quantities of paper. For some consumers, such as small businesses, this
distinction is blurred.
4.2.1 The Personal Market
Comments from distributors who sell paper through retail outlets or catalogs to personal
consumers illustrated two distinct personal consumer markets. One group, a small, very
environmentally-aware segment of the population, buys MCF or TCP bleached paper out of a
concern for and commitment to environmental and health issues. They actively seek out and
request unbleached or alternatively bleached products, particularly for printing and writing
papers and tissue papers. One consumer survey conducted by a paper distributor found them
to be "more affluent, well-educated, environmentally conscious consumers". For them,
"unbleached tissue is the number one seller in [our] whole catalog". In fact, the distributor
reported receiving many calls requesting unbleached paper before they carried it. Earth Care,
a paper distributor that targets environmental consumers, reports that its best selling product is
its Minimum Impact line, a 100 percent post consumer unrebleached recycled paper. The
general public, however, is not aware of or concerned with the differences in bleaching
processes. Unbleached grey paper alternatives are very hard to sell to this group.
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4.2.2 The Commercial Market
Distributors felt that small- and medium-sized corporations are concerned that using grey
or off-white paper would hurt their image. Exceptions can be found in some nonprofits and
outdoor equipment retailers. In addition, one commercial distributor found that wholesalers
were often more willing than large businesses to buy unbleached paper. A very large
corporation with an established market share could use the switch to unbleached or alternatively
bleached paper as a public relations tool to enhance its environmental image. McDonalds, for
example, has enhanced its image by switching to unbleached recycled paper packaging.
In addition to a concern with image, distributors said that inertia plays a role in American
companies' failure to switch to unbleached or alternatively bleached paper. For example,
although most of the high quality paper purchased by an office is used internally (and therefore
does not affect a corporation's public image), companies are not used to buying or using
unbleached or alternatively bleached paper. The perception that "white is better", coupled with
a lack of knowledge of or concern with paper bleaching processes, inhibits the switch to MCF
or TCP office paper, even for uses where white paper is not essential (such as draft reports or
internal memos). Several experts felt that it would take the very large corporations to establish
a trend by switching to unbleached or alternatively bleached paper before the small- and
medium-sized companies would feel comfortable doing so.
4.3 Paper Market: Unbleached versus Alternatively Bleached
Demand for unbleached paper differs from demand for papers bleached with alternative
processes. The only group in the United States shown to be buying unbleached grey paper
products is what one distributor termed the 'diehards'. This group will actively seek out
unbleached or alternatively bleached paper products out of a concern that chlorine bleaching is
linked to dioxin production. For this group, paper that is unbleached is a value-added
commodity, and they will pay a premium to buy it.
Among personal consumers in this group, unbleached tissues are selling better than
unbleached writing papers. Unbleached writing and printing papers are used mainly by nonprofit
organizations for their newsletters. Personal users are characterized as those having a strong
concern for the environment. As a spokesperson from Seventh Generation described them, they
are the "cutting edge environmental consumer," the people who were looking for recycled
content paper 5 to 10 years ago. As mentioned above, the general public is reluctant to buy
grey unbleached paper because "it doesn't look right". People expect white paper even on
products where bleaching does not affect the function of the product (i.e.,.file folders).
Distributors agreed that alternatively or bleached products outsell unbleached papers. In
general, unbleached writing and printing papers have more market limitations than do
alternatively bleached paper. They are limited to fewer paper grades; i.e., they cannot be sold
as the highest brightness papers, and they reportedly do not work with some copiers.
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Alan Rooks from the Paper Industry Management Association felt that the first
unbleached products to be accepted by the general public would be "sensitive" products
perceived to directly affect human health: coffee filters, diapers, etc. In fact, unbleached coffee
filters have done quite well among the general public (e.g., Melitta, Rockline Natural Brew
Coffee Filters). According to one manufacturer, all coffee filter producers are voluntarily
moving away from molecular chlorine bleaching.
Surprisingly, many companies are choosing not to advertise their products as unbleached
or alternatively bleached. In the majority of paper catalogs examined, no mention was made of
bleaching processes, even in cases where the bleaching agent was not chlorine or the product
was unbleached. Paper manufacturers may be reluctant to highlight any aspect of the bleaching
process, particularly if most of them are switching processes, thus eliminating any competitive
advantage. In addition, many manufacturers are producing chlorine bleached products in
addition to MCF or TCP products and may therefore be hesitant to publicize the chlorine issue
and risk reflecting negatively on their other products. One paperboard manufacturer said that
his company did not advertise their conversion to MCF bleaching because he thought that it was
not a strong enough selling point.
H. A. Simons, a Canadian research firm, and AF-IPK, a Swedish company, are currently
preparing a comprehensive analysis of the future of paper markets (H.A. Simons, 1991). Their
summary of the potential market for alternatively bleached paper products is as follows:
In markets such as North America and Western Europe, there are signs that
consumers are, increasingly, favoring papers made from TCP bleached pulp. We
believe this trend is going to grow worldwide. However, the trend has created
a significant dichotomy; more and more consumers want TCP alternatives for the
higher quality grade of paper, while the market still demands its traditional high
standards of performance.
Until now, technology has had only limited success reconciling these conflicting
expectations. For products requiring bleached kraft pulp furnish (such as wood-
free printing and writing paper, and bleached board), chlorine bleach still
dominates. However, chlorine dioxide and oxygen are expected to replace this
process during the next decade.
Increasingly, however, paper produced by alternative bleaching processes can match the
quality and cost of conventionally bleached paper. One paperboard producer who switched from
molecular chlorine bleaching to a MONOX-L system said that the quality produced by the new
system was identical to the products they made with chlorine, and that the new products occupy
the identical market niche. In cases where the quality and the cost of a TCP product are
equivalent to the quality and cost of conventionally bleached products, the TCF product has a
market advantage.
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The expected decline in chlorine sales is an indication of the growing shift from chlorine
to other bleaching chemicals. According to a recent announcement in Chemicalweek (3/18/92),
"bleaching alternatives to chlorine — which will lose almost half its market by 1996 — including
ozone, enzymes, and electrolytes, will grow to almost $1.8 billion [in 1996, an] almost eight
percent per year growth from last year's $1.2 billion. Chemicals used in recycling paper,
especially deinking, will also grow rapidly".
As alternatively bleached paper products equal or surpass the quality standards demanded
by the market,9 distributors expect that consumer demand will increase. One distributor felt that
"people would love to buy TCP alternatives that gave them the quality they want if that was an
option". Just as recycled paper products are now enjoying a wider appeal, several distributors
expect that alternatively bleached papers will become more accepted and desired as mainstream
consumers became more aware of the differences between bleaching processes and the
availability of alternative products.10
4.4 The European Market
According to sources at the European Paper Institute (EPI) in Paris, the international pulp
and paper industry finds itself involved in many major environmental concerns and controversies
due to its use of 1) forest resources, 2) water, 3) chemicals, and 4) recycled material. While
the degree of public concern on any specific paper related issue varies from country to country,
the top five paper-related environmental concerns in Europe are:
Acid rain and deforestation
Paper recycling and increased use of waste paper
Hygienic product safety
Labeling paper grades as environmentally friendly
The elimination of "unnecessarily" high quality paper grades
Several sources mentioned that Europe is much more accepting of off-white or grey paper
and has gone further with alternative bleaching technologies than the United States. In Europe,
for example, insurance companies advertise on their envelopes that their stationery is produced
from TCP bleached pulp. The German Paper Industry Association (VDP) and the German
Magazine Publishers (VDZ) have stated that they will use only chemical pulps bleached with low
levels of molecular chlorine and produced with an adsorbable organo-halogens (AOX) discharge
of less than 2kg/t (Suess, 1992). Chemical Marketing Reporter (9/24/90) reported that "tighter
emission standards on chlorinated organic compounds combined with consumer worries about
'Note that this is affected by changing either the product quality or the market standards.
10Several sources state that demand currently exceeds supply. See section 4.5.3 for further
discussion.
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dioxin residues in paper products are rapidly reducing the amount of chlorine bleaching of pulp
in Europe". Many European mills are switching to chlorine dioxide and, to a lesser extent,
hydrogen peroxide. While chlorine dioxide is the cheaper "quick-fix" solution, pulp-makers
with a longer-term view are introducing oxygen delignification. While oxygen is usually used
in conjunction with a bleaching step or steps (which may include chlorine dioxide), new mills
are being designed for oxygen and may not need chlorate (Chemical Marketing Reporter.
9/24/90).
The article also cites a study of bleaching in Western Europe by the Price and Pierce
Group. The study predicts that West European chlorine consumption for bleaching will drop
24 percent by 1993. The current European glut of pulp could accelerate this decrease in the use
of chlorine, as the makers of chlorine-bleached pulp are put at a greater competitive
disadvantage in the market. In situations where excess supply exists, competition for purchasers
becomes more intense and the ability to offer a product with desirable characteristics, such as
being TCP, becomes more important.
The article further states that Germany has the toughest environmental regulations
affecting both the paper and pulp industries, and that new emission standards were scheduled.
The new standards were designed to set maximum effluent levels for AOX and biological and
chemical oxygen demand. Tighter emission standards on chlorinated organic compounds, along
with consumer concerns regarding dioxin residues in paper products, resulted in the total
elimination of molecular chlorine bleaching in Germany by the end of 1990. As in the United
States, German mills are shifting to chlorine dioxide, hydrogen peroxide, and oxygen
delignification.
According to a paper presented at a recent conference on TCP, the European market for
alternatively bleached paper was largely influenced by the Germans (Suess, 1992). Germany
relies on sulfite pulp mills, which require less bleaching to produce high brightness and are more
easily converted than kraft pulp mills to MCF bleaching technologies. When chlorine bleaching
became an environmental concern, German mills switched to alternative bleaching processes.
In addition, German paper mills and printers restricted AOX effluent levels in pulp and paper
imported into and used in Germany. They are expected to eventually require zero AOX
emissions for all paper or pulp imported into the country. This has forced mills in other
countries, particularly Sweden and Finland, to convert to alternative processes or face losing the
lucrative German market (Suess, 1992)." In the United States, however, there is a large kraft
pulp industry, which would require relatively substantial capital investment in new equipment
to change to MCF bleaching technologies. One environmental group reasoned that the lag in
the use of alternatively bleached papers may be due more to industry reluctance to make costly
conversions than to lack of consumer acceptance of these papers.
"The government of British Columbia also recently announced regulations, put into effect
July 1, 1992, requiring mills in the province to eliminate AOX produced in the bleaching
process by December 31, 2002.
4-27
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A second possible reason offered for Europeans' willingness to accept unbleached or
alternatively bleached paper is that pollution from pulp and paper mills in Europe is more readily
apparent to the public than it is in the United States. Much of the effluent from Western
European industry drains into the Baltic Sea, which is mainly enclosed and slow-draining
compared to the rivers and coastline of North America. Coupled with a historical lack of
secondary waste treatment by European pulp and paper mills, the long local residence time of
marine pollutants has had a dramatic negative impact on the Baltic Sea ecosystem. It may be
that the visible pollution of the Baltic Sea has heightened the awareness of European consumers
and increased the percentage of the market willing to buy unbleached paper products out of
concern for the environment (Greenpeace).
Both Germany and Sweden have well developed markets for unbleached and alternatively
bleached paper. Germany is very different from Sweden, however, in that Germany is a densely
populated country with little forest land. Unlike the Swedish economy, in which half of the
gross domestic product (GDP) is derived from pulp and paper industries, the German economy
is highly diversified, with paper production being only a small fraction of GDP.
According to a report on the German pulp and paper industry, Germany produced 46
percent of its paper and paperboard using post-consumer recycled paper in 1988. Compared to
Germany, United States use of recycled paper is low (26% in 1988). The Federal government
of Germany supports large scale waste paper collection systems capable of sorting acceptable
waste paper. Using this system, approximately five million metric tons of paper were collected
and recycled in 1988. Waste paper is the fiber most used in Germany to produce paper. Fiber
usage, not including additives and fillers, in Germany in 1989 as a percent of total paper and
paperboard manufacture was:
Fiber Usage
Fiber Type
Waste paper
Chemical pulp
Mechanical pulp
German Use12
49%
35%
16%
Source: Ver Band Deutscher Papier Fabriken, 1990.
"Paper products were classified in a category if at least SO percent of the fibers in the paper
fit the category.
4-28
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Germany has practiced forest management for over 150 years; conservation of healthy
forest resources is not a new issue to the industry. Conversely, awareness of resource
management is somewhat new to the public. Two programs that exist in Germany but not in
the United States serve to support German environmentalism. One is the paper collection system
described above. The other is the "Blue Angel Environmental Label", the symbol of a federally-
administered labeling program for products. As of 1990, labels had not yet been awarded for
TCP paper products, but the Environmental Label Jury had approved criteria by which to
evaluate "paper products, whose basic constituents are manufactured without chlorine bleach"
(Umweltbundesamt, 1990).
In Sweden, TCP products are also in high demand. According to a report by Pulp and
Paper International (3/90, European edition), Swedish shelves are full of products displaying
environmentally-friendly badges and slogans. For example, diaper boxes say "Swedish pulp.
Not bleached with chlorine". Toilet paper wrappers claim "environmentally-friendly recycled
paper saves the forests," and unbleached brown coffee filters are packaged with the claim
"environmentally-friendly unbleached paper — for the best coffee aroma".
TCP bleached Swedish products available include:
Toilet paper
Kitchen towels
Disposable diapers
Paper handkerchiefs
Sanitary napkins/
Panty liners
Paper napkins
Disposable face cloths
Coffee filters
Paper plates
Baking sheet paper
Baking/Muffin paper cups
Stationary/Envelopes
Printing paper
Unglazed multiwall sack kraft paper
Milk cartons
Note that this list covers a wide variety of types of products, from tissue to boxboard to writing
paper.
The three largest Swedish paper firms, STORA, MoDo and SCA, account for 75 percent
of Swedish pulp and paper production. Because these enterprises are internationally integrated
and geared to export between 80 and 90 percent of their products, they are looking for markets,
and market advantages, for their "clean" paper products. These consortia are primary suppliers
to much of Europe's retail and wholesale markets. According to the Swedish Trade Council,
all three export unbleached paper products to the United States.
4.5 Inhibiting Factors Slowing Conversion From Molecular Chlorine Bleaching
No intrinsic technological barriers to eventual production of virtually all grades of paper
and paperboard without the use of molecular chlorine exist. Although admitting that the highest
4-29
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brightness papers are not yet achievable without molecular chlorine, a spokesperson for Earth
Care argued:
I see no reason ever to use molecular chlorine...We can satisfy 99 percent of our paper
needs using alternatives...And the number of products using alternative bleaching
processes is expanding all the time...I see no inherent technological barriers to eventually
producing alternatively bleached products for all paper grades.
Several site-specific limitations, however, have hindered the conversion of existing mills to new
technologies. In a recent survey by the EPA, chemical pulping mills were asked to list
inhibiting factors that prevented them from further reducing or eliminating their chlorine use.
Table 4.3 summarizes their responses. The number of responses (139) exceeds the number of
mills (105) because some mills listed more than one inhibiting factor. The results listed by the
chemical pulp mills can be grouped into three categories; market limitations, economic
limitations, and technological limitations.
Table 4.3
Factors Inhibiting Chlorine Reduction
Inhibiting Factors Number of Mills
Product quality, customer satisfaction, brightness 42
Chlorine dioxide generation capacity 38
Cost 24
Equipment not available or compatible with bleach plant 17
Effluent dioxin levels already low 8
Looking into it or unsure of compatibility 4
Other 6
Source: Table 6. 1990 National Census of Pulp, Paper, and Paperboard Manufacturing
Facilities. Preliminary Summary Report of Questionnaire Responses for Mills that Bleach
Chemical Pulps. Revised. Radian Corporation for OST/OW/U.S. EPA. 10-31-91.
4.5.1 Market Limitations
Market limitations (e.g., product quality, customer satisfaction, and brightness) were the
top inhibiting factors listed by mills. When asked to list the product specifications that inhibit
chlorine reduction, the bleached pulp mills provided the answers shown in Table 4.4. Again,
many mills indicated multiple constraints. As the two tables show, paper brightness is the
overarching factor industry reports as inhibiting conversion to alternative bleaching processes
in the United States. This is echoed in distributors' comments that "people expect paper to be
white".
4-30
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Table 4.4
Product Specification Constraints Inhibiting Chlorine Reduction
Product Constraints Number of Mills
Brightness 84
Dirt count 31
Strength 19
Cleanliness 20
Other paper property or customer acceptance 11
Viscosity 6
Shive count 3
Cost 2
None/Unknown 3
Other reason 15
Source: Table 7. 1990 National Census of Pulp, Paper, and Paperboard Manufacturing
Facilities. Preliminary Summary Report of Questionnaire Responses for Mills that Bleach
Chemical Pulps. Revised.3 Radian Corporation for OST/OW/U.S. EPA. 10-31-91.
Although new technologies promise to increase options for achieving high brightness
levels without using molecular chlorine, several of them are still in the laboratory or pilot project
stages.13 For existing mills, the highest brightness levels are not yet achievable without the use
of molecular chlorine. Unless new technologies become available that enable existing mills to
achieve these high brightness levels without molecular chlorine, a change in consumer
acceptance of lower brightness papers will be the single most important determinant of whether
or not mills convert their bleaching processes.
One distributor felt that to an extent, the paper industry itself encouraged current
consumer preference. He found that the industry emphasized that purity of paper is achieved
through bleaching. Distributors differed in opinion as to whether or not education would
encourage consumers to buy alternatively bleached papers. Most felt that consumer
understanding is quite low, and that education is critical to increasing the market for unbleached
or alternatively bleached products in this country. Another distributor felt that while consumers
would accept alternatively bleached products equal in quality to molecular chlorine bleached
"For a detailed discussion of new technologies, see: U.S. EPA Office of Pollution
Prevention. 1991. "Multimedia Analysis of Alternative Pulp and Paper Technologies - Draft
Final Report". Prepared by Eastern Research Group, Inc.
4-31
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ones, education alone would not encourage consumers to switch to unbleached products. He
explained that, "people know that junk food is bad for them, but they still buy it because they
like to. They would rather buy the fluffy white toilet paper, even though they call themselves
environmentalists".
4.5.2 Economic Limitations
Cost is a second major inhibiting factor discouraging mills from converting to alternative
bleaching processes. While the cost of new mill construction with most new technologies is
comparable to that with conventional technologies, the current cost of converting existing mills
to new technologies can be prohibitively expensive (U.S. EPA, 1991a). One distributor felt that
cost, not technological or market limitations, was the main reason that mills did not want to
change to alternative bleaching processes.
Economies of scale exacerbate the cost question; the relatively low production levels of
alternatively bleached papers currently result in higher per unit costs. Smaller brokers and mills
cannot afford to sell their papers retail, where the markup is higher, because the production costs
for these papers is higher. Instead, alternatively bleached papers have largely been sold
wholesale and through catalogs and health food stores, rather than retailed in mainstream chains.
Alternatively bleached products are beginning to appear in mainstream stores as 1) larger mills
and brokers (who can afford the smaller profit margin) are selling the papers, and 2) larger
volumes of alternatively bleached paper are being produced, thereby decreasing the cost per
volume of the papers.
Another industry cost concern is uncertainty about regulations; they do not want to make
substantial capital commitments if the new processes will later be unacceptable. One Canadian
mill worried that the Canadian government would promote unbleached paper over all bleached
papers. They said that the paper industry had invested millions of dollars to develop alternative
bleaching processes and did not want the government to invalidate their efforts by insisting that
bleached paper is unsafe. American mills that have converted their bleaching processes to
increase their use of chlorine dioxide over molecular chlorine echo this concern.
A related uncertainty concerns the comparative risks of chlorine substitutes. Without risk
assessments, there continue to be conflicting opinions as to whether the replacement of molecular
chlorine with chlorine compounds, or reduced levels of use of molecular chlorine, are adequate
industry responses to the problems posed by organochlorines. Although many manufacturers
have changed or are considering changing their bleaching processes to reduce the use of
molecular chlorine, the use of chlorine has persisted due to its efficiency and low cost as a raw
material. Due to the cost which would be incurred to retrofit a null for the use of TCP
bleaching agents, some mills are employing chlorine compounds (e.g., chlorine dioxide and
hypochlorite), or reducing the quantity of chlorine used rather than switching to a TCP-based
system. For example, Westvaco Corporation has reduced the amount of chlorine they use by
using chlorine in more numerous, smaller batches, and by using a lower acidity.
4-32
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Risks resulting from the use of chlorine compounds, (e.g., chlorine dioxide and
hypochlorite) to bleach paper have not been calculated. Further, only a few organochlorines
other than dioxin have been assessed for their toxicity. It is possible that analyses will find the
risk from organochlorines produced as a by-product of bleaching with chlorine compounds to
be unacceptable. This view was expressed by the environmental organization, Greenpeace.
Greenpeace believes that, although industry has reduced discharges of chlorinated organic
chemicals, the "new levels continue to pollute massively and the capital investment in halfway
measures undermines a truly preventive approach aimed at maximizing protection of the
environment" (Greenpeace, 1990a). According to Greenpeace, chlorine dioxide produces about
one sixth of the organochlorines produced by pure chlorine, but leads to the production of large
quantities of chlorate, a powerful herbicide (Greenpeace, 1990b). Hypochlorite is linked to the
production of chloroform, a suspected human carcinogen that is known to cause liver disease.
Industry perspective differs, however. Some mills are assuring their customers that
hypochlorite bleaching does not create environmental problems. One mill representative stated
that, "The company, along with EPA, has run tests of emissions that showed no dioxin [resulting
from the hypochlorite bleaching process]". A representative of another mill said that the
company has "tested their effluent from the hypochlorite bleaching process and no dioxins are
detectable. Hypochlorite is like household bleach".
4.5.3 Technological and Logistical Limits
Finally, mills responding to the 1990 EPA. Survey mentioned technological limitations
that inhibited them from converting processes. These limitations included chlorine dioxide
generation capacity, and incompatible or unavailable equipment. The EPA study indicated that
many of the mills planned to eliminate these equipment limitations; this appears largely to be
a short-term concern (U.S. EPA, 1991a).
A technical concern not mentioned in the mill study is that shifts in bleaching processes
may require changes in other technologies, such as printing methods. Printing methods may
need to be altered to achieve good results on new papers. One manufacturer of recycled,
hypochlorite-bleached paper provided the paper for two major clothing companies' catalogues.
For one company, he sent the uncoated paper to Japan where a color transparency process was
developed for the paper. He felt that the print looked as good as it had on virgin paper. The
other company used standard printing processes developed for coated paper. The ink showed
increased dot gain, or spreading, and the pictures were not as clear as they had been on virgin
paper. The second company printed a disclaimer on their catalogue indicating that although
recycled paper did not look as good as virgin paper, using it was worthwhile and would help the
environment. The problem lay not in the paper itself, but in the way in which it was combined
with the printing process. To the extent that alternative printing processes are more expensive
or unproven, the use of recycled and alternatively bleached printing papers will be discouraged.
A logistical concern slowing the reduction of molecular chlorine use in the United States
is the lack of an infrastructure for collecting and recycling high-grade papers. As Table 4.1
4-33
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shows, paper recycling and alternative bleaching are currently closely linked. Using previously-
bleached, high grade recycled paper as a feedstock reduces or eliminates the need to use
additional bleaching agents. Several mill representatives stated that the sporadic supply of high
grade recycled papers was the major hindrance to producing a paper with high post-consumer
recycled content. Apparently there is a glut of newspaper and other low-grade papers, while
there is an unmet demand by the manufacturers for post-consumer office paper. One mill in
California contracted for office paper with several municipalities in New Jersey, where recycling
is mandatory. The mill representative said that in states without mandatory recycling, the supply
of post-consumer paper was extremely erratic: "If it rains, forget it". In an effort to stabilize
the supply of post-consumer paper, another mill has set up reciprocal programs with major
nearby corporations. The corporations collect their paper, sell it to the mill, and are then
encouraged to purchase the recycled paper. Office paper appears to be a valuable but largely
wasted commodity. An infrastructure to support office paper recycling could benefit
corporations by reducing disposal costs, municipalities by freeing landfill space, and paper mills
by supplying a consistent secondary fiber source.
These limiting factors have led to a delayed response to the increasing demand for
alternatively bleached papers. This has translated into numerous wholesalers and retailers stating
that their demand for unbleached and alternatively bleached paper is unmet. In several cases,
the retailers were not large enough to interest mills, who viewed the alternatively bleached
products as specialty products and were unwilling to invest in new production processes required
to produce the papers. Conversely, manufacturers of recycled, unrebleached, and alternatively
bleached papers report that their mills are at full capacity.
Wholesalers and retailers said that they were often obligated to offer chlorine bleached
products when they felt that TCP products would sell well, or TCP products when they wanted
to sell unbleached products. When retailers were able to obtain the paper they desired, they
frequently had little flexibility and bargaining power because they were often limited to buying
from a single mill. Similarly, several retailers that had been selling recycled unbleached papers
stopped doing so due to the erratic supply of these papers.
Greenpeace, in searching for paper whose production results in minimal pollution,
purchased oxygen-bleached paper from Holman, a Swedish company. A United States
distributor of Holman's paper stated that currently the demand for TCP paper exceeds the
supply. Alte Schule, a U.S. distributor of recycled, unbleached stationery, diaries, and photo
albums, mentioned that they get many requests for unbleached office paper, a product they do
not carry.
4.6 Future Trends
In 1988, the Canadian government published a series of reports called Canada's Forest
Industry: The Next Twenty Years: Prospects and Priorities. The volume on pulp and paper
predicted the structure of North American and overseas markets for bleached and unbleached
4-34
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paper and paperboard products. The authors found two important potential shifts in the use of
bleached papers:
• A significant proportion of the office papers produced and used is of an
unnecessarily high quality. Much of the need for these papers is for short term,
disposable uses; this need can be readily met using unbleached or alternatively
bleached low brightness papers.
• Newsprint, historically a low bleached commodity, is being increasingly bleached
for use in newspapers, such as USA Today, that employ four-color printing.
Although this "improved" newsprint still comprises a small proportion of the
market, its market share is expected to increase significantly.
•
In addition, the market for bleached paperboard in the United States is expected to
increase, particularly for use as food service containers. The largest growth market in the
United States is expected to be solid unbleached sulfate boxboard.
The study also described the highly concentrated, highly competitive nature of the United
States tissue industry, noting that five companies control 75 percent of the market (see Table
4.2). The top United States tissue manufacturers are seen as world technological leaders, and
several of them have reputations for having strong corporate environmental policies as well.
Because the industry is highly concentrated and led by very large companies known to be
technological innovators, conversion by industry leaders to alternative bleaching processes would
change the market dramatically in a short period of time. Some of these companies, such as
Fort Howard and Scott Paper, are already producing alternatively bleached and unbleached lines.
Clearly, many sectors of the paper market are changing rapidly, and the use of alternative
bleaching agents and recycled paper feedstocks is increasing. According to several mills, until
a few years ago paper was never advertised as recycled because recycled fibers were viewed as
a liability rather than as an asset. In only the last few years, recycled fibers have been in
demand. Similarly, consumer awareness of the potential drawbacks of bleached paper products
has increased in the last few years. According to manufacturers and distributors, however,
consumers do not yet generally recognize the difference between chlorine-bleached, MCF, and
TCP papers.
Coinciding with increased consumer demand, alternatively bleached and unbleached
products are beginning to be carried by large distributors and retailers. Until recently, most
retailers and distributors of recycled and alternative paper products were small start-up
companies; now major distributors have begun to carry them. The shift to larger distributors
will potentially make recycled and alternatively bleached paper more accessible to consumers.
Over the last several years, mills have begun to respond to consumers' concerns about
the use of molecular chlorine and virgin pulp in the pulp and paper industry. By 1995, the use
of molecular chlorine is projected to decrease to about 25 percent of 1986-87 usage levels
4-35
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(Chemical Marketing Reporter. 9/24/90). More recently, Chemicalweek predicts an even
greater decline in the use of chlorine. "Chlorine will lose almost one half of its market by
1996" (Chemicalweek. 3/18/92). In addition, the American Paper Institute has announced a goal
of 40 percent paper recovery by 1995. The projected conversion to non-molecular chlorine
bleaching may be slowed, however, due to the current economic slowdown in the pulp and paper
industry.
As indicated by the Section 308 National Census (U.S. EPA, 1991b) and echoed by
comments from distributors and manufacturers, industry conversion from the use of molecular
chlorine is already underway (see Chapter 1 for more discussion). Unbleached and alternatively
bleached papers are enjoying commercial success in Europe and among environmental consumers
in this country; demand for these papers is expected to continue to increase. Chlorine dioxide,
hydrogen peroxide, and oxygen in particular are expected to replace molecular chlorine during
the next decade.
As alternative bleaching technologies are increasingly developed and adopted that meet
market specifications for bleached papers, alternatively bleached papers are expected to become
the norm for all but perhaps the highest brightness papers. As one distributor contended, "if you
[can] get a TCP bleached alternative with the same quality and price, then there [is] no reason
not to buy it".
4-36
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Chapter 4 References
American Paper Institute, (1980). The Dictionary of Paper. 4th Edition. New York: API.
Resource Recycling, (1990). "Fine Printing and Writing Paper - It's Recycled Too". May.
Canadian Forestry Service, (1988). Canada's Forest Industry: The Next Twenty Years:
Prospects and Priorities. Volume III: Pulp and Paper. Prepared by H.A. Simons Ltd.
Chemical Marketing Reporter, (1990). Schnell Publishing Company, Inc. NY, NY.
ChemicalWeek. (1992). NY, NY.
H.A. Simons Ltd. and AF-IPK., (1991). Future Fibers: Prospectus. Vancouver, British
Columbia, and Stockholm, Sweden.
Greenpeace, (1990a). Correspondence from Greenpeace to Mr. Charles Elkins, Director, Office
of Toxic Substances, EPA. July 31.
Greenpeace, (1990b). The Greenpeace Guide to Paper. January.
Pulp and Paper International, (1990). European Edition.
Suess, Hans U., (1992). "Chlorine-free Bleaching — Current Status and Trends in Central and
Southern Europe". Paper presented at the Non-chlorine Bleaching Conference, March 2-5.
Umweltbundesamt (German Federal Environmental Protection Agency), (1990). Information
sheet on the 'Environmental Label'. Section 1.1. Berlin.
U.S. EPA., (1990a). "Assessing the Market Segment for Environmental Consumers". Draft.
EPA Contract No. 68-09-0169. June.
U.S. EPA., (1990b). "Summary of Technologies for the Control and Reduction of Chlorinated
Organicsfrom the Bleaching Chemical Pulping Subcategories of the Pulp and Paper Industry".
April 27.
U.S. EPA., (1991a). "Multimedia Analysis of Alternative Pulp and Paper Technologies - Draft
Final Report". Office of Pollution Prevention. Dec 3.
U.S. EPA., (1991b). "1990 National Census of Pulp, Paper and Paperboard Manufacturing
Facilities: Preliminary Summary Report of Questionnaire Responses for Mills that Bleach
Chemical Pulps". Office of Science and Technology, Office of Water. October 31.
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APPENDIX 2.A
BLEACHED AND UNBLEACHED PULP PRODUCTION VOLUMES
2.A-1
-------
APPENDIX 2.A
BLEACHED AND UNBLEACHED PULP PRODUCTION VOLUMES
This section presents additional data on mill outputs compiled from self-reported data contained in the
Lockwood-Post Directory of the Pulp. Paper, and Allied Trades. It includes an analysis of bleached and unbleached
pulp production volumes for 99 of 104 mills in the EPA study group.
The Lockwood-Post's data used here appears to be of reasonable quality; nevertheless several caveats are
necessary. First, because there is no consistent system used by mills to report their outputs, the responses may
suffer from a reporting bias, i.e. mills producing the same product may describe and report it differently. Second,
some mills provide production volumes while other simply list the products. Thus, aggregate production quantities
are generally not available. A final problem is that some mills provide greater detail in describing their output than
others. For example, one may report production of "single-ply toilet tissue" while another indicates only that
"tissue" is produced. The products were coded to whatever level of detail was appropriate, given the directory
entries for each mill.
Table 2. A presents data on pulp and total paper production for the 99 mills. Note that some mills do not
report which type(s) of pulp are produced and others indicate the type but not the quantity. Total production of
bleached pulp ranges from ISO to over 2,200 tons per day, depending on the mill. The two firms apparently most
active in production of bleached pulp are Champion International, with 6 mills and 5,765 reported tpd production,
and International Paper Co., which operates 9 mills and reports 5,663 tpd production.
2.A-2
-------
Table 2.A
Outputs of 99 Pulp Mills From EPA'a Study Group
ol 104 Bleached Pulp Mills, by Firm and Mill Location
Mill No. Company Name
1 Alaska Pulp CO.
2 Appleton Papers. Inc.
3 Badger Paper Mills. Inc.
4 Boise Cascade Corp.
6 Bols* Cascade Corp,
8 Boise Cascade Corp.
7 Boise Cascade Corp.
8 Boise Cascade Corp.
. :••".,;. 0 >. Boise Cascade Corp.
10 BowaterCorp.
: •', 11;;;;;B water Cor jfe;;*;;:;
12 Brunswick Pulp and Paper
x 1 3 Buckeye Cellulose
14 Buckeye Cellulose
•::..': IS Champion International
18 Champion International
17 Champion International
18 Champion International
:':•• 10 • Champion International
20 Champion International
21 Chesapeake Corp.
22 Container Corp. of America
23 Federal Paper Board Co,
24 Federal Paper Board Co.
;;;; 26 :j; Finch Pruyn ACo:. Inc.
28 Flambeau Papers (dlv. Pentalr)
,,;:• 27 Gaylord Container Corp.
28 Georgla-Pacinc Corp.
• : :::: 29 y Georgia-Pacing Corp.
30 Georgla-Pacinc Corp.
•••'••} 31 $ Georgia-Pacific Corp.
32 Gilman Paper Co.
.:'•':•: 33 Gulf States Paper Corp.
34 Hammermlll Paper Co.
.. : 35 Hammermlll Paper Co,
38 International Paper Co.
; 37 : International Paper Co.
38 International Paper Co.
Town
Sitka
Roaring Springs
Peshtlgo
Jackson
Perldder
Rumford
International Falls
St. Helens
Wallula
Catawba
Calhoun'
Brunswick
Perry
Oglethorpe
Courtland :
Cantonment
Qulnnaseo
Canton
Houston:
Lufkln
West Point
Brewton
Augusta
Rlegelwood
Glenns Falls
Park Falls
Antloch
Crosset
Palatka
Woodland
Belllngham
St. Marys
Demopolis
Selma
Erie
Mobile
Pine Bluff
Bastrop
State
AK
PA
Wl
AL
LA
ME
MN
OR
WA
SC
TN
GA
FL
QA
AL
FL
Ml
NC
TX
TX
VA
AL
QA
NC
NY
Wl
CA
AR
FL
ME
WA
GA
AL
AL
PA
AL
AR
LA
Bleached Kraft Pulp (tpd)
Total
Softwood Hardwood
Unbleached Kraft Pulp (tpd)
Total Softwood Hardwood
_ . : . _ - _
200
|a|
(a)
_____
— ^--.. :.-..•__..• _ . . • • — —
600 |a| |a| — — —
260
610
250 .I*.:':! :••::..
260
. —
370
1.050 : 1.050 —
— — — .
400 (a) : |a| — . _ _
_ _ _ — 955 —
_ _ ;,•:, '• — 803 803 —
1.350
700
1.800
1.100
750
1.300
1.350
700 :;.:,-... •:.'......
1.800
1.100
|a|
550 '..:.. .. '.
—
— - - :
|a|
750
_ — —
. : . . — r ,...-. .. — •' '. '•". . —
_ — —
_ — • —
_ — —
— . — —
1.400 |a| |a] — — —
825
1.440
600
300
1.900
450
: 1.300;
— - -.:'.
875
600
lal
1.450
450
250 1
825
565
—
|a|
450
—
.050
— ••..— —
_ — —
_ — —
100 —
— — —
650 650
—
2.260 |a| |a| — —
-* •—,-.:": — — • — —
_ _ _ _ —
— ' !— • — 700 (a) |a|
1.500
460
840
600
W
900
|a| '
840
_ — —
750 |a| |a|
_ _ _
— — ...••. — — — —
—
900
—
— 300 —
: 600 : |a| |a| — — —
1.375
—
345
M
|a|
(a)
—
|a|
— —
— — ' —
690 |a| |a|
1,112 |a| : .-.;.' |a| ; — . — —
— — — _ —
Total
Paper
Quantity '
(tpd)
—
210
210
240
2.300
1.475
570
700
|a|
920
2.150
530
—
—
1.550
1,025
—
.675
.310
.262
,300
.200
.370
910
575
375
1.500
1.336
1,195
313
250
1.200
625
525
550
(a)
(a|
606
-------
Table 2.A
(cont.)
Outpula ol 99 Pulp Mills From EPA'8 Study Group
pi 104 Bleached Pulp Mill*, by Firm and Mill Location
Mill No. Company Name Town State
39 International Paper Co. Jay ME
40 International Paper Co. Natchez MS
41 International Paper Co. Mo«« Point MS
42 International Paper Co. Ticonderoga NY
43 International Paper Co. Georgetown . SO
44 International Paper Co. Texarkana TX
45 ITT-Rayonler, Ino. _ Femandlna Beach FL
40 ITT-Rayonler. Inc. Jesup GA
47 |TT-R»yoni*r. Ind. Hoqulam WA
48 ITT-Rayonler. Ino. PortAngele* WA
49 Jame* River Corp. t St. Fraricetvllle LA
60 Jame* River Corp. Old Town ME
61 Jame* River Corp. Berlin NH
62 Jame* River Corp. Clatckanle OR
63 Jame* River Corp, . . Came* WA
64 Jame* River Corp. Green Bay Wl
65 Ketchikacl Pulp & Paper Co. Ketchlkan AK
60 Kimberly-Clark Corp. Coosa Pines AL
67 Leaf Rlv*r Forest Product* New Augusta MS
68 Lincoln Pulp and Paper Lincoln ME
69 Longvlew Fiber Co. Longvlew • • WA
00 Louisiana Pacific Corp. Samoa CA
01 Mead Corporation Escanaba Ml
02 Mead Corporation Chlllicothe OH
03 Mead Corporation Nngsport TN
04 Nekoo** Paper*. Inc. Ashdown AR
95 Nekoo** Paper*. Inq. Port Edward* Wl
00 NekooM Paper*. Ino. Nekoosa Wl
07 Penntech Paper*. Ino, Johnsonburg PA
08 Pope & Talbot. Inc. Halsey OR
99 PotlatchCorp, McGhee AR .
70 Potlatch Corp. Lewieton ID
71 Potlatch Corp. Cloquet MN
72 Proctor & Gamble Co. Mahoopany PA
73 P.H.QIaMelterCo. Spring Grove . PA
74 Scott Paper Co. Mobile AL
76 Scott Paper Co. Hlnckley ME
70 Scott Paper Co. Westbrook ME
Bleached Kraft Pulp (Ipd) Unbleached Kraft Pulp (tpd)
Total Softwood Hardwood Total Softwood Hardwood
1.200 |a| |a| — — —
600 —
600 —
601 |a) |a| _;....._- _
630 |a| |a| — — —
(a| (a| ';• • ;: v '.;: •,. ;:.:; : — • "''; :/- ;• •'• :-: •,;.:.. -r- : ; V.' : •'. •' V; ••': '-•—••-. ;:•: : • ' : — - : • •• •
1.216 |a| |a| — — -
_ — •••:.;••'> .;:': -—•'.• • . :-:.• ~':-';:::'v/'::- >• — ....' ,' : :. — •
1.725 1.725 — — — —
— • — •'•'•'•;£. ' — • ' — •• ••-' ' — —
— — — — — —
675 |a| |a| _ _ _
600 |a
700 |a
|a| — — —
|a| 100 |a| (a|
830 |a| |a| _ — -
1.000 |a|x:v:y-i-s;-,;,.|a| •;.::• .•_-.:.... — . • — .
— — — — — —
— — :"•,?•:. .:/:—. ' • — .'. •. — ' — .
1.200 |a| |a| — — —
1.484 |a| |a| — — -
340 —
340 _
230 |a| |a| 2.400 |a| |a|
600 600 — — — —
600 200 400 — — —
870 |a| |a| — — _
250 —
250 — — —
1.350 750 600 — — —
_ _ _ -.• . _ _
350 |a| |a| - _ -
216 —
215-; ' -..-_-•• _ . _
520 520 — — _ —
450 |a| |a| — — _
1.300 |a| |a| - — -
620 r 100 420V: : — — —
______
660 |a] |a| ; - _ —
— —
— — — —
»00 - (a) |a|:.;;:;-:-V::--:-:..-.r--" -: :•.:;•••: r- ...••• -: -:: —
300 160 140 _
Total
Paper
Quantity'
(tpd)
1.350
—
760
690
:. : (a)
|a|
'... —
—
—
—
075
|a|
— -
910
1.450
470
—
1.200
— i
270
2.000
—
1.4SO
1.171
550
—
440
575
400
—
500
925
: 550
la]
800
2.450
if' ?: 600 ,:
(a)
-------
Table 2.A
(cont.)
Outputs of 99 Pulp Mllli From EPA'i Study Group
01 104 Bleached Pulp Millt. by Htm and Mill Location
Mill No. Company Name Town State
77 Scott Paper Co. Mutkegoo Ml
78 Scott Paper Co. Everett WA
79 Simpson Paper Co, Anderson CA
80 Simpson Paper Co. Fairhaven CA
81 i Simpson Paper Co. Pasadena TX
82 Simpson Paper Co. Tacome WA
83 Stone Container Corp. SnowHake AZ
84 Stone Container Corp. Panama City FL
: 85 Stone Container Corp. Mlssoula MT
86 St. Joe Paper Co. Port St. Joe FL
87 Union Camp Corp, Eastover SC
88 Union Camp Corp. Franklin VA
89 Wausau Pulp and Paper ' Brokaw Wl
90 WettvacoCorp. Wickliffe KY
-,•:.: 91 •xWestvacciCorp. _ ^ Luke MD
92 WettvacoCorp. Covington VA
'•:;: 93 W»^ihiui»tuCo^K:!:'My.\^li:-r--- Plymouth ';•'*:<% :$? <:• •:•••.'•* NC..-'. :
94 Weyerhauser Co. New Bern NC
95 WeyerhaueerCo. Longview . . ; . • :. • . . : WA
96 Weyerhauser Co. Everett WA
97 WeyerhaueerCo. Cosmopolis :;: WA
98 WeyerhaueerCo. Rolhchlld Wl
;: 99 Wllamette Industrie* Hawetvllle KY
— None reported.
(a) Some production Indicated, but quantity not separately reported.
Source: Lockwood-Poet't Directory of the Pulp. Paper, and Allied Trades
(1990). as coded by ERQ.
Bleached Kraft Pulp (tpd) Unbleached Kraft Pulp (tpd) Total
Paper
Quantity'
Total Softwood Hardwood Total Softwood Hardwood (tpd)
250 : 125 126 . — — — |a|
— — — — — — |a|
250 250 — — . — ~ 420
580 127 453 — — — —
726 400 325 — — — 760
|a| |a| |a| 1.200 1.200 — 870
150 150 — ; 550 ;; 550 — 1.250
725
725 800 800 — 800
— — — 1.910 1.910 — 1.910
600
500 1.200 1.200 — 1.400
600 [a| |a| — — — 600
1.950 |a| |a| -- — — 1,900
--, — — ; — — — 480
930 c
913 i
i |a| — — — 600
i |a| — — — 1.174
1.400 |a| |a| — — — 2.000
;: 055V: : 620 436 — 450 — |a|
811 |a| |a| _____
750 750 — — — — 855
385 385 — — — — —
'.. ' \if^--- " ' '—
_____ _ _ _ 350
700 — 700 — — — —
n
-------
APPENDIX 2.B
COMPREHENSIVE LISTING OF MILL OUTPUTS
FOR ALL PAPER AND PAPERBOARD GRADES
99 OF 104 MILLS IN EPA'S
BLEACHED PULP MILL STUDY GROUP
2.B-1
-------
Ouanmim and QndM of Pupef and Board
Produced at 99 of 104 Bleached Pulp Mill*
in EPA Study vweight lood conulnera. M. kn*
Plat*, dish a hey. M. Wen
Other boxboard. M. kraB
Other paper board
1
Alaska Pulp Co,
SUkt
Maaka
/&/
. .•••,,.:•• •-,'
.••'.- •- .;;•/:•::•
"
» < V.
0
< *-«•
,.<.<:*
' -~> -,* ^'i
^w\* > > 5>
\
v-~ - , -
' ~ s"
v •* < ^
*
2
AppMon
Paper*. Inc.
Rowing Spitng*
210
210
1
Badger Paper
Mills, me.
Pcsntlgo
Wisconsin
210
X
X
X
X
X
X
•
•>,
"•.,
« ^i'
4
Boise Csscade
Corp.
Jackton
Alabama
HO
X
X
X
X
X
X
6
Bain Caaoade
Corp.
OwMdM
Louisiana
S.300
t.too
000
. •:•:• . ... .,;.,-.
, 4-
000
^ •• •• ^^
/ ?^> < ^>
v v v-^v <
""*'
- ^'X?.-.
, &\
- •> ",
^v'>'v ^
, , ~
X - Quantity net reported.
|*Rb|c| See note* at end o( table.
Sourc*: Lockweed Poet'• (MracMry O««M Pulp. Pip*' md
Allied Trede* (1900). aa coded oy ERQ.
2.B-2
-------
QuanmiM and Gtadet of Paper and Board
Produced «t 00 of 104 Bleacned Pulp Mllta
In EPA Study Group
TOTAL PAPCR VOLUME
Pap™. ailgtadM
Nnwtprml
Printing and wrrting papera
Uncoated groundwood
Publishing and printing paper
Convnr itng paper
Coaled papera
Uncoaied free eheet
Bond and wnling
Form bond
Ledger
Mimeograph
DuDlicadng
Manifold
Papeierie and wedding
Ctrbonleia
Opaque circular
Cover and text papera
M.F.. E.F., and auo«r calendered
OIlMt
White wove envelope
Tablet
Kralt envelope - brown
Kratt envelope - bleached
Other
Thin papera
Conon hber pepera
Bono and writing
Other Buaineaa
Technical and other
Bleached Brietole
Tabulating Indei
File tolder
lnde> Briatol
Ptinting BriMol
Poetcerd
Coated Brieiol
Packaging, induetrlal and other
Packaging, Induatrlel and other, untH. krall
Wrapping. unM. krall
Bag ana aaek (axe. ahtpplno). unM. raft
Shipping aack, unbl. kralt
Other connecting (pkg g A Indut). unbl. kraB
Packaging, InduKrlel end other. M. krall
Wrapping, bi.
Bag and aack (axe. enlpplng). M.
Snipping aaek.M.
. Other convening (pkg g» Indue). W.
Special Induetrtal Papera
Tlaaue
Sanitary neaue
TortettJteue
Facial neaue emek
Napkin etock
Towel ting
Wiper arack
Other •annarvnaaue
Other naaue
Paperboetd, all gradee
Contakwrooard
Unerboard
Unerboard. unbl. kraft
Unerboard. M. krall
Luterboerd, recycled
Corrugating meteriel
Corrugating materiel, unbl. kraft
Corrugating material, eenii^ineniteel
Corrugating materiel, recycled
Crap end Wler boerd. recycled
Box board
Folding boxboerd
Folding taoxboerd. M. kraft
Folding onboard, recycled
Setup onboard, recycled
Milk canon bunbuard. W. krarl
HeevfweigM food contajnere, H< kraA
Plate, dim* tray. W.krafl
Other onboard. M. krall
Other box board, racydod
Other paperboard
e
BoieeCaacada
Corp.
Rumlord
Maine
I.47S
X
X
X
X
X
7
Sola* Caaead*
Corp.
ntamallonal Falll
Mlnneaota
570
X
•• •-..-,• • :• ;,,.. .
•• - •• ••'-••- .-•
'
~ " .-
™ > - \ •- -
X > !--
. , >l' "
,\ *J>,\*,>~
--S !« >, \ '
. \4\, ~ -<" <\ "
,* ," "- 1 ~,M-T»
' > *-" tv -,«"•
»>i -,.,;s'f^
i , : , !->.~isM-
v; ;>,«>its'-
' ->'-X X->
„ >i <• &'f.~
• • v>* V
. "> 'WA"
~ . -i^ i!^
. N
* *>~ !
.-,,"«< !- ,*<**K.r~
'-\ •
t
Bolae Caacade
Corp.
Oregon
TOO
X
X
X
X
X
9
Bolae Caaoada
Corp.
Walluta
Waahlngton
<05
680
.....
< .
V s "
." < <
, *
,. -i' ,
t- >.
. •,*,,"
" «.< »
•>>• ,A
>. ' .
- <^.
; , Ml
, •< -A,.f
• , ,/^t.v
, ,:\,%>^t
,<0~
• X"k, *f
••«. 1 V
• <--
» *•<* *
10
BowatarCorp.
Catawba
South Carolina
(00
820
X - Ouinrily noi rtporwJ.
|i|b|e| SMMW««*naett(M*.
Some*: Lortwood PMT* Directory 0( *• W*p. P^»r «nd
AHlwl Tr«d« (1990). •• eod«d by EHO.
2.B-3
-------
Omnium ind Gradea ol Pupal and Board
Produced 11 B» o) 104 Bleached Pulp Mill!
In EPA Study Ofoup
TOTAL PAPER VOLUME
Papot. ill gradai
Nuwiprinl
Printing ind writing pepere
UncMtM groundwood
Publithing d. all gradea
Containarboard
Uner board
Unerbotrd. unM. ktaft
Unerboard. M. krafl
Uner board, recycled
Corrugating matenel
Corrugating material. unM. kraR
Cunuuailim mtlailal. atnH nhtnUual
Corrugating material, recycled
Chip and SMer board, recycled
Braboaid
Fotdtoo boiootrd
Folding bnboiid. M. kra*
FoMrno boxbotrd. reoyded
Setup boiboaid, ftcycltd
Milk carton boxbotrd. M. kraR
Heavyweight tood oonulnera. M. kraR
Plate, dim ft tray. M. kraR
Other boxboanl recycled
11
BonralarCorp.
Calhoun
Tenneattt
1.1 SO
X
. . -.:-.
>>,
.
•• , t
* ' --'V
wi •• K
.. ^ ., ..^
'> *AS w?
< -~,, -.-, : t'-f.
••<* >i "' * Xv^ <>yNy
" ", ', ,..',«
,<••"><••» >«H
>- ",>, v.T*^!
f*«it#tar*i»
,>--,'-'>*-!»',
-»,.«-'<*'™^/
«^ ^'"vw' ^>$
* :''' , ^••v^S'Jr
*>';~<, -n'lffa
f-' ^'"^
> •* , t iS
<:
•-
-
,
12
Bnmewtck Pulp
and Paper
Brunewtc*
Qtorglt
sx
X
X
X
X
13
Buckeye
Celluleee
Perry
Florida
/»/
• •'•;•;
-• • ™*,s
• • •• :/;
;;•••
^%
>
.
*
^ 0
, .-.>... X-Nx^
". ;-..<«u?
* - * ^yw*..
-'- .- '"V-yT
„ ^M^l^s^-
-feSS-^5!»
" ' * *'V ---^
<," <$*<
-------
Oimnliliii ind Qndaa ol Pupar and Board
Ptnducad II Mat 104 Blaachad Pulp Mlll»
In EP* Sludy Qroup
roMt supra VOLUME
Pipor. nil gradai
IJewionm
Prinimg and writing papan
Uncoitad groundwood
Publishing and printing papar
Converting papar
Coaiad oapara
Uncoalad baa Waal
Bond and willing
Form bond
Ladga>
Mimaograph
Duplicating
Minilold
Papatana and wadding
Caibontaw
Opaqua circular
Covar and tan papari
M.F.. E.F.. and aupar calandafad
OIlMt
Whtt0 wov* vnvvtopt
Tiblal
Ktan envelop* - brown
Kralt envelope - bleached
Othar
Thin papart
Cotton float papari
Bond and writing
Othar Buainaaa
Technical and olhar
Blaachad BilatoO
Tabulating rndax
Fila Mdar
Indai Briatol
Printmg Briatol
Poatcard
Coaiad Briatol
Packaging. Industrial and othef
Packaging, indud'lal and other. unM. kraft
Wrapping. unW. draft
Bag and aaek (axo. ahlpplng). unM. raft
Shipping aack. unbl. kraR
Othar conwrting (pkg'g 4 Indua). unbl. kraft
Packaging, induatrlal md othw. M. krafi
Wrapprno.M.
Bag and aack (an. ahlpplng). 61.
Shipping aack. M.
Othar converting (pkg g 4 Indua). M.
Spatial kvruatrtal papaca
Tlaaua
Sanitary liaaua
ToiNMHaaua
Facial tliaua atock
Napkin atock
TowaMtng
Wipat atock
Othar aanrtarytlaaua
Dinar liaaua
Piparoowd. an gradaa
Contiinwbovd
Linar board
Unarbovd. unM. kra«
Unacboatd. M. kra*
Unartward.taeTCtad
Conugalingmatarta)
Corrugating malarial. unM. kra*
Corrugating matarlal, aaml chanHeal
ConugcUng malartal. racydad
Chip and Mlar bond. faeycM
Boitaoaid
FokMnQ boxbOaWd
Folding beorboard. M. kra«
Folding bont>oard. ntoygtod
Samp boiboard. laeyelad
Milk canon Doxbowd. M. kraJl
((••^wMoM tood contaatlfWfSa M> kfcft
Plata.dlahAmy.M.krtf
Otha> boiboard. M. k>M
Othar Doiboard. raerOad
Olhar piparboard
\e
Champion
Intarnatkmal
Cantonmani
Flwldi
I.02S
X
X
X
X
17
Champion
IntamatlonaJ
Qulnnaaao
Michigan
/»/
.*>••• .
. •-•• •••• .,..:..•
r v ^ " **
,'X>_»
^
^, -
™ -
•f •*•
•.
* \ -. « ••>
'
, V,'
* ' ^f ^->
, X. -f - *,
* * ^x^
,< ' v.,^^.
* V "*" V-A\^
^**3A4N<.V'!'55^>
*n **') *K-^ff$*«
0.\,/>..1,vS«'«»
•fr.\4* ^^^-jr-^
« >y A- j>^s»*-v
;-*,* -iSf^^
,- >VS,*w.f^S,
> -,,*'SHVi>
. ,»- , A-t,-\
%v VV w,',^*'
„ ,-> , » -,>.••
> • — - ^jiaii.
j>
%"
11
Champion
Intamallonal
Canton
Nonh Carolina
1.875
102
162
182
1«1
101
ISt
M3
It
Champion
InlamatJonal
Houaton
Taui
1.3/0
1.310
»
* ^ ^
^
V s™
^.^^•v.*
x
*^ x
X »
VI >'
^ A
\
f ^
X t
-
.>
"
20
Champion
Intamutonal
Ulkln
Ta«a«
i.tn
172
290
X - Quantity not raponad.
|a|b|c| SavnotaaalanddUMa.
Sourca:LockwoodPoafaOlrae«orTO(lhaPulp.Papa»a
AWad Tradai (1MO). •• cocM by CRd.
2.B-5
-------
Omnium anrl Oradea ol Paper and Board
Produced HI g» of 104 Bleached Pulp Mllla
In EPA Study Otoup
TOTAL PAPER VOLUME
Pnpor. nil qradee
Now«prmt
Printing and writing papere
Uncoaled groundwood
Publlthtng and printing paper
Converting paper
Coaled pepere
Uncalled Irn eheel
Bond and writing
Form bond
Ledger
Mimeograph
Duplicating
Manifold
Papetetie and wedding
Caibonlaee
Opaque circular
Cover and text papera
M.F.. E.F.. and tuper calendered
OIlMI
White wove envelope
Tablet
Kialt envelope - brown
Kraft envelope - bleached
Other
Thin papera
Cotton fiber papere
Bond and writing
Other Bueineee
Technical and other
Bleached Brielole
Tabulating lnde»
File lolder
Indei Briatol
Printing Briatol
Pocteard
Coated BriaM
Packaging. Indualrlal and other
Packaging. Indualrlal and other. unM. krafl
Wrapping. unW. krafl
Bag and aack (•«. ehipping). unM. rail
Shipping aack. unbl. kran
Other converting (pkg g & Indua). unbl. krafl
Peckagmg. induatral and other. M. kratl
Wrapping, bl.
Bag and aack (a«c. aMpptng). bl.
Shipping aack. M.
Other converting (pkg'g A Indua). M.
Special Inoueaia) papata
Tirnue
Senitarv lieaue
ToUMIIeaue
Facial Neaue etotk
Napkin alack
Towelling
Wiper etock
Other unitary Ueeue
Other tlwue
Paperboard. all gradee
Container board
Unerboaid
Unerboete'.«HW. kra*
Unerboard. M. kr«R
Unerboard. recvded
Corruoatlng material
Corrugating material, recycled
Chip and Met board, recycled
Bmbowd
Folding boxfaovr)
riiHlliip hiaiiiiaiil hi In in
Fording umooart, reovded
Setup boiboard. recycled
Milk carton bruboerd. M. krad
1 laevyweighl Hod eontaroera. bt. kraJI
Plate.diah4B«y.ol. krad
Other tambour). M. kta,«
21
Cheaapeake
Corp.
Weal Point
Virginia
1.300
',,.
175
17«
• ..•::.';
' *4*
' f •• ~
tan
;• ,-
• ~ '- ,--*V
"- ,-1M
f * f A^,
- ••' f,<
-• - •> *«•
-'" ~*
> V ,,, ,1
..'*,<:
-
«t
22
ConUlner
Corp. of
America
Brewlon
Alabama
1.200
X
X
23
Federal Paper
Board Co.
Augutte
Georgia
t.m
X
--
.
•• V ^
• • - ~ '-\
'.M? s >
•
'V " ^ -.
~<
,- • -
X ,-,.
<
'
• X
24
Federal Paper
Board Co.
Riegelwood
North Carolina
810
X
X
X
X
X
X
K
Flnchpniyna
Co.. Ino.
Qlann»Fall«
New York
sn
X
X
X
X
X
..-•• 1 .
< , >
~- ,
»»•.«•:,
1 ^. '
> -.i' -> ,\f*
« < A •"
;..•:-
'A svVsw>?
4\,!y
V^^^^(WX?
^ {'•/'&> 4
* •• w*' V*'A •$
- ,'?•.,:.>
•*,<"*
, '..•„ *.
r, '
X-Quantity not reported.
|«Ub|c| See noteeal end ol Hole.
Source: Lockwcod Poet'a Okeetary of lh» fvtp. fte* «"d
AWed Tradee (IQSO). •» coded by EM.
2.B-6
-------
Qunnniini and Qnd«l ol P«p«f «nd Bond
Ptnaucad ai cop) I0< Blaaehad Pulp Mini
In EPA Study Oieup
TO Ml P/4PCfl W31WUE
PMpni. nlloradaa
Nnwiormt
Pnntmq and writing papara
Uncoaiad groundwcod
Publishing ind printing papar
Convantng papar
ConlOd papal 1
Uncoaiad ItM •AMI
Bond and writing
Form bond
Ladgar
Mimaogiaph
Duplicating
Manifold
Pupataiia and wadding
CaiDonlaaa
Opaqua cneulal
Cow and tan papari
M.F.. E.F.. and aupar calandarad
OIlMI
wrtlta wo»a anvalopa
Tabiai
Kiali anvalopa - brawn
Kraft anvalopa - olaacnad
Olhar
Thm papafa
Cotton tibar papara
Bond and witting
Othar Buainaaa
Tachnieal and oihat
BlaacKad Sriatola
Tabulating Indai
FilaMdar
lnda> Btiatol
Printing Briatd
Poatcaid
Coatad 8t latol
Packaging, tnduattial and oUw
Packaging, tnduattial and Mhar. unM. kratl
Wrapping. unM. krafl
Bag and aack (aic. aMpptng). unbl. rail
Shipping aack. unbl. krafl
Othar converting (pkg'g 4 Indua). unbl. kra*
Packaging, rnduautal and onwr. M. krafl
Wrapping, bl.
Bag and aaek (an. arUpping). bl.
StHpptnQ Mck. ol.
Othar camamng (pkg'g « Indua). M.
Spatial Industrial papata
TUau*
Sanitary tlaaua
TnMtitaua
Facial tiiauaatock
Napkin nock
TowalUng
Wipatauxk
Othar aanMaryttaaua
Oinarrjaaua
Paparboafd. all gradaa
Canlainacboard
Unarboard
Unarboard. unM. halt
Unarboard. M. k»a«
Unarboard. racwdad
COf fUflartmQ HMMfiw
Comigadng nutarlal. unM. krafl
Corrugating malarial, aamt-chamical
CofniQMMQ nuMftWt ncyotod
Chip wicf W9f bovd, MoyBtod
Borbaatd
Folding bonboard
Folding baabuard. M. kra*
Folding bo.rboard.racTdad
Satup bortoard, faeivaad
MM canon bmbeard. bt. toa*
Haavymlgni food conulnara. M. krafl
Plata, dtah 4 tray. M. krafl
Othar taatOMd. M. kra*
Olhar bortoard. raofdad
Othar pa par board
»\
Qaorgla-PaclBo
Corp.
Balllngham
Waahlngton
16O
-
X
X
X
X
^•»
•
- »
^
<. ,.
y-
„ \
•V A (
" V "S,
< rt^
i ^*.iJ «* ^
- *».--
^ * ^i \ f"\wx *4^
,„>' ->v.'!--Vx*,x
^v •. , "• ->J s
, >•• *••.
"f ::*
32
Oilman Papar
Co.
SI. Maryi
Qaorgia
i.roo
176
ITS
176
176
600
M
QuIISatai
Papar Corp.
Datnooolla
Alabama
eea
.
' : -..:':
,.
,.
, ,
^ «..~
X
X
M
Hammarmilt
Papar Co.
Salmi
Alabama
5?5
X
15
HammamtlU
Papar Co.
Erla
Pannaylvanla
550
X
X
X
X
X
X
X
X
.-•V. .
. *•••
..'.«•,;
•••• I
••' • .":
• •--•.., ..•;[:- i
...' • . . , :*. ,;;.
s • ^> "'
' '• :. :>•'$;.•»
'- ' • •••":' "SAv
. , " ,.,Wi\-.i
'•'".:' \'-tt*'...
•- • • -ax-Zi'
*••••:':•••;, :.<-..:* *»!!:•
•'<•.:.. i ^TR.sii
.:™vV.V-... .iJK&
.:•.»•-""• I.^Sft
.. -,:-\ ; .. ••;•.-. -t:^.
: ':'- " -""•'-•**«:-
•••:••••*.:• -..;*>*$>.
-.:•.;;•
.. ...
:-*'?
X-Quantity not raponad.
|a|b|c| SaanotaaatandolUMa.
Sourca: Lockwood Poat'a OraeMry of tha Pulp. Papar and
AMad Tradaa
-------
Ou«niiU«» and Oradaa ol Paper «nd Bo«rd
Produced >t taol 104 Bleached Pulp Mllli
In EPA Study Group
TOTAL PAPER VOLUME
Papor, all gradee
Nowtprint
Piintmg end writing paper!
Uncoaled groundwood
Publishing and printing paper
Convening paper
Coaled paper!
Uncoeied rrae iheet
Bond and willing
Form bond
Ledger
Mimtograph
Duplicating
Mamlold
Papeiene and wadding
Caibonlati
Ooaqua eircuiar
Covar and tail papara
M.F.. E.F.. and aupaf calendered
Otltal
White won envelope
Tablet
KraR envelope - brown
Knit envelope - blaachad
Dinar
Thin papaii
Cotton liber papere
Bond and willing
Olhar Buamesa
Tachnical and cxiwr
Blaachad Briatola
Tabulating Indai
Fil*tolda>
lnda« Brielol
Priming Briatol
Poatcard
Coaiad Brielol
Packaging, induaulal and olhar
Packaging, mduatrial and other. unM. kr*R
Wrapping, unbl. kra«
Bag and aacK (aie. ehtpping). unM. ran
Shipping aack. unbl. kraft
Other convening (pkgg A Indus). unM. kra*
Packaging. Industrial and olhw , M. ktan
Wrapping. M.
Bag and aack (a«c. ahipping). M.
Shipping aack. M.
Olhar convening (pkg'g & rndm). M.
Special Induemal pape>t
Tiuue
Sanitary ttaeue
TolMUHue
Facial Uaeue clock
Napkin etock
Towelling
Wiper etock
Other aanttttyMaeue
Other HMue
Paperboard. all gredaa
Containerbowd
Une. board
Uneiboaid. unbl. kralt
Unerboaid. M. kra«
Unerooafd. recrded
ConugaUng matena*
CorrueaNng mateeW. unW. kraH
Comiganng material, eerm chemical
Corrugating maierlal. recycled
Chip and Utter bond, recycled
Boxboafd
FoWino boiboatd
FoMma banboeid. M. krafl
Folding boxbood. recycled
Setup boxtacMfd. recycled
Milk canon bonboard. M. kre.ll
HeavywelgrH tood contaloera. M. kra".
Plate. d(eh» tray. W.kraB.
Olho boxboeid. M. kiafl
Other poxbocrd. recycled
M
ITT-«ayonler.
Inc.
Farnandlna Beach
Rorldi
l»l
y>
ITT-neyonler;
Inc.
Jaaup
Qeorgla
W
•• ,-.. ...••• •. • ••
.... -,..-.
.-.-•. ••;:?.
- - , '
t. » '
-••-,-
.- ,-, " .
, < V »
^ V
. :- » :,
0.' s ' ^ J '• * '4
•• *s> - »> ^,Cv
^ ,< ^ ^ ', ^ ,>vf.
; vv s *«.i
< r ', ',-?.'*;: -.^vv.
'>~*«t', Si , •lr-J'*v
v -,> ,
V \ V ^ > '.. ^i
; ,*»< , -v y *>t
»',>, fi," -. sX?'**?i
' "•% ~*^ V-*' .
-X-V-%,-. "V ->,As
w»"t '-, ' x- »;
*<• ;•*' .'\ -C -. '$ ?
-*-'•<-, t ••<•>
t. ••• xt -VK <
f. , % V/v
,,i ', * S
- ,>,-•
3*
ITT-B«yonler.
Inc.
Hoqulam
Waehlngton
/>/
39
ITT-Aayonler.
Ine.
Port Angelei
Waahlngten
W
•••:. •
,, ,
,, V
,
-,-,
-,,,
•. »
, V
•
* ' ^^
•• v ,*
• , •",*.«.*
• ' ',.",-
^ ' ^^'•~
..-„ / ,^v
A^ \ •* ^ x> ;*f*
* •. ,->>'- ~\
>••',>"{•„*!»
'>- «K
- < t •<<•;•,
N.~ »
••' ~A^
^ -."t.
, „
.. •:••.
40
InlemaHonal
Paper Co.
Mobile
Alabama
1*1
X
X
X
X
X-Quantity not reported.
|*|bgc| SeemMcelendellaM*.
Source: Lockwood Poet'* OHecwy eX the Pulp. Paper end
MM Trade* (IMO). M eooM by EM.
2.B-8
-------
Oimntitlft* and Gradat of Piipar and Board
Produced II 99 01 104 Blaachad Pulp Milll
In EPA Sludy Group
TOTAL p*r>ea VOLUME
Piinm. Mllaradai
Nawtpnnt
Printing ana writing papara
UncoiiM groundwood
Publishing and printing papar
Convainng papa*
Coatnd papar a
Uncontad tiaa ahaal
Bond and writing
Form pond
Ladgar
Mimaograph
Duplicating
Manifold
Paoataiia and wedding
Carbonlaaa
Opaqua circular
Covar and Ian papata
M.F . E.F.. and aupar calandacad
Olltai
whita wova anvatopa
Tablal
Kiafl anvatop* - brown
Kran anvalop* - blaachad
Otn«f
Thin papara
Conon hbar papaf a
Bond and writing
Otnar Buatnaaa
Tachnieai and olhar
BlaacMd BilatoH
Tabulating lnda«
Flla toldar
Indai Brlatol
Printing Brlatol
Poatcard
Coatad Brlalol
Packaging. induatriaJ and otha*
Packaging, indualriaJ and othar, unbl. kraft .
Wrapping, unbl. kralt
Bag and aack Inc. anlpprng). unM. ran
Snipping aack. unbl. kr«*
Othar comwttng (pkg'g ft Indua). unM. kraJI
Packaging, mduanial and otrtar. M. toad
Wraopmg. U.
Bag and aack (aw. ahlpptng). bl.
Shipping aack. bl.
Olh»r comanlng (pkg g ft Indua). M.
Spacial mduaoial papaca
Tiaaua
Saraiaiy maua
ToikMttaaiw
Facial maua atock
Napkin Mock
TowaWng
Wipar atock
Olhat •aruUry ttaau*
Olha» tiiaua
Papafbowd. all grada*
Coniamwbowd
Unawoowd
Unatbeavd. unM. knU
Una>bea>d.M.ki«*
Unarboaid. raeycMd
Corrugattng malarial
Corrugating malarial. unM. kraft
COfflfQfttinQ RIAMfUla Mfllv'wMIINOM
CorruoaSng malartal. racyctod
Chip and Hla> boart. raoyctad
Boxboard
Fordino bnoeant
FoMino taoxboaftl. racwjlaa
Soup buibond. (aoyaad
Milk canon bOMboan). M. k»«
Hcdi^MtQtil tood oonttinwrt, U. krwl
Plata. diah» Bay. W. ban
Ornar baiooard. M. an*
Olhac bortoard. racydad
Ottwf pipw Docra
41
Inlacnatlonal
Papar Co.
Pirn Bluff
Arkanaaa
I'l
X
.-.., ;.
. :™\
, , -
> O'
„
•> ,>^v
^^ \
" - •..!
^ ^ ^ V
^ ,»vt.
^> V% ^ % %\ /^
•s.>r«,,vJ*
V s ^ ' N " */
^ n " * Wi ^
•. > ,0>r
•-s<*\
», . -, - f \<
•>->.. -\
, ^y,^ ,^3,
-^Xs <«><*-
t , -~V>
s *, V
<
^
42
Intamattonal
Papac Co.
Baatrop
Loulalana
009
X
43
Intamatfonal
Papar Co.
Jay
Main.
I.3SO
X
X
X
•
- ,1
0
- vS
, ' ~I'>
*.-.•.,•;
* ~Vsv
,, M-,
> * \\
„ AV>
i -^ •• -X** ss
-W.
^'v'-- ,
~ -!•«,
, "
• ;
^
^ -
,~.
5 ;.
. :,»;:
44
Intamational
Papar Co.
Moaa Point
Mlaalaalppl
TOO
X
X
X
X
46
Intamational
Paper Co.
Natehai
Mlaalaalppl
IV
-. .•<
: ••-• .
•. ^*
*.*
',(
,
», v, !. ,
"4 X-
1A «<\\«* %
„».-» ^>-
s 'v\*fcS^
j «•<„- ,^~,<,
«A-K»X,
»> A'- '
v^ S< * ^%W**
•* "J^A ^ >*» S^
^ « ^ > SXj SS*
"*'s>-^^A
"4-\ ^ ",v**r-
!••* A *"•«-* >•• ^'
v^' , -^-^v
'•x-^^- ,
% *V yl*
- «,,*•
* -
„
X - Ouanrity not raportad.
lalbfc) SaanocaaalandolIlM*.
Sourca:Loelrwooi«r>o«-aOtraaory«l»>»Pulp.
MIM Tradaa (HOD). M codad by ERQ.
2.B-9
-------
Omnllliei Una Gradae el Paper and Board
Prnrtuced «l 9» eM04 Bleached Pulp Mlll»
In 6P« Study Qroup
TOTAL PAPER VOLUME
Paper, all grid«
Newsprint
Printing and writing pepere
Uncoated groundwood
Publithing and printing paper
Converting papar
Coaiad papara
Uncoatad free eheet
Bond and waiting
Foim bond
Ledger
Mimeograph
Duplicating
Mamlold
Papeieria and wedding
Caibonleta
Opaoue circular
Cover and Hit papera
M.F.. E.F.. and tuper calendered
Olleel
White wove envelope
Tablet
Kralt envelope - brown
Kraft envelope - bleached
Other
Thin papen
Cotton fiber papere
Bond and writing
Other Bueineaa
Technical and other
Bleached Brittoie
Tabulating index
File folder
Indei Brielol
Printing B/IHC4
Poetcard
Coaled Brleto!
Packaging, induMrlal and other
Packaging. Imluetilal and e«h«r. unM. kiefl
Wrapping, unM. kiift
Bag and aaek (en. ahlpping). unM. call
Shipping eac*. unbl. kritl
Other convening (pkg'g & Indua). unbl. loan
Packaging, tnduatttal and other. M. krafl
Wrapping. M.
Beg and aeek (e«c. ehlpplng). M.
Shipping eack. M.
Other convening (pkg g & Indue), bl.
Special mdunrlal papen
TiMue
Sanitary lieeua
Toilet naeue
Facial uuue etock
Napkin etock
Towelling
Wiper nock
Other nmtaryttMue
Other neeue
Paper board, all gtedee
Conlamer board
Unerboeid
Unerboard. unM. kitft
Unerboafd. M. kran
Unaf boif d, rvoyckwl
Corrugaltng maierud
ComjQattno fiuMftel, unbli fcnift
Corrugating materiel, eeml rhemloel
CoflUQMrllQ fnelfjful, raOfajifM
Chip and filler board, recycled
BwboanJ
Folding ooxDOtrd
Folding boJrtwarc!. M. kraft
Folding boxbovc}, feoyoMQ
Setup bcorboaid, lecrded
MHk canon bcorboerd. M. tm»
Heavyweight food comalnera. M. kraR
Plaia.dian4Bar.bl.krar)
Other boiboard. M. kraft
Other boiooafd. recrOed
Other paperboard
29
Flembeau
Papera (dlv.
Penulr)
Park Falle
Wlecontan
37S
X
X
X
X
27
Qiylord
Container Corp.
Anttooh
California
1.300
't
'
»
- ^
^
x ~~
•V
•' <
- ~ &*:
} *"
.?<««JW*?^
xJ'wllSM**''"*1
"Sf*X*y%f**
w.,Ptv&i%fmsti£
^'jsr^oAS-!'*
••"' * 'vA^
l &* «>^>-X.
>,'"•'> "•*•
^ Z~,t !
•.^ «^x >
-
s<~ -
-: '
"
<
21
Qeorgla-Pecific
Corp.
Croieat
Aikanea*
1.338
400
110
110
110
110
148
141
146
29
Oeorgle-Peclflc
Corp.
Palatki
Florida
i.iee
140
340
it*
~ i»
12B
340
•
* " \
--,
* <•• -, f, ?, ,
'« •> -."Vi--
'' '•• ^ ^%^ "f
> . .- ;- wi>,
•. ^ * 4-v ft
0 ' vi,V -'^
•••*••> .-'.*««'.»
'•.',' *&H&9
•?'»i*i«J
- - '- \ V 1 •/
^ , ^
•> 1
'-
»
Oeorgla-Peclflo
Corp.
Woodland
Maine
313
X
X
X - Quantity not reported
laHbnrl See noleeal end o< table.
Sourer Lockwood Poel'a Okeetenr of ttw Pulp. rHper and
Allied Trade* (1880). •• coded by ERO.
2.B-10
-------
Ounntitlea and Qradea ol Pip«c «nd Bo«rd
Produced «l 99 ol 104 Bleached Pulp Mllli
in EPA Study Group
TOTAL PAPER VOLUME
PHD4W. allgredea
Newrtprint
Printing and wrillng papera
Uncoatee groundwood
Publlehmg and printing paper
Converting paper
Coaiad papera
Uncoated bee aneet
Bond and wfitlng
Form bond
Ltdgar
Mimeograph
Duplicating
Manifold
Papeierie and wadding
CarbonlaM
Opaqua circular
Cover and taxi papara
M.F.. E.F.. and eupef calendared
Ollaal
While wove envelope
Tablat
Kraft envelope - brown
Kraft envelope - bleached
Other
Thin papera
Cotton fiber papera
Bond and writing
Other Buuneaa
Technical and other
Bleached Briatoia
Tabulating Index
File (older
Index Brinol
Printing Bridal
Poefcerd
Coated Brletol
Packaging, induauial and other
Packaging, mduatrlal and other. unM. kratl
Wrapping, unbl. krafl
Bag and aack (axe. ehtppmg). unM. ran
Snipping aack. unbl. krafl
Other convening (pkg'g A Indua). unM. toalt
Packaging, mdualnal and other. M. krafl
Wrapping, bt.
Bag and aack (axe. aMpptng). M.
Shipping aack. M.
Other convening (pkg'g & Indua). bl.
Special toduatnal papera
Tiaeue
Sanitary ttaaue
ToHettlaaue
Facial haaue etcck
Napkin neck
Towelling
Wiper etock
Other aenrtarytiMue
Other tiieue
Paperboerd. all gradee
COnt iltifWft)OrBftf
Uner board
Unei board. unM. krali
Uner board, bl. krar)
UftwbCMfd, fvVcydvd
Conugaiiog matartal
Comigattng material. unM. km*
Conugatlng material, iiml enantlcar;
Corrugating matartal. recycled
CNpaodlUierboert.reooied
BOKeMrBftl
FoMtna braboefd
• Folding DOMboerd. bl. kre*
Setup boxftewd. reoyded
Milk carton txnboard. M. and
Hwnr^MiQtti teod oonUeVMra, M. kfeW
Plata.diah4iray.pl. kraR
Other bmboard.bl.kralt
Othaf bcnboerd. recycled
Other peperboard
40
Internallonal
Paper Co.
Tlcondaroga
New York
47
International
Paper Co.
Oeorgetown
South Carolina
B»0| IH
X
X
X
X
X
X
X
X
X
•' ••• • : •• .:
• -
- -
, > > ,
> . SN~ .,
.-
-s~- f! <„
; .'
-V,,
O , - s '« ,
' -v- i<"«*>.^*'*s.
\ >•'-• ~*rt ."•
-. >> ^-^ ^v\^
•t\ ^ ^Ai,^>^
-, .. <>„ >•- ->
-*«^», >>s'^-,»,
^A*- Nt^^^-V
*^/ ^&->J; ^svjf^i
•* ^ \-f *¥ v *\ "•
; ^-i"
v ^ V \
» «-•-•-.
4«
International
Paper Co.
Taxarkana
Texaa
/••/
X
48
Jamea River
Corp.
St. FranoeaMM
Loulalana
071
700
27t
- '. ^:.-
,!
.
<*
<
• •VSo
" ,1\-i
•»tiw
:, > i-X»
f. - ^<,*
:. * * .<*»>«* »
; Jws* \
• ,- o*
v- ' v ^**<>
«X "
«^
—VS
M
Jamea River
Corp.
Old Town
Maine
I'l
X
X
X
X
X - Ouandty not reported.
|a|b|c| See notaaat end ol table.
MHed Tredea (ItBO). m cooed by EDO.
2.B-11
-------
Ounniiilm and Oradaa cl Paper end Beard
Produced «1 M ol 104 Bleached Pulp Mill!
In EPA Sludy Group
TOTAL PAPCn VOLUME
Papnr. nil gradea
MnwRpiint
Printing and writing papera
Uncoaled groundwood
Publishing and printing paper
Convening paper
Coated paper*
Uncomed IIM itiMl
Bond and uniting
Form bond
lodger
Mimeograph
Duplicating
Manilold
Piipeteri* and wedding
Carbonleif
Opaque circular
Cover and tail paper a
M.F.. E.F.. and aupar calendered
Ollaal
Whita wove envelop*
Tablet
Kmfl envelope - brown
KraK envelope - bleached
Other
Thin papers
Cotton fiber papere
Bond and writing
Other Buainaae
Technical and other
Bleached Briatote
Tabulating Index
File raider
lnde> Britlal
Printing Brletol
Poitcard
Coated Britlol
Packaging, induetrial and other
Packaging, industrial and other. unM. kralt
Wrapping, unbl. kran
Bag and aack (e»c. «nlpping). unbl. ran
Shipping teek. unbl. kran
Other converting (pug'g & Indue), unbl. kran
Packaging. Induelrtel and other. M. knit
Wrapping. M.
Bag and eack (eic. ahipptng). W.
Shipping aack. bl.
Other converting (p*g g & Indua). M.
Special Industrial papeta
Tinue
Sanriarytitaue
Toilet ttttue
Facial Hteue Mock
Napkin atoek
Towetling
Wlpw Mock
Other aanrtafyUeeiM
Other II HIM
Paper boerd. ell gradee
Conlainerboard
Unerboerd
Uner board. unM. kraJI
Unerboard. M. kra«
UOWbOAfd, f90)ffl9d
Corrugating melertel. unM. kran
Cot ruoadnQ inatanw* aanH^nenHMi
Cotrugetinn nmertel. recycled
Chip end miafboafd. recycled
Bmboard
Folding boxtwerd. M. kran
S*vtup bo)ibo-*
' "¥ X ^ "\ V/JK
•~, !,*,"•% "*«•
f,;:, ;-?^-s<;<
»»S?"",«
" 'Vxt .%"''
'ft,-. - >y><
,••' • \-
x.*xV«-
- •-
>
i
62
Jamee River
Corp.
Claltkanle
Oregon
ato
175
176
300
65
W
as
M
S3
Can-
Ctmee
Waahlngton
1.4SO
X
X
X
. ••••; .'.;.
• . * .
.!.•:•:•.»•!•
X--..: .-;.
x.-- ..• ••
X. •
X.
X
'"-."
„,*»,.'
•• v*x &,
' > ^i'**
•.•>'/*S-
- ,,'•
v' " /'
^ ^^yc
/»•*?*•
-.-. ''•.o-i wj
'< ' * ^tV^'i**.
•> 0 xV^h1^
«V¥«
•^ v
, %"V s*W,
X-Ouenuy not reported.
|agt>Kc| SeenoteeetendolUble.
Source: Leckweod Poet'* Otrectory ol the Pulp. Piper end
Allied Trade* (1890). aa ceiled by ERQ.
2.B-12
-------
Oimnnlies and Qredes ot Paper and Board
Pirolucod II 99 ol 104 Bleeched Pulp Mills
In EPA Study Group
TOTAL PAPER VOLUME
Papor. all grades
Nowcortnt
Prinlrng ene* writing pepere
Uncoeted groundwoad
Publishing and printing peper
Converting paper
Coaled papers
Uncoated Ire* ihnt
Bond ind writing
Form bond
Ledger
Mimeograph
Duplicating
Munilold
Papelerie end wedding
Carbonless
Opaque circular
Covar and text papara
M f.. E.F.. and super calendered
OIlMt
While wove envelope
Tablet
Kralt envelope - brown
Kraft envelope - bleached
Othar
Thin papers
Cotton tibar papara
Bond and writing
Other Bustnoea
Technical and other
Bleached BnetoU
Tabulating Index
File (older
Index Brlelol
Priming Brietol
Poatcard
Coated Brietol
Packaging. Induetrlal and other
Packaging. Industrial and other. unM. kraft
Wrapping. unM. kraft
Bag and sack («e. ehlppmg). unM. raft
Shipping tack. unM. kraft
Other eanventng (pfcg'O A Indue). unM. kiaft
Packaging, induetrtel and othe». M. kraft
Wttipomt), M.
Beg end eack (eic. eWoptng). M.
Shipping aack. M.
Other converting (pkg g * Indua). M.
Spvctttl IndiiaMftel pcpw •
Tliaue
Sanitary tteeue
ToilMHaau*
Facial tinue etoek
Napkin erack
TawwtttnQ
Wiper etoek
Other eentteryHeaue
Other tteaue
Peperboard. an grade*
Container board
Linerboerd
Unerboard. unM. k/a«
Unerboatd. M. krall
Unerboard. reevcled
Corrugating materiel
Corrugating materiel. unM. km*
COffUQCtlflQ (llattVrtWe MHlt^tMdllOW
Corrugating materiel, recycled
Chip and (War board, recycled
Boxboerd
FokMngboi board
Folding boboetd. M. an*
Folding boxboerd.reeyeM
Saftup boxlKMfd. rveyolwl
Milk cAfton MotbOiWd, W. krall
H ••^^MMQht POOO CQntAllMfS, M* RfAn
Plate, dlah 4 My. M. kra«
Other boxtooerd. M. kraft
Other txnboard. recycled
Other peoerboard
54
Klmberty-CI«ik
Corp.
Cooee Flnea
Alabama
l.iOO
X
X
S7
La.lBlver
Fcrett Prodliote
New Auguata
Mlielealppl
l»
"
- >
" ^
-
( > * XX
-. < ^
^ \ -X V f.
* •> "*
•*', « ' *^
"
>*. s- *• < ^
„ , . v
>. -i «.
v V <~
V \
^\ ^
A*W¥^v^*
^ < <•><•>
•>*<«%
>
-•*
>
SI
UneolnPulp
and Paper
Lincoln
Maine
170
57
57
M
33
33
34
sa
LongvtewRpet
Co.
Longview
Withlngton
i.eoo
200
200
200
V»
MO
• MO
, *,-
. %
\ ~\ f •• V'"* ^
•.*#* *x , vX
. „»•>*> -.^^
•• *«.~ \ raO
. s • "
•
1 \ f »** v ->-^
•vs .,-7oa
- ^jn*** ?\
. I, AS, V" ^
>,\^"«li*
,-'>• -v?«*
«, ,', -~f XAr*1
--;," -•',«. if
.- ;y-vn-
- , <, -. —
' V '$
V^^N>
: <>
80
Louisiana
PecMo Corp.
Samoa
California
/»/
X - Ouenuty not reported.
|a|b|c| Seenoteae)endo
-------
Oimnlilim and Otadaa el P«par and Board
Ptodueaa m roof 104 Blaaehad Pulp Milla
In EPA Study Gioiip
TOTAL PAPER VOLUME
Pnpar. ill giadat
NewRprint
Printing and writing papara
Uncoatad groundwood
Publishing and printing papar
Converting papaf
Coalod papara
Uncoalad Iraa anaal
Bond and writing
Form bond
Ladqnr
Mimaograph
Duplicating
Manilold
Papalaiia and wadding
Caibonlau
Opaqua circular
Covar and lain papari
M.F.. E.F.. and aupar calandarad
OtlMt
whita wova anvalopa
Tablat
Kralt anvalopa - brown
Kratt anvalopa - Maaenad
Olhar
Thin papara
Cotton Ttbar papari
Bond and writing
Othar Buainaaa
Tachnical and othar
Blaacnad Brialola
Tabulating lnda«
Fila loldar
lnda> Brlatol
Printing Briatol
Poalcard
Coatad Brlaol
Packaging. Induatilal and othaf
Packaging. Induttrial and otnar, unM. kralt
Wrapping. unM. kraft
Bag and aack (a«e. (hipping). unM. raft
Shipping aack. unM. kralt
Olnar convanlng ~d
Folding bmooard. M. kra«
S«tup boxaMard. r«eyciM
Milk canon bonttOaWd. M. kralt
HvC^WVtQtlf tootf COfltBwKfi, M. RVftll
Plata, di ah » oar, bl.kran
Olhat boxbaard. M. kra«
Othar paparboard
ai
Maad
CorporaUon
Etcanaoa
Mlchlgin
I.4SO
X
• :. .™;:.
...,'-:••
,*.
,
v ^
". v
vtjj $
« *• -V
•" ^ v
> >-v^
V <~ If
•< f
•**• < v <•
^ Ctv >.*
02
Maad
Corporation
Chllllcotha
Ohio
1.171
X
X
X
X
X
X
X
u
Maad
Corporation
Klngaport
Tannaaaaa
ssa
X
X
X
X
X
..,....-
0
' *#
• - •*'
«-
,
V*"?-
... - -v^
< ' .-W.'
,~!
•-
,
"^^
...I;.
M
Nakooaa
Papara. Inc.
Aandown
Arkanaaa
I.3SO
X
X
X
X
X
X
r»
Nakooaa
Papara. Inc.
Nakooaa
Wlaeonaln
575
X
X
X
X
.
"~vv « £<
,>. ,f»
1
'XjA1- . •***
, < , '»
-> < ^_;
, , < >*•(««
v t- »^*»»*-"
K<\*v^^^
„ ,tr-" VO&
-- " ""•
, ,X-!J ,',*..»
^ ', ^ /• ^
^ :f V^
' ' V *••
- '
X - Ouantriy not raponad.
|a|b|c| Sa«»maaalandoltabU.
Souw:Uriwrjo
-------
Quantities and Grades o< Paper and Board
Produced it M 01104 Bleached Pulp Mills
In EPA Sludy Oroup
TOTAL PAPea VOLUME
Pflpor. Ill glades
Nawsprmt
Priming and writing pipers
Uncoiled groundwood
Publishing end printing paper
Converting paper
Coaled papers
Uncoiled tree sheet
Bond and writing
Form bond
Ledger
Mlmeogrsph
Duplicating
Manilold
Panetene and wadding
Csibonless
Opaqua circular
Covar and tan pipers
M.F.. E.F.. and aupar calandarad
Ollaal
Whita wova anvalopa
Tablal
Krall envelope - brown
Kraft anvalopa - blaachad
Otlwr
Thin papers
Cotton liber papara
Bond and wrrling
Othar Business
Tacnnical and oihar
Blaachad Brratola
Tabulating inden
Fila Mdar
inden Bristol
Printtng Bristol
Poatcard
Coatad Bristol
Packaging. Industrial and othar
Packaging. InduanlaJ and «har. unM. kran
Wrapping, unM. krarl
Bag and aack (aic. anlppmg), unM. ran
Shipping nek. unM. kran
Oihar eonvwttng (pkg'g 4 Indira). unt4. kral
Packaging, mduattial and othar. M. kra«
WraptJlrig, bl.
Bag and aack (an. aMpprng). M.
Snipping aaek. M.
Oihar converting (pkg'g 4 Indua). M.
Spccttil Intftictftal pcpcfv
Tiaaua
Sanitary niaue
Tollaitiaaua
Facial Haaua atock
Napkin aioclc
TowaUIng
Wlparwocn
Othar aanrlary Naaua
Other tlwua
Paparcoatd. al oradM
Conf liiMf botird
Unar board
UfWAovd* uftM* kfAft
Unarboard. M. krarl
UnwbMf d, racyclttd
Corruflatmg malarial
Corrugating malarial. unM. kra«
Corrugating malarial, aarnl chamlcaj
Conugatmg matarlal. racyotad
Cnip tnd RNw bOMtl. rac^nl«M
Boxbowd
Folding bcrt«r ••"-... •.
,
-»
\ r. \' V
"* , * '
- , »,
•<\,-N ' >\~ -JV
" ' is-" '
™s ^ >>S*" < >*- ->
, x •«"-. •, "**£
> ,,-->. •~»,«jsi>.
'\^v >\* ^^^
!•' ,\~v -«• ,->-<,
•<\s>r',x -%^
"I-? >".•—.*>
•• * ' '<~1* ^O
"jv ^^ X-v^" *
, - ' - -vs" ;
* •• f V --> „ -
, •• -.v
"''••.
, •* •
- ^
-
81
Penntech
Papara. Inc.
Johnaonburg
Pannavtvanla
409
X
X
X
X
X
X
w
Popa4Talbot.
Ine.
Halaay
Oregon
/»/
v
^
~
J.
A
* v
t
v
70
Potlatch Corp.
McQhae
Arkanaai
500
X.
X
X
X-OoanWy not reported.
laRbfcl See notea el end C4 table.
Source: lockwood Poat'a Directory el MM Pulp. Paper end
Allied Tretfee(IMO). as coded by ERO.
2.B-15
-------
Omnium and Grudaa nl Papar and Bo«rd
Pioduc«a «l B» of 104 Blaachad Pulp Mllla
In EPA Sludy Oceup
TOTAL PAPER VOLUUE
Pflpm. altgraaaa
NowKOiml
Pnntinq end writing papara
Uncoalad groundwood
Pubinhing and printing papar
Converting papar
Coatad papare
Uncoiled Irea ahaol
Bond ind writing
Form bond
Ledger
Mimtograph
Duplicating
MtnikUd
PaDeierie and wedding
CaiDonleae
Opaque circular
Cover and lam papere
M.F . E.F.. and euper calendared
OIlMI
Whita wove envelope
T«iet
Kraft envelope - brown
Krati envelope - bleached
Othar
Thin p«oera
Cotton fibar papere
Bond and writing
Olhar Buaineee
Tacnnical and other
Blaacnad BrlttoH
Tatxilaiing Index
File (older
Indai Brinol
Priming Briatol
Poatevd
Ccatad Briatol
Packaging, induatrlal and othw
Paeugmg. induatriaJ and otlwr. unM. kralt
Wrapping. unM. kraR
Bag and aack (a«. ahipping). unbl. rait
Shipping aack. unbl. kraa
Otha> eomatting (pkg'g & Indua). unM. krajl
Packaging, induatrlal and olhar. N. krall
Wrapping, pi.
Bag and aack (aic. ahlpprng). 61.
Shipping aack. M.
OIIMC cenvwMng (pkg'g ft Indua). W.
Spatial mduatrial papara
Tiaaua
Sanitary naaiw
ToiMtiaaiM
Facial btaua «ock
Napunatoek
Tow«llng
Wlpacatock
Ollm aanMary llaaua
Othaftiaau*
Papoboard. all gradaa
Contam» board
Unatboacd
Unacpoard. unW. krall
Unaiboard.Dl.kra«
Unw bOaVd, f^c^fttttd
CorrugtnnQntaUwttl
CorrugtUng iMMriatl, unM. tan*
CoiniOMiflO RMtaffW, MAl^CiSiMniOAl
CoffUQittHQ nuMflaH< fvcyctad
Chtp tttlt fiHW bOaatfda M&fCtGQ
OoxbOatfd
FotdlnQ boxbovo
FoMtna. bojteoart. M. krcjt
FoWing boxboard. raeyetad
Samp boibeaid. racyetad
Milk canon boboafd. W. kraR
Haa^
, - .. '*"<&
,, , i f;
A ^ N -•* «>.,
v^'vX -
-',!>y» V
';. -V, ,VJ
^ ' C>'£-!?S
V ^
^'' i\vi
, , » ,,
At <•;•,
X' >(
• X'*,' ,>,,
X- , / "
X .' •
72
Potlatch Corp.
Cloqual
Mlnnaaola
seo
X
73
Proctor 4
Gambia Co.
Manoopany
Pannaytvania
1*1
X
>•
,
'• %'••
;.
' •• ^
v - >
--•,
;
,
74
Scon Papar Co.
Moblla
Alabama
2.4SO
X
X
75
Seed Papar Co.
Hlncklcy
Malna
000
000
. ... . •
. ..•:.,.-• ..••:
-
^v •• ,-.,< \
', .«,^
' ?* ' ' V
^ ; ,wu.i ^ *
- • <.v< '
•• ^ >%>«<'/
.'.. f-^^.»
; - •>; •; »*K<,
v^ ' V ^
^ n vv^(>3'v"
s -, ,' %'-il
, A. '*^J
«."••••. .---"»I^J
; ^' ^"x-^ <'»•."
. >-, ~ ^,,-'-,
1 • ; >"vv/
, ' S, ~'v.
v> v
V- , ,„ ,
\
X - OiunWy not raporMd.
|a||bRc| Sa«neiaaala«de«laMa.
Sourer Lodmaed P^al'i Otraoory of In* Pulp. Papa* and
AlUad Tradaa (IMO). •• eodM by EM.
23-16
-------
Ounmiilat ind Oricm el Paper ind Board
PiodueM «t M ot 104 Bleached Pulp Milla
In EPA Study QfOUP
TOTAL PAPER VOLUME
Pnp«f. all grades
Newsprint
Priming and writing papers
Uncosted groundwood
Publishing and printing paper
. Converting paper
Coaled papers
Uncoated ITM sheet
Bond and writing
For m bond
Ledger
Mimaoqriph
Duplicating
Maniloid
Papeterre and wadding
Carbonleis
Opaque circular
Cover and leu papere
M.F.. E.F.. and auow calendered
OIIMI
Whita wov* envelope
Ttblal
Kralt envelope - brown
KraR envelope - blMCfwd
Othar
Thin papara
Cotton llbar papwa
Bond and writing
Othaf Buelneea
Technical and ether
Bleached B'luoK
Tabulating inaai
Fila (older
lnda> Briatol
Printing Bristol
Pottcard
Coalad Bristol
Packaging. Industrial and other
Packaging, Industrial and other. unM. kra«
Wrapping, unbl kralt
Bag and aaek (aw. aMpping). unbl. raft
Shipping aack. unbl. kran
Othar converting (pkg'g « Indua). unM. ban
Packagmg. induaula) and othar. M. krall
Wrapping. M.
Bag and ctck (aic. ahlpptng). 61.
Shipping aack. M.
Other converting (pkg'g A Indua). M.
Special tnduatrial papara
Tlaaue
Sanitary Name
Toitett)«eue
Facial UMue auek
Napkin rmek
TowMUng
Wiper eiock
OtharaanttaryHaaue
Other Naaue
Paperboard. al gradea
Container board
Llnerbocrd
Unarboard. unM. krall
Unarboard. M. krall
Unarboard. raoycMo
ComjgaHng material
Corrugating material. unM. kra*
Corrugating malarial, recycled
Chip and Wer board, recycled
Bo> board
Folding boxboard
Fording boodMafd. M. (trail
Folding boxbovd. racyded
Setup bortoard. recycled
Milk canon peaboatd. M. krar)
HeavywalgN load cenMnara. M. kra*
Plate, died A nay. M. krall
Other txnboard. M. krall
Other boiboard. recychx)
Other pa per ooerd
78
Scon Paper Co.
Weetbrook
Maine
I'l
X
X
X
77
Scon Paper Co.
Muakegon
Michigan
/•/
X
•.. • .-..>
»
•V> v
s
.
-. V V,
•
M t >
»< V*
•,"*
* <.
, .- *•>%•
~t>i>& ! 4~V
-^ " v*,. »
Y*1! > " -•**#
><>,x» - « "s
* t ^ ^
f y-f^
,. V ^ V*XS \
> s ts<. v
* ^-f " \
V
vx ^
^ *«
^ X
•>,-•>.
71
Scon Paper Co.
Everett
Washington
I'l
X
X
X
X
79
Slmpeon Paper
Co.
Andaraon
Calltomla
490
X
X
X
X
X
«-
V*.
\ ^
»
\J
•
f f
to
Slmpeon Paper
Co.
FtlrtMWO
Callromla
W
X * OiMntity not rapovtvo.
|a|b|c| SeenoteaaiendolUWe.
Source: Lockwood Poet'e OkeaMfy c« the PXilp. Payer a
AMed Tradee (ItOO). aa coded by CTO.
2.B-17
-------
Ouanmiei and Grndei of Paper and Bonrd
Produced it 89 ol 104 Bleached Pulp Mill.
In EPA Sludv Croup
TOTAL PAPER VOLUME
Paper, atfcgradee
Nftwtpnnt
Printing and writing paper!
Uncoalad groundwood
Publiihmg and printing paper
Convening paper
Coaled papera
Uncoeled Iree eheel
Bond and writing
Form bond
Ledger
Mimeograph
Duplicating
Manilold
Papelerle and wedding
Carbonieii
Opague circular
Covet end leit papere
M.F.. E.F.. and tuper calendered
Olleet
While wove envelope
Tablet
Krarl envelope - brown
Krarl envelope - bleached
Other
Thin paperi
Cotton fiber peperi
Bond and writing
Other Bueineea
Technical and other
Bleached Button
Tabulating Index
File folder
lnde> Brielol
Printing Brlalol
Poatcard
Coated Brielol
Packeging, Industrial and other
Packaging, Induttrial and ether. unM. kraft
Wrapping. unM. krafl
Bag and neck (exc. Happing), unM. raft
Shipping lack, unM. kraft
Other converting (pkgg ft Indua). unM. kraft
Peckeging. Indintfial and other. M. kraft
Wrapping, M.
Bag and aack '"•!
„ ^^-,- O^KjJ,
.- , < - ,i; ^-5
- -.*>,'*!»'
,« "-St.,)*.-!.
','•*
- -+ * ^ ,,^
, '-."
•• t+J- .,
•S'r
82
Slmpeon Paper
Co.
T acorn*
Weehmgton
in
u
St. Joe Paper
Co.
Port St. Joe
Florida
t.4oa
\
X
X
X
X
X
, •••• .
. •• •••-..
• X
X.
,
-,•*,-•
, -,,
>
'
•
M
Stone
Container Corp.
Snowtleke
Arltona
I.ZSO
700
230
230
,
U
Stone
Container Corp.
Panama City
Florida
too
, .
,,
- " , '
- > t ~
,% -n-,.
'f •• -
no
-• ,»v
• '. ,-'#
>,>..,,< *~«
- - , '«»«, ,>V«5tC(t
, v , <\4-,>S>-
,,!„ tew.
' '" ,
•. - >'..
- J. 4\
v,;
X - Quantity net reported.
|agb|c| Seerwtei eland ol table.
Source: Lockwood Poal'i Orreetory el »• Pulp. Plpw and
Allied Tredee (1000). aa coded by EM.
2.B-18
-------
Qusniiim ind Oiadea of Pupal ind Beard
PrrxtiieM at W of 104 Bleached Pulp Mllll
In EPA SludY Qioup
10TAL PAPER VOLUME
Papoi. ill and"
New«onnt
Pilming and writing papera
Uncoeted gioundwood
Publishing and prmimo papet
Converting paper
Coated papaia
Uncoated hee (AMI
Bond and wilting
Foim pond
Ladgei
Mimeogteph
Duplicating
Manifold
Piipeieiia and wedding
Caibonlait
Opegue circular
COM> and Mit papera
M F.. E.F.. and auper calandarad
Ofleet
Whit* wove envelope
Tablet
Ki«n envelope - biown
Kialt envelope - bleached
Oihai
Thin papara
Cotton fiber papaca
Bond and writing
Other Buainaaa
Technical and other
Bleached Bilatola
Tabulating lnde»
Fila loWai
Indn Bridal
Printing Bllatol
Poatcwd
Coatatf Blind
Packaging. indutlilaJ and olMr
Packaging. Induatltal and othw. unM. krtR
Wraopmo. <"">(. kialt
Bag and aaek t««c. thlpping). unM. raft
Shipping aack. unbl. luafl
Othar eon»afHno (pkg g & (ndtia). unM. kiall
Packaging. Indualnat and «hw. M. kratt
Wrapping. M.
Bag and aack (aic. ahlpptng), bl.
Snipping aack. M.
Othw converting (pkg g & Indut). M.
Spaeial tnouatitml papan
Tlaaua
Sanitary tt«au»
Toilal Haaira
Facial tiaaiw atock
Nap«lnatoe«
TowaWrrg
Wlpararodt
OtharianManrbaaua
Otnwtttaua
PttpVftoOiWtl. tU QfWMC
Contains Board
Unafboard
Unar Board, unbl. knR
Unarboard. M. ktall
Unartward. racnefad
Corrugating matarial
Corrugating maMrW. unM. tea*
Corrugating mataoaJ. aatnl rhialeal
Corrugattng matartal. racyelad
Chip and Mar beard. r»cyetad
Boxboard
FoMlflQ bOKOOaWu
FoMtfig boabOaWd. M. kraft
FoWIng bwibopnJ, i*w^*Wi
SaMup boxftOaWdt MO^tad
Milk canon bacbaanj. M. «n*
Haavywatgm tood conuloara, M. krall
Plata.dlah4Baif. W.krall
00M« boiooaid. M. «ia«
OttMr bexbeard. raoctad
Othar pap« board
•a
Slona
ConlalnarCorp.
Mlaaoula
Montana
1.910
X
•7
Union Camp
Corp.
Eaatowr
South Carolina
000
too
::••
?^ • '
- -, „•*„•,
,, »
^ ,i' ^
V
y.%
, * ,
>,, - ,- » > ^
% V "'
, V. -, ,,> ,,,«
^ , - -i'^.X
' -s ts^« «
, -O.-N-X •.<; s*
^ v% v* A% % **A^
\ % o~">i<>. *il^-v
. y V^itJ),,^
w v 4' ** <.*^v\;^^
>"-! <<> < «.^»l-
X^x,* -S>^,-S»
^ <'-^ ,VA^^
.'. •-»,«••>* "*r
* f>*t '••Z''^ SJ^<^
' , s - ,S~r»>.!5
^ A -^S' "<"
•^ <. 'v*"\''1
, - - >. ',
,.
"
u
Unwn Ccrnp
Corp.
Ftanklln
Virginia
1.900
X
X
X
X
X
X
X
*
M
Wauaau Pulp
and Paper
BroMw
Wlaconaln
4*0
X
X
X
X
X
X
X
X •-•••:-
... ;:•
v>
,
.-
s .,
•»
?
" A^
~?!\.
^> -^ ,O» ~J<
c"> I <
(* IJ^
<^
-
< , -a»
"» f
V*>\
<«x
vr>
QO
WaanacoCorp.
WtekUNe
Kantucky
eoo
X
X
X
X-Ouenntr not reported.
|a|b|c| Sea note** and ol table.
AMadTiaoa* (t«00). aa coded
2.B-19
-------
Omnium snd Grades ol P«p»f tnd Board
Produced II 99 of 104 Bleaehed_Pu!o_Mllls
in EPA Study Group
TOTAL PAPER VOLUME
Papor. all grades
Newsprint
Printing and wining pap*ra
Uncoalad groundwood
Publishing and printing papar
Convarimg paper
Coalsd papara
Uncoalad fraa sheet
Bond and writing
Form bond
Ladgar
Mimeograph
Duplicating
ManihXd
Pnpelerie and wadding
Carbonlaia
Opaqua circular
Covar and tail papara
M.F.. E.F.. and super calendered
Ollaal
Whin wov» anvalooa
TaWal
Kraft envelope - brown
Kraft anvalopa - bleached
Olhar
Thin papers
Cotton fibar papac a
Bond and writing
Olhar Buainaaa
Technical and other
Bleached Brialola
Tabulating index
Fila toldaf
lnda> Britlol
Printing Bristol
Poatcard
Coaled Bhrlol
Packaging, industrial and other
Packaging, industrial and other, unbl. kraft
Wrapping, unbl. draft
Bag and sack (axe. shipping), unbl. ran
Shipping sack. unW. kran
Other convening (pkg g A Indus). unM. Waft
Packaging. Industrial and other. M. toaft
Wrapping. M.
Bag and sack (me. shipping), bl.
Shipping sack. bl.
Other convening (pkg g ft Indus). M.
Special Industrial papers
Tissue
Sanitary tissue
Toilet tissue
Facial tissue etock
NapMnetoek
ToweWng
Wiper stock
Other sanitary tjesue
Other Ussue
Paparboard. all gradee
Container board
Unarboard
Unerboerd. unM. krell
Unarboard. M. krafl
LJntfbocrd. f9cyct*9o
CorruQ«ttno mttttrtel
CorruQBting iratwt.il, unbl. kran
CoffUQItiflQ flMtWHUe fVCyBWO
CMp sitd flltof bOMDt fvoyowo
Boxbeatd
Folding boxboerd
Folding botbeajd. M. anil
FoMlm boxbowd. recnOed
Setup boxboaid. recycled
Milk canon boxboaid. M. kraH
Hffan^wvtQtit food oonuliMra! w. kv AR
Plate, dtsh a tray. M. k»a«
Other boxbowd. M. krafl
Other boxboaid recycled
Bl
WastvecoCarp.
Luke
Maryland
1.174
X
X
X.: :•.. .•
'"
,v
-
1
- .'
^ v
,, „
.,"• — >
-- <
'• '"•**
, ~.J
•^ < >A ••f?*,.
•• y ^ %
****.• * x^
4"-'v^&*v
"'•'•'> ^
<, ^.">i»
^ t.^&Z-'f-.
** *.>*$'•*?*"
* ^ f »,&
v v ^li^^
" ' •Xf'Sf
•, •t^",'^
^ iv*«~ *y&
> & • •*
V" «'>-,"
»., ,
82
WeanraeoCorp.
Covington
Virginia
2.000
X
X
X
«3
Weyerheuser Co.
New Bern
North Caroline
W
'.
,
^
-
B4
Wayarhauser Co.
Plymouth
North Carolina
/«/
X
X
X
96
WayertleueerCo.
Coemopolls
WiinlnQton
w
. . ./
,-,
,- x '
v'< •
' *,
v " - i;
^ \ ', H
*V»
1 <,/ >
' " "2>'«Sx
;„:> -
, ,
- >* f< ;
.- 'vO^O
^ ^
, > '
- \
X-Quantity not reported.
|a|b|c| See notes el end o* table.
Source: Lockwood Poefe Directory of the Pulp. Paper and
Allied Tredes (1990). as coded by EBO.
2.B-20
-------
OlirmWJM «r»d Oiad«l of P«p«r nnd Board
Prortucod itoool 104 Bleached Pulp Mllll
In EP* Study O'OUO
ro)>i PAPER VOLUME
Pftpm. all grade*
Now«onnl
Pimling unit wining paper!
Uncoated Qioundwood
PuGlithing and printing piper
Convening paper
Coiled paperi
Uncoiled tin efieel
Bond and writing
Form bond
Ledger
Mimeoqiaph
Duplicating
Manitold
Pnoetene tnd wedding
CarbonieM
Opaaue circular
Cover and lew, oapert
M.F.. E.F.. and auper calendered
OIIMI
wnm won envelope
T.t.1.1
Kraft envelope - brown
Krall envelope - bleached
Other
Thin paperi
Cotton fiber papera
Bond and writing
Other Butineei
Technical and otnar
BlMchtd Button
TtbuUting tnd«
Fil. toldH
InaM BMBOl
Printing Brifloi
Po«cnd
Co«*d Bintol
Picktgmg. InOimiMI ind otrwr
Pickiging. (ndumul tna otlwr. unM. kraR
Wripplng. unM. k»*
Bag and aaek (tie. •nipping), unbl. carl
Shipping «acn. unM. tain
Othw convMtlng (pkg'g & mdua). unM. knll
Packaging, induxnal and eUwr. M. kraft
Wrapping, M.
Bag and tack (aie. (hipping). M.
Snipping aaek. M.
Other ciniMMIrig, (pkg'g 4 Indua). M.
Special rndunrlal papen
Tlawe
Swirtary titaue
Toilet UMue
Facial tmoe Modi
Napkin atock
Towawng
Wiper deck
Other aimury ttaaue
Other Heaue
Paperboard. all gtadee
Container board
Unerboard
Une» board. unM. Ural
Unerboard. M. krarl
Unw board, recycled
Corrugating material
Corrugadng materlat. unM. knM
CwrugaUnB nwtaviel, evmt^cli^lMCB
CMp and Mer board, renmteO
Boxooafd
Folding boxboafd
FoMJnrj DUB board, M. kraR
Folding boibuMd, recycUd
Setup boxboard. recycled
Milk canon onboard, M. kraft
1 l»a»yweiahl rood contalneca. M. Kraft
Plate, oiex A tray, M. kta*
Other boiboard. M. kra«
Other boiboard. recycled
Other oaperooard
M
Weyerluuaer Co.
Evarafl
Waehtndton
W
07
Weyerhauaac Co.
tongvlew
Waehlngton
105
«
>%
v
*°
^ -^,
<
^ , ^ ^ v
H v
V %< f
>• S V > • ', .
- • * - .>*\,,1
* , ' ^* f
™ i,V -• ',i
' ^ f A-" v
,,- o« ,^--.
, ;-, , ->!^«v
' ^.' i,**« ^v 0^
"^^^V"*'- ** x^<«
', ''^ - »?>-M
>»'4J"tiv*l?4St
^ «^VT" ^ fvtfp.-
^%S~^4^X.% «\>
>\«<»s.*«~toaV
* o-*>:! \^f -s* SSI?
\'WU!49>t&H&
.*•>«" ,W,M
\?-,*-?*%t- >"V
-- »-.— -t\- -^
,--• K-
- , , , vl
-, , ,> »' k\*
, ~
< MO
aa
Weyerhaueer Co.
Rothcnild
Wlaeonaln
350
X
89
Wilamette
Induetriea
HawatvMle
Kentucky
l»l
.. - .. •:,.
.. •.
- ,
*•> ,
^ v
-», '-, >
- * »/
1 v,,, ,
v\v ^r
> f
<-vtSsx
S<'AV<
- - -At'
* < •. \J?\\
* ^ > ^'^
-3Htn?'
,V^^X ^S»
~> .«'» <*s^*
* ~~*f&f-
;.-,'
^ < ^ "^^ti^K
-»•>„•*•*,
f->
' , , -A)
^x!f
M--,«..
(a) Due to the lack ol a conrittent reporting •cheme for product* in the Lockwood Post
directory, mill outputs were coded to varying levels of detail.
|b] Mill produces market pulp only.
|c] Quantity not reported or combined with market pulp quantities.
2.B-21
-------
APPENDIX 2.C
MILLS AND FIRMS PRODUCING PRODUCTS WITH HIGH OR MEDIUM
BLEACHED PULP CONTENT
2.C-1
-------
APPENDIX 2.C
MILLS AND FIRMS PRODUCING PRODUCTS WITH HIGH OR MEDIUM
BLEACHED PULP CONTENT
This section presents additional data on mill outputs compiled from self-reported data contained in the
Lockwood-Post Directory of the Pulp. Paper, and Allied Trades. It examines the numbers of mills which produce
in each of the product categories identified as having high or medium bleached pulp content.
The Lockwood-Post's data used here appears to be of reasonable quality; nevertheless several caveats are
necessary. First, because there is no consistent system used by mills to report their outputs, the responses may
suffer from a reporting bias, i.e. mills producing the same product may describe and report it differently. Second,
some mills provide production volumes while other simply list the products. Thus, aggregate production quantities
are generally not available. A final problem is that some mills provide greater detail in describing their output than
others. For example, one may report production of "single-ply toilet tissue" while another indicates only that
"tissue" is produced. The products were coded to whatever level of detail was appropriate, given the directory
entries for each mill.
As shown in Table 2.C-1, there are few categories of product where more than 10-15 mills report
production. The two products with the highest number of mills are offset and coated papers (19 mills) and bond
and writing (17 mills), both of which happen to be among the highest volume paper grades. Following these, there
are IS mills reporting production in the "other" uncoated free sheet category and 13 mills reporting production of
white wove envelope.
Tables 2.C-2 to 2.C-9 list the mills which produce in each of the high and medium bleached pulp content
product categories. Within the high bleached pulp content categories, a total of 19 mills produce coated papers
(both groundwood and free sheet), 37 mills report production of uncoated free sheet grades, 3 mills produce thin
papers, 9 each produce bleached bristols and bleached packaging and industrial papers, and 24 produce bleached
paperboard products. In the medium bleached pulp content categories, 3 mills produce special industrial papers and
11 produce tissue grades.
2.C-2
-------
raoxe ^.c-l.
Number of Mills Coded in Product Categories
with High and Medium Bleached Puia Content
Type and Grade of Product [fj
No. of
Mills [a]
%of
All Mills
HIGH BLEACHED PULP CONTENT
Coated papers
Uncoated free sheet [b]
Bond and writing
Form bond
Ledger
Mimeograph
Duplicating
Manifold
Papeterie and wedding
Carbonless
Opaque circular
Cover and text papers
M.F., E.F., and super calendered
Offset
White wove envelope
Tablet
Kraft envelope - brown
Kraft envelope - bitched
Other
Thin papers
Bleached Bristols [c]
Tabulating index
File folder
Index Bristol
Printing Bristol
Postcard
Coated Bristol
Bleached packaging & industrial papers [d]
Wrapping
Bag and sack (exc. chipping)
Shipping sack
Other converting (pkg'g & indust)
Solid bleached paperboard
Linerboard
Folding boxboard
Milk carton boxboard
Heavyweight food containerboard
Plate, dish & tray board
Other boxboard
MEDIUM BLEACHED PULP CONTENT
Special industrial papers
Tissue [e]
Sanitary tissue
Toilet tissue
Facial tissue stock
Napkin stock
Towelling
Wiper stock
Other sanitary tissue
Other tissue
19
37
3
9
24
3
11
17
7
8
7
10
0
2
1
5
7
3
19
13
7
0
0
15
0
3
3
1
1
2
3
2
1
5
10
9
7
5
8
1
2
6
5
5
5
0
0
0
19.2%
37.4%
3.0%
9.1%
9.1%
24.0%
3.0%
11.1%
17.2%
7.1%
8.1%
7.1%
10.1%
0.0%
2.0%
1.0%
5.1%
7.1%
3.0%
19.2%
13.1%
7.1%
0.0%
0.0%
15.2%
0.0%
3.0%
3.0%
1.0%
1.0%
2.0%
3.0%
2.0%
1.0%
5.1%
10.1%
9.1%
7.1%
5.1%
8.1%
1.0%
2.0%
6.1%
5.1%
5.1%
5.1%
0.0%
0.0%
0.0%
Sub-categories will not add to category toUU since milli may report output in aevenl subcategories.
4 milli were coded simply as *imcoated free sbcet*.
2 milli were coded simply as "bleached bristol".
9 mills were coded as simply 'bleached packaging & industrial paper*.
11 mills were coded as simply 'tissue*.
a
b
C
d
c
Source: Lockwood-Posfs Directory of Pulp, Paper, & Allied Trades (1990), as coded by ERO.
2.C-3
-------
Table 2.C-2.
Mills Producing Coated Papers
(High Bleached Pulp Content)
Firm Town State
1 Boise Cascade Corp.
2 BowaterCorp.
3 Federal Paper Board Co.
4 Finch Pruyn & Co., Inc.
5 International Paper Co.
6 International Paper Co.
7 James River Corp.
8 Mead Corporation
9 Mead Corporation
10 Mead Corporation
1 1 Penntech Papers, Inc.
12 Potlatch Corp.
13 Potlatch Corp.
14 P.M. Glatfelter Co.
15 Scott Paper Co.
16 Scott Paper Co.
17 Scott Paper Co.
18 Simpson Paper Co.
19 Simpson Paper Co.
Rumford
Catawba
Riegelwood
Glenns Falls
Pine Bluff
Jay
St. Francesville
Escanaba
Chillicothe
Kingsport
Johnsonburg
Lewiston
Cloquet
Spring Grove
Hinckley
Westbrook
Muskegon
Anderson
Pasadena
Maine
South Carolina
North Carolina
New York
Arkansas
Maine
Louisiana
Michigan
Ohio
Tennessee
Pennsylvania
Idaho
Minnesota
Pennsylvania
Maine
Maine
Michigan
California
Texas
Source: Lockwood-Post's Directory of the Pulp, Paper, & Allied Trades (1990),
as coded by ERG.
2.C-4
-------
Table 2.C-3.
Mills Producing Uncoated Free Sheet
(High
Firm
1 Badger Paper Mills. Inc.
2 Boise Cascade Corp.
3 Boise Cascade Corp.
4 Boise Cascade Corp.
5 Boise Cascade Corp.
6 Champion International
7 Champion International
8 Champion International
9 Finch Pruyn & Co.. Inc.
10 Flambeau Papers (div. Pentai
1 1 Georgia-Pacific Corp.
12 Georgia-Pacific Corp.
1 3 Hammermill Paper Co.
U Hammermill Paper Co.
15 International Paper Co.
16 International Paper Co.
17 International Paper Co.
1 8 International Paper Co.
19 James River Corp.
20 James River Corp.
21 Lincoln Pulp and Paper
22 Mead Corporation
23 Mead Corporation
24 Nekoosa Papers, Inc.
25 Nekoosa Papers, Inc.
26 Nekoosa Papers. Inc.
27 P.M. Glatfelter Co.
28 Penntech Papers, Inc.
29 Scott Paper Co.
30 Simpson Paper Co.
31 Simpson Paper Co.
32 Union Camp Corp.
33 Union Camp Corp.
34 Wausau Pulp and Paper
35 Westvaco Corp.
36 Westvaco Corp.
37 Weyerhauser Co.
Bleached Pulp Content)
Town
Peshtigo
International Falls
Jackson
Rumford
St. Helens
Canton
Cantonment
Courtland
Glenns Falls
Park Falls
Cresset
Woodland
Erie
Selma
Georgetown
Jay
Mobile
Ticonderoga
Games
Clatskanie
Lincoln
Chillicothe
Wngsport
Ashdown
Nekoosa
Port Edwards
Spring Grove
Johnsonburg
Westbrook
Anderson
Pasadena
East over
Franklin
Brokaw
Luke
Wickllrfe
Rothcnild
State
Wisconsin
Minnesota
Alabama
Maine
Oregon
North Carolina
Florida
Alabama
New York
Wisconsin
Arkansas
Maine
Pennsylvania
Alabama
South Carolina
Maine
Alabama
New York
Washington
Oregon
Maine
Ohio
Tennessee
Arkansas
Wisconsin
Wisconsin
Pennsylvania
Pennsylvania
Maine
California
Texas
South Carolina
Virginia
Wisconsin
Maryland
Kentucky
Wisconsin
Source: Lockwood-Post's Directory of the Pulp. Paper, & Allied Trades (1990).
as coded by ERG.
2.C-5
-------
Table 2.C-4.
Mills Producing Thin Papers
(High Bleached Pulp Content)
Firm Town State
1 Appleton Papers. Inc. Roaring Springs Pennsylvania
2 International Paper Co. Jay Maine
3 Mead Corporation Chillicothe Ohio
Source: Lockwood-Post's Directory of the Pulp, Paper, & Allied Trades (1990),
as coded by ERG.
2.C-6
-------
Table 2.C-5.
Mills Producing Bleached Bristols
(High Bleached Pulp Content)
Firm Town State
1 Brunswick Pulp and Paper
2 Federal Paper Board Co.
3 Federal Paper Board Co.
4 Hammermill Paper Co.
5 International Paper Co.
6 International Paper Co.
7 Potlatch Corp.
8 Union Camp Corp.
9 Wausau Pulp and Paper
Brunswick
Augusta
Riegelwood
Erie
Georgetown
Moss Point
Lewiston
Franklin
Brokaw
Georgia
Georgia
North Carolina
Pennsylvania
South Carolina
Mississippi
Idaho
Virginia
Wisconsin
Source: Lockwood-Post's Directory of the Pulp, Paper, & Allied Trades (1990),
as coded by ERG.
2.C-7
-------
Table 2.C-6.
Mills Producing Bleached Packaging & Industrial Papers
(High Bleached Pulp Content)
Firm
Town
State
1 Badger Paper Mills, Inc.
2 Champion International
3 Gilman Paper Co.
4 International Paper Co.
5 International Paper Co.
6 James River Corp.
7 James River Corp.
8 Longview Fiber Cc.
9 Simpson Paper Co.
Peshtigo
Cantonment
St. Marys
Mobile
Moss Point
Games
St. Francesville
Longview
Tacome
Wisconsin
Florida
Georgia
Alabama
Mississippi
Washington
Louisiana
Washington
Washington
Source: Lockwood-Post's Directory of the Pulp. Paper, & Allied Trades (1990),
as coded by ERG.
2.C-8
-------
Table 2.C-7.
Mills Producing Bleached Paoarboard
(Hiah Bleached Pulo Content)
Firm
1 Brunswick Pulp and Paper
2 Champion International
3 Champion International
4 Container Corp. of America
5 Federal Paper Board Co.
6 Federal Paper Board Co.
7 Gaylord Container Corp.
8 Georgia-Pacific Corp.
9 Gilman Paper Co.
10 Gulf States Paper Corp.
1 1 International Paper Co.
12 International Paper Co.
13 International Paper Co.
14 International Paper Co.
15 Potlatch Corp.
16 Potlatch Corp.
17 Scott Paper Co.
18 Simpson Paper Co.
19 St. Joe Paper Co.
20 Stone Container Corp.
21 Union Camp Corp.
22 Westvaco Corp.
23 Weyerhauser Co.
24 Weyerhauser Co.
Town
Brunswick
Canton
Cantonment
Brewton
Augusta
Riegelwood
Antiocn
Crosset
St. Marys
Demopolis
Georgetown
Moss Point
Pine Bluff
Texarkana
Lewiston
McGhee
Mobile
Tacome
Port St. Joe
Snowflake
Franklin
Covington
Longview
Plymouth
State
Georgia
North Carolina
Florida
Alabama
Georgia
North Carolina
California
Arkansas
Georgia
Alabama
South Carolina
Mississippi
Arkansas
Texas
Idaho
Arkansas
Alabama
Washington
Florida
Arizona
Virginia
Virginia
Washington
North Carolina
Source: Lockwood-Post's Directory of the Pulp, Paper, & Allied Trades (1990),
as coded by ERG.
2.C-9
-------
Table 2.C-8.
Mills Producing Special Industrial Papers
(Medium Bleached Pulp Content)
Firm Town State
1 James River Corp. Cames Washington
2 Nekoosa Papers, Inc. Port Edwards Wisconsin
3 Wausau Pulp and Paper Brokaw Wisconsin
Source: Lockwood-Post's Directory of the Pulp, Paper, & Allied Trades (1990).
as coded by ERG.
2.C-10
-------
Table 2.C-9.
Mills Producing Tissue
(Medium Bleached Pulp Content)
Firm
Town
State
1 Boise Cascade Corp.
2 Georgia-Pacific Corp.
3 Georgia-Pacific Corp.
4 Georgia-Pacific Corp.
5 James River Corp.
6 James River Corp.
7 James River Corp.
8 James River Corp.
9 Lincoln Pulp and Paper
10 Proctor & Gamble Co.
11 Scott Paper Co.
St. Helens
Bellingham
Crosset
Palatka
Games
Clatskanie
Green Bay
Old Town
Lincoln
Mahoopany
Everett
Oregon
Washington
Arkansas
Florida
Washington
Oregon
Wisconsin
Maine
Maine
Pennsylvania
Washington
Source: Lockwood-Post's Directory of the Pulp. Paper, & Allied Trades (1990),
as coded by ERG.
2.C-11
-------
APPENDIX 2.D
BUREAU OF CENSUS DATA
2.D-1
-------
APPENDIX 2.D
BUREAU OF CENSUS DATA
Further data on the percent of paper and board grades that are bleached was obtained from a special
tabulation by the U.S. Bureau of the Census from its Pulp, Paper, and Board Survey (MA26A). The survey covers
all pulp and paper mills in the U.S., and is designed to collect information on aggregate U.S.shipments of pulp,
paper, and paperboard products. For purposes of this analysis, shipment data was provided separately for:
(1) mills that produce bleached kraft pulp (referred to here as bleached kraft producers);
(2) mills that consume, but do not produce, bleached kraft pulp (bleached kraft consumers);
and
(3) mills that neither produce nor consume bleached kraft pulp (other mills).
Table 2.D-1 shows 1989 shipments for these three mill categories.
Since mills in the "bleached kraft producers" and "bleached kraft consumers" categories may also produce
unbleached products, Table 2.D-1 does not serve to show the exact percentages of the paper grades that are
produced in a bleached form. However, the table does indicate the minimum quantity and percentage of paper and
board grades that are produced in an unbleached form since all shipments by "other mills" are unbleached.
Therefore, from the table, it can be seen that a minimum of about 44% of all paper and board is unbleached.
Specific grades with a relatively high minimum percentage of unbleached shipments include: newsprint (minimum
of 24% unbleached), uncoated groundwood paper (8%), packaging and industrial converting paper (44%), sanitary
tissue (8%), tissue paper excluding sanitary and thin (28%), solid wood pulp furnish paperboard (68%), recycled
paperboard (89%), and construction paper and board (97%). This information is consistent with the estimates of
bleached virgin pulp content by product that was presented in Table 2.19.
2.D-2
-------
1989 Shipments ol Paper and Board, by Type o( Producer
(Quantity In short tons)
Product Description
Producers of Bleached
Kraft Pulp (a]
Shipments Percent
Consumers of Bleached
Kraft Pulp [b]
Shipments Percent
Other
Mills [c|
Shipments Percent
TOTAL
Shipments Percent
All Grades
28,913,397
36.8%
15.324,271
19.5% 34.429,561
43.8%
78,667.229 100.0%
Paper
Printing, writing, and related papers
Newsprint
Uncoated groundwood
Publication and printing
Form bond
Other converting and misc. groundwood
Body stock for coating
Clay coated printing & converted paper
Coated groundwood & prime coated body sloe
Coated free sheet
Coated one side
Coated two sides
Uncoated (ree sheet
Writing, chemical woodpulp
Bond and writing
Form bond In rolls
Ledger
Mimeograph, all woodpulp furnishes
Gelatin & spirit process duplicating
Papaterle and wedding
Body stock for communication,
copying, and related papers
Other technical & reproduction papers
Tablet
Other
20.352,712
16,649,763
3.092,989
375.983
285.442
IDJ
ID]
|Dl
3,922.315
1,521.291
2,401,024
338.052
2.062.972
8,052,566
4,904,400
2,428,056
1,581,621
50.201
ID1
20,436
32.982
314.335
ID]
272.241
39.915
53.5%
59.7%
51.3%
21.3%
19.5%
52.0%
36.7%
70.8%
58.1%
73.4%
74.1%
77.7%
79.0%
79.9%
84.0%
66.8%
64.9%
90.5%
79.6%
66.8%
13.538,437
9,605,676
1,474.980
1.251.574
1.051.279
ID]
106.033
ID]
3.621.875
2,629,466
992,409
243,323
749.086
2.789,348
ID]
ID]
ID]
9,586
ID]
10.154
17.802
32.948
101
69.888
19.862
35.6%
34.5%
24.5%
71.0%
71.7%
69.9%
48.0%
63.3%
29.2%
41.9%
26.6%
25.7%
16.0%
33.2%
35.1%
9.5%
20.4%
33.2%
4.182.404
1.623.522
1.455.931
135.978
128.690
--
ID]
—
—
—
—
—
—
27.894
ID]
ID]
ID]
--
—
—
—
—
—
—
— ~
11.0%
5.8%
24.2%
7.7%
8.8%
0.0%
0.0%
0.0%
0.0%
0.0%
0.3%
0.0%
0.0%
0.0%
0.0%
0.0%
0.0%
0.0%
0.0%
38.073.553
27.878.961
6.023,900
1.763.535
1.465.411
ID]
151,797
ID]
7.544.190
4.150.757
3.393.433
581,375
2.812.058
10,869.808
6.314.408
3.074.539
1 .979.954
59.787
25.270
30.590
50.785
347.283
344.294
342.129
59.777
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
(Com.)
-------
Table 2.D-1. (cont
1989 Shipments of Paper and Board, by Type of Producer
e
(Quantity in short tons)
Producers o! Bleached
Kraft Pulp [a]
Product Description
Paper Publication and printing
(cont.) Plain, Including M.F., E.F., antique,
bulking, eggshell, & supercalendered
Offset
Other publication & printing freesheet
Cover and text papers
Other converting & misc. freesheet
Envelope (white woven)
Kraft envelope-bleached & brown
Body stock for coating
Bleached brlstols
Tag and file folder
Other uncoated brlstols. Including tabulating
card stock, Index, printing, and postcard
Coated brlstols
Cotton fiber writing paper & thin paper
Writing, cotton fiber
Bond and writing
Other
Thin paper
Packaging & Industrial converting paper
Unbleached kralt packaging and
Industrial converting paper
Wrapping
Shipping sack
Bag and sack, other than shipping sack
Specialty packaging
Other convening. Including creplng
Shipments
1.801.815
ID)
1,171.794
ID|
193,506
1,152.845
698.531
348.488
105.826
ID)
ID)
226.396
ID)
ID)
ID)
ID)
—
ID)
1,349.881
739.644
ID)
260.257
338,708
ID)
96.217
Percent
66.4%
65.6%
43.0%
82.8%
95.5%
95.8%
35.7%
66.8%
0.0%
28.5%
25.0%
38.6%
20.4%
19.8%
Consumers of Bleached
Kraft Pulp [b]
Shipments Percent
894.243 32.9%
ID)
614.211 34.4%
ID)
ID]
ID)
33.190 4.5%
ID)
ID)
65.745 5.3%
ID)
ID)
ID)
402.154 94.6%
158.714 97.2%
ID)
ID)
ID)
1,313.349 27.7%
256.368 8.7%
ID)
ID]
103.527 6.2%
ID]
129.339 26.7%
Other
Mills |c|
Shipments Percent
17,970 0.7%
0.0%
0.0%
ID]
ID)
ID)
0.0%
ID]
ID]
ID]
0.0%
ID]
0.0%
ID]
ID]
ID]
ID]
0.0%
2.080.345 43.9%
1.956.859 66.3%
ID)
ID)
1.215.524 73.3%
ID]
259.330 53.5%
TOTAL
Shipments
2.714.028
324.028
1.786.005
603.995
449.622
1.391.750
731.721
363.732
296.297
1.252.243
438.402
338.797
475.044
425.285
163.225
133.053
30.172
262.060
4.743.575
2.952.871
68.113
673.696
1.657.759
68.417
484.886
Percent
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
(Cont.)
-------
Table 2.D-1. (cont.)
1989 Shipments ot Paper and Board, bv Type of Producer
(Quantity In short tons)
Producers ol Bleached
Kralt Pulp |a]
Product Description
paper Packaging & Industrial converting paper,
(cont.) except unbleached kraft wrapping
Wrapping
Shipping sack
Other bag and sack
Other converting
Specialty packaging
^ Qlasslne, g'reaseproof. & vegetable parchment
M Specialty Industrial paper, except
J, specialty packaging
Tissue
Sanitary paper
Toilet tissue
Facial tissue, other than towelling,
napkin and toilet
Napkin stock, Industrial and resale
- Towelling, excluding wiper stock,
Industrial and household
Wiper stock, regular, facial, & wadding
Sanitary napkin stock wadding &
other sanitary stock
Tissue paper, excluding sanitary & thin
Shipments
560.841
33,740
155,404
ID]
81,630
IDJ
ID]
49.396
2,353,068
2.334,863
1,062,294
114,156
242,105
886.086
ID]
|D|
18.205
Percent
50.2%
67.0%
68.3%
53.4%
7.3%
43.2%
44.1%
50.6%
34.4%
34.6%
47.7%
11.4%
Consumers ol Bleached
Kralt Pulp |b|
Shipments
475.412
ID]
ID]
ID]
71.333
|D|
ID)
581,569
2.619,412
2.522,134
924.012
200.922
369.733
752.410
ID]
|D|
97.278
Percent
42.6%
46.6%
86.3%
48.1%
47.7%
44.1%
60.6%
52.9%
40.5%
60.8%
Other
Mills (c|
Shipments
80,526
ID]
ID]
—
—
—
—
42,960
478.537
434.075
111.088
16.459
87.184
219.344
—
—
44,462
Percent
7.2%
0.0%
0.0%
0.0%
0.0%
6.4%
8.8%
8.2%
5.3%
5.0%
12.5%
11.8%
0.0%
0.0%
27.8%
TOTAL
Shipments
1.116,779
50,381
227.608
230,758
153,163
206.950
247.919
673.925
5.451.017
5.291.072
2.097.394
331.537
699.022
1.857.840
155,678
149.601
159,945
Percent
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
(Cont.)
-------
Table 2.D-1. (Cont.)
1989 Shipments of Paper and Board, by Type of Producer
(Quantity In short tons)
Producers of Bleached
Kraft Pulp (a]
Product Description
Paperboard
Solid woodpulp furnish paperboard
• Unbleached kraft packaging and
Industrial converting paperboard
Unbleached llnerboard
Tube, can, and drum paperboard
Other
Bleached packaging and
Industrial converting paperboard
Llnerboard
Folding carton type board
Milk carton board
Heavyweight cup & round neeted food contain
Plate, dish, and tray stock
Bleached paperboard for misc. packaging
Other solid bleached board
Semlchemlcal paperboard, Including
corrugating medium and other uses
Recycled paperboard
Shipping contalnerboard
Folding carton
Setup
Packaging and Industrial converting
Wet machine board, Including binder's
board and shoe board
Shipments
8.560,685
8.203.432
2.751.864
2.647.697
ID)
|D|
4.886.250
445.476
2.211.352
1,143,115
425,682
319.583
73,353
267.689
565.318
357,253
357,253
«
—
—
—
Percent
22.5%
28.4%
14.6%
.15.3%
99.6%
100.0%
100.0%
100.0%
100.0%
99.1%
100.0%
94.3%
10.9%
3.9%
11.6%
0.0%
0.0%
0.0%
0.0%
Consumers of Bleached
Kraft Pulp |b|
Shipments Percent
1.718.463 4.5%
1,085.697 3.8%
ID]
ID)
|D|
|D|
19.385 0.4%
0.0%
ID)
0.0%
0.0%
ID)
0.0%
ID]
ID)
621.061 6.9%
109.593 3.5%
343.127 13.4%
ID]
ID)
ID]
Olher
Mills |cj
Shipments Percent
27.768,165 73.0%
19.610.275 67.9%
ID]
ID]
ID]
|D|
0.0%
0.0%
ID]
0.0%
0.0%
ID]
0.0%
ID]
ID]
8.067.337 89.2%
2.623.212 84.9%
2.221.333 86.6%
ID]
ID]
ID)
TOTAL
Shipments
38.047.313
28.899.404
18.794.872
17.356,067
59.869
1.378.936
4.905.635
445.476
2.211.665
1.143.115
425.682
322.567
73.353
283.777
5.198.897
9.045.651
3.090.058
2.564.460
291.873
3.099.260
102.258
Percent
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
(Cont.)
-------
Table 2.D-1. (cont.)
1989 Shipments of Paper and Board, by Type of Producer
(Quantity In short tons)
Product Description
Construction Paper and Board
Construction paper
Structural Insulation board:
Insulating board
Hardboard
Producers of Bleached Consumers of Bleached Other
Kraft Pulp [a] Kraft Pulp |b| Mills [c] TOTAL
Shipments Percent Shipments Percent Shipments Percent Shipments Percent
0.0% 67.371 2.6% 2.478.992 97.4% 2.546.363 100.0%
0.0% |D] |D] 334.997 100.0%
0.0% — 0.0% 517.634 100.0% 517.634 100.0%
0.0% — 0.0% 1,693.732 100.0% 1.693.732 100.0%
> — Represents zero. (O) Data withheld by Census Bureau to avoid disclosing figures for Individual companies.
1 |a] Mills that produce bleached kraft pulp.
i |b) Mills that consume bleached krafl pulp (market pulp).
(c| Mills that neither produce nor consume bleached kraft pulp.
Source: U.S. Department of Commerce, Bureau of the Census, 1989 Pulp, Paper, and Board Survey (MA26A). Special Tabulation for Bleached Pulp.
-------
APPENDIX 3.A
OVERVIEW OF THE PULPING PROCESS
3.A-1
-------
APPENDIX 3.A
OVERVIEW OF THE PULPING PROCESS
This appendix presents a brief overview of the production processes used to manufacture pulps. It
illustrates the integrated nature of the process with respect to impacts of raw material selection and processing on
final products.
Raw Materials
There are four major types of fiber used for papermaking:
a. Hardwood
b. Softwood
c. Secondary fibers (recycled fiber)
d. Nonwood fibers
Pulps produced from hardwood trees (oak, maple, birch, beech, etc.) contain relatively short fibers,
typically one to 2.5 mm in length, making them less desirable than pulps produced from softwood trees from the
standpoint of strength. Pulps produced from softwood trees (pine, spruce, hemlock, etc.) contain fibers from about
three to more than 5 mm in length. Many papers are made from blends of hardwood and softwood pulps to take
advantage of the strength of the softwood pulp and the dense hardwood pulp. In the U.S., about twice as much
softwood pulp is produced compared to hardwood pulp.
Secondary fibers are derived from recycle of paper and paperboard. Depending upon waste paper
segregation and processing, secondary fibers can be converted into low to high grades of finished paper. Examples
of nonwood fibers include cotton, sugar cane waste called bagasse, bamboo, and wheat straw. Nonwood fibers are
often converted to low volume, specialty grades of paper. Certain plastics and latexes are also used for specialty
papermaking.
Pulping Processes
In 1988, the U.S. pulp and paper industry produced about 61 million tons of wood pulp by the following
processes:
Bleached Sulfate (Kraft) 43.0%
Unbleached Sulfate 35.4%
Semichemical 7.1 %
Groundwood and Refiner 5.0%
Thermomechanical 4.7%
3.A-2
-------
Total Sulfite 2.6%
Dissolving and Special Alpha 2.2%
Total 100.0%
The principal distinguishing characteristics and the major products associated with each pulping process
are briefly reviewed below.
Mechanical Pulp - Stone Groundwood
Stone groundwood pulp is produced by forcing logs against a grindstone by mechanical pressure. Nearly
all of the log is converted into a low grade pulp used principally for newsprint and other products where permnnence
is not an important factor. Lignin, which binds wood fibers together, imparts color to pulp and causes yellowing
of paper, is not removed in this process. Other products made from stone groundwood pulp include towels,
inexpensive writing paper and molded products such as egg cartons.
For newsprint production, groundwood pulp is usually blended with about 20 % chemical pulp for added
strength. Groundwood pulp is usually not bleached, or, if bleached, not to a high degree of brightness. The frayed
and broken fibers obtained from groundwood pulping are quick to absorb printing inks and are thus suitable for high
speed printing.
Refiner Mechanical Pulp
In this process wood chips are passed through double-disc refiners where the fibers are mechanically
separated as opposed to grinding on a stone. The fibers are frayed for better bonding, but are not chopped
indiscriminately as in the groundwood process. Consequently, refiner mechanical pulp is stronger than groundwood
pulp and more suitable for certain uses where strength is an important factor.
Tbennomechanical Pulp (TMP)
Thermomechanical pulp is produced by preheating wood chips with steam prior to refining as described
above. The heat acts to soften the lignin which binds the wood fibers together, allowing for separating fibers which
are nearly intact This results in a stronger pulp than obtainable by the groundwood process and minimir»B the need
for more expensive chemical pulp in newsprint production.
Pulp
3.A-3
-------
In this process, wood chips are processed in a relatively mild chemical solution prior to mechanical refining
for fiber separation. The chemical solution is usually a neutral sodium sulfite/sodium carbonate liquor which acts
to soften the lignin and promote fiber separation. Hence, the name neutral sulfite semichemical (NSSC) pulp. The
yield of semichemical pulping is dependant on the specific process used, and may be in the range of 65 to 85
percent. Most semichemical pulps are not bleached and are used for corrugated board, newsprint and specialty
boards. Bleached NSSC pulps can be used to make writing and bond papers, offset papers, tissue and toweling.
Chemical Pulps
Chemical pulp production for 1987 was nearly 50 million tons. The breakdown by pulping process and
bleaching practice is summarized below:
Bleached Kraft 51.0 %
Unbleached Kraft 43.0 %
Bleached Sulfite 2.7 %
Unbleached Sulfite 0.3 %
Specialty Grades 3.0 %
Total 100.0 %
The dominance of the kraft pulping process is apparent. The kraft process accounted for about 94 % of
chemical pulp production in 1987 vs. 83 % in 1964. About 54 % of kraft pulp was bleached in 1987, vs. 40 %
in 1964.
In the kraft and sulfite pulping processes, hardwood or softwood chips are cooked in chemical solutions
under heat and pressure to dissolve the lignin that binds cellulose wood fibers together. The kraft or "sulfate"
process uses an alkaline solution of primarily sodium sulfide (Na2S) and sodium hydroxide (NaOH). Sodium sulfate
(Na2SO4) and lime (CaO) are used to replenish the pulping liquor as part of the chemical and energy recovery
operations associated with the process. The yield of the kraft process is about 50 percent.
The sulfite process is an acid process in which chips are cooked in a liquor consisting of calcium,
magnesium, sodium or ammonia salts of sulfurous acid. The distinguishing characteristics of the kraft and sulfite
pulping processes and kraft and sulfite pulps are presented in Table 3.A.I.
3.A-4
-------
Table 3.A.I.
Comparison of Kraft and Sulfite Pulping Processes
Kraft Process
Sulfite Process
Cellulosic Raw Material
Principal Reaction in Digester
Composition of Cooking Liquor
Cooking Conditions
Chemical Recovery
Pulp Characteristics
Typical Paper Products
Almost any kind of wood, soft or hard
Usually coniferous, must be of good
color and free of certain hydroxy
phenolic compounds
Sulfonation and solubization of lignin
with bisulfite; hydrolytic splitting of the
cellulose-lignin
7% by weight SO2, of which 4.5% is
present as sulfurous acid, and 2.5 % Ca
or Mg (HS03)2
2-5 hours at 340-350 F and 100-135 psi 6-12 hours at 257-320 F and 90-110 psi
Hydrolysis of lignins to alcohols and
acids; mercaptans are formed
12.5% solution NaOH, Na2S and
Na2CO3
Most of process is devoted to recovery
of cooking chemicals, with energy
recovery from burning organic matter
dissolved in liquor. Chemical losses are
replenished with salt cake, Na2SO4
Brown color; difficult to bleach; strong
fibers; resistant to mechanical refining
Strong brown bag and wrapping;
multiwall gabs; gumming paper;
building paper; white papers from
bleached kraft; paperboards for cartons,
containers and corrugated board
SO2 relief gas recovered; Mg liquor
recovered after wood digestion and
washing
Dull white color; easily bleached; fibers
weaker than kraft fibers
Book paper, bread wrap, sanitary tissue
------- |