A Book of Exposition

by Homer Heath Nugent

While one is watching the operations carried on here, it is impossible to repress the wish that rags might be bought otherwise than by the pound, for, unfortunately, filth, dust, and dirt weigh, and to wash rags only reduces the weight. While this is a true reflection of the condition in the average mill, it is pleasant to know, however, there are others of the higher class that are decided exceptions as far as dust and dirt are concerned. Such are the mills making high-grade ledger and bond papers, as well as the mill manufacturing the paper that is used for the printing of our "greenbacks," to which further reference will be made later. In these exceptional mills everything is neat and perfectly clean, all the stock used being new and fresh from the cotton or linen mills, or from factories producing cloth goods, like shirt and corset factories, and others of the same sort. The sorting and shredding room is always large and light, with windows on all sides, and well ventilated, offering a decided contrast in many respects to the less cleanly mills first referred to where the women must wear bonnets or hoods for the protection of the hair. In either case the process is certainly an improvement over the old plan of leaving the rags to decay in a cellar to expedite the removal of the glutinous matter from them.

From the "sorting" and "shredding" room the rags are conveyed to the "cutter," where they are cut and chopped by revolving knives, leaving them in small pieces and much freer from dust and grit. Various ingenious devices are employed for removing metal and other hard and injurious matter, magnetic brushes serving this purpose in some mills. When the "cutter" has finished its work, the still very dirty rags go for a further cleansing to the "devil," or "whipper," a hollow cone with spikes projecting within, against which work the spikes of a drum, dashing the rags about at great speed. Human lives are often freed of their baser elements and restored to purity and beauty through the chastening influences of tribulation or adversity; in like manner the "whipper" carries the rags forward a step in the process of purification that is necessary before they can be brought to their highest usefulness. But the cleansing process, which is only a preparation for what is to follow, does not end with the "whipper," which has served merely to loosen, not to dislodge, a great deal of dust and dirt. The final operation in the preliminary cleaning is performed by the "duster" proper, which is a conical revolving sieve. As the mass of rags is tossed and shaken about, the loosened dust is carried away by the suction of the air, which draws the dust particles into tubes furnished with suction fans. In most modern mills the rags are carried forward from the "duster" on an endless belt, and a careful watch is kept upon them as they emerge to detect the presence of unchopped pieces, buttons, or other foreign substances. The journey of the rags over this endless belt or conveyor terminates in a receiving-room, in the floor of which there are several openings, and immediately below these the mouths of the "digesters," which are in a room beneath. The "digesters," as they are suggestively and appropriately termed, are huge revolving boilers, usually upright, which often have as great a diameter as eight feet, with a height of twenty-two feet and a digestive capacity of upward of five tons of rags each. The rags that are to be "cooked" are fed in to the "digesters" through the openings in the floor, and the great movable manhole plates are then put in place and closed, hermetically sealing the openings or mouths through which the boilers have been fed, these having first been charged with a mixed solution of lime and soda and with live hot steam in lieu of gastric juice as a digesting fluid and force. In some mills the boilers are placed in a horizontal position, while in others they are in the form of a large ball or globe, in either case being operated in the manner described; those of upright form, however, are most commonly in use. The rags are boiled under steam pressure of about forty pounds to the square inch, and the cooking is continued from twelve to fourteen hours.

It is here that the process of cleaning begins in earnest; and as the mass of rags is tumbled about in its scalding bath of steam-heated lime-water, or "milk of lime," the coloring and glutinous matters, as well as all other impurities, are loosened from the fibers, which are in the end so cleansed and purified as to come forth unstained and of virgin purity. Having been sufficiently boiled and digested, the mushy material, still looking dark and forbidding, is emptied onto the floor below or into receptacles placed directly beneath the boilers, where the color and dirt are allowed to drain off. The mass is then conveyed to the "washers," great tub-like receptacles, which are known as "Hollanders," from the fact that these rag engines were invented in Holland about the year 1750 A.D. They are oval-shaped tubs, about twenty feet long, nine feet wide, and three feet high, varying somewhat according to the conditions. Each tub is divided for two-thirds of its length by an upright partition, or "mid-feather," as it is called, which makes a narrow course around the vat. On one side of the partition, the tub is raised in a half-circle, close to which revolves an iron roll about three or four feet in diameter, and covered with knives; in the bottom of the tub, and directly under the revolving roll, is another set of knives called a "bed-plate," which is stationary, and against which the roll can be lowered. But let us not anticipate. When the emptyings from the boiler have been thrown into the "washer," a continuous stream of water is turned in at one end, the knife-roll having been adjusted so as to open up the rags as they are set in motion. These then begin a lively chase around the edge of the vat, through the race-course formed by the "mid-feather," and under the rag-opening knives, where the water is given a chance to wash out all impurities, then on up the incline over the "back-fall," so-called from the elevation in the tub. A cylinder of wire-cloth, partly immersed in the moving mass, holds back the now rapidly whitening fibers, while the dirty water escapes into buckets inside the wire-cloth drum, and is discharged into and through an escape-spout. The heavy particles of dirt settle into what is termed a "sand-trap" at the bottom of the tub.

As the water clears, the roll is lowered closer and closer to the bottom of the bed-plate, in order to open up the fibers more thoroughly for the free circulation of the water among them. When the several agencies of the "washer" have accomplished their purpose and the water runs clear and unsullied, a bleaching material is put into the mass, which in the course of from two to six hours becomes as white as milk. The dirty offscourings of all ragdom, first seen in the original bales, and gathered from the four corners of the globe, have endured many buffetings, many bruisings and tribulations, and having been washed come forth pure, sweet, and clean. From the washers the rags are precipitated through a trap into drainers, which are chambers made of stone and brick, with a false bottom through which the water is allowed to drain. This rag pulp, now called half stock, is kept in this receptacle until the water and liquor are thoroughly drained off, when it becomes a white and compact mass of fibers.

The rags should stand in the drainers for at least one week, though better results are obtained if they are left for a period two or three times as long, as the fibers become more subdued. The process of paper-making as it has already been described, applies more particularly to papers made from rags. To-day, a very large proportion of the cheaper papers are made from wood, either entirely or in part, and these wood-made papers are subjected to a different treatment, to which further reference will be made.

From the drainer the mass is carted to the beating engine, or "beater," which is very similar in construction to the washer just described. The knives on the roll in the beater are grouped three together instead of two, and are placed nearer the bottom or bed-plate in order to separate more thoroughly the fibers. In the beater are performed many and varying manipulations, designed not only to secure a more perfect product but also to produce different varieties of paper. It is the theory of the beating process that the fibers are not cut, but are drawn out to their utmost extent. In watching the operations of the "beater," one notices on the surface of the slowly revolving mass of fibers, floating bluing, such as the thrifty housewife uses to whiten fine fabrics. This familiar agency of the laundry is introduced into the solution of fibers with the same end in view that is sought in the washtub—to give the clear white color that is so desirable. Many of the inventions and discoveries by which the world has profited largely have been due primarily to some fortunate accident, and according to a pretty story upon which paper-makers have set the seal of their belief for more than one hundred and fifty years, the use of bluing was brought about in the same way. About the year 1746, so runs the story, a Mrs. Buttonshaw, the wife of an English paper-maker, accidentally dropped into a tub of pulp the bag of bluing, or its contents, which she was about to use in a washing of fine linen. Frightened at what she had done and considering it the part of wisdom to keep silence, she discreetly held her peace and awaited results. But when her husband had expressed great wonder and admiration over the paper made from that particular pulp, and had sold it in London at an advance of several shillings over the price of his other paper, which had not met with any such accident, she realized that the time for silence had passed. Her account of the happy accident led her grateful husband to purchase a costly scarlet cloak for her on his next visit to London town. This accident brought about another result which was to prove of inestimable value to the future paper-maker—the use of bluing in paper when especial whiteness is desired.

Important as the bluing or coloring is, however, it is only one of the numerous operations or manipulations that take place in the beater. Many of these, such as engine-sizing and body-coloring, require skill and constant watchfulness. Here, too, if anywhere, adulteration takes place. It is sometimes necessary to secure a fine-appearing paper at small cost, and it is profitable to add to its weight. In such cases a process of "loading" takes place here, and clay or cheap, heavy fibers are added. Clay is of value not only to increase the weight but also to render the paper more opaque, so as to prevent type or illustrations from showing through, while at the same time it makes possible a smoother surface by filling the pores in the paper. But while it adds to the weight, clay must, of necessity, weaken the paper. In engine-sizing, which is done in the beater, the size is thoroughly incorporated with the fibers as these revolve or flow around the engine. This sizing renders the paper more nearly impervious to moisture. The difference between a paper that is sized and that has a repellent surface which prevents the ink from settling into it when it is written upon, and an ordinary blotting-paper with its absorbent surface, is due entirely to the fact that the former is most carefully treated with sizing both in the beating engine and in the size tub or vat referred to later, whereas in the latter paper it is omitted. If the paper is to be tinted or body-colored, colors made from aniline are generally used. Only in the highest grade of writing-paper and in some few papers that demand colors fast to the light is any other order of coloring matter employed. As may be easily imagined, considerable skill is required to secure exactly the desired tint, and to get the coloring matter so evenly mixed that each small fiber shall receive its proper tint, and thus to insure that the paper when finished shall be of uniform color and not present a mottled appearance.

When the operations of the beating engine have been completed, a most interesting process begins which marks a vast advance over the earlier method of forming the sheets of paper with mould and deckel, straining off the water, and shaking the frame with a quick motion to mat the fibers together. The patient striving toward something better which has marked all the centuries since man first learned to carve his rude records, finds its consummation in the process of making paper in a continuous web. This result is accomplished by a machine first invented by Louis Robert, a workman in a mill at Enonnes, France, who obtained a French patent, with a bounty of eight thousand francs for its development. This he later sold to M. Didot, the proprietor of the mill, who crossed the Channel into England, where, with the aid of a skilled mechanic, the machine was in a measure perfected, and then sold to Henry and Sealy Fourdrinier. They, with the further aid of Bryan Donkin, their employee and expert engineer, made many additional improvements, and sank in the enterprise some sixty thousand pounds sterling, for which their only reward was blighted hopes and embittered lives. In 1847 the London Times made a fruitless appeal on behalf of the surviving brother, who was eighty years of age and in great poverty. It is seldom that the world voluntarily makes return to those who have bestowed upon it great material or moral benefits, though it is ever ready to expend its treasure for engines of destruction and to magnify and reward those who have been most successful in destroying human life.

The first "machine" mill was started at Frogmore, Hertz, England, in 1803, which was the year of the great Louisiana Purchase by the United States, and it is not difficult to say which event has been productive of the greater and more beneficial results to this nation. Through this invention and its improvements, the modern newspaper and magazine, with their tens and hundreds of thousands of copies daily, have been made possible, and men of all classes have been brought in touch with the best thought of the day. Whatever makes for greater intelligence and enlightenment throughout a nation makes for the greater stability of the national life, and gives new emphasis to Bulwer's words:

Take away the sword; States can be saved without it—bring the pen.