A How-to: Make Thick Paper From Recycled Scrap Paper

Today we’re sharing a how-to about learning to make thick paper from recycled scrap paper. The first step in a project to make Christmas Gift Box lamps.

Okay, my research isn’t very successful.

I want to make heavy cardboard from scratch, so I can make the decorative gift boxes with lights inside, as seen in the Kohl’s ad below. Which happen to cost $140 on sale.

The paper needs to be sturdy, with a little blotchy see-through ability, and stringy fibers in the paper. Mulberry paper has the right look, but is definitely not sturdy enough to make a box.

So, as I begin looking for answers I come across this article:

“

Development and quality assessment of handmade papers using underutilized agro based natural fibres

- K. Sannapapamma, Shweta Mariyappanavar, Vidya V. Sangannavar, D. Jamadar, J. Vastrad, Shameembanu A Byadagi
- Environmental Science
- 2020

Management of crop residue for industrial application is an upcoming researchable issue for sustainable environment. Locally available eco-friendly renewable resources viz., sugarcane bagasse, sisal fibre and maize husk have been used for development of handmade papers along with cotton rags and waste paper with different blend proportions. Among the papers, bagasse/cotton (60:40) handmade paper possessed significantly greater thickness, more uneven surface, low folding endurance with greater bursting and tears strength. Further, bursting, tear and tensile strength was found to be greater in bagasse/sisal/cotton (40:30:30) handmade paper followed by bagasse/ waste paper/ cotton paper which can be used as packaging materials to disposable paper plates. Effective management and utilization of agriculture crop residue with other cellulosic waste can be aptly suitable for production of eco friendly handmade papers which will provide sustainable enterprise for rural artisans.
“

I think it basically says that paper made with sisal in it is stronger than without sisal. How much did these scientists get paid to figure this out, I wonder?

Unfortunately, it does nothing to enlighten me about the process.

I want to recycle paper from the trash bin, add sisal fibers, and end up with an almost white paper.

Here’s the consensus of what I found:

How-to for Handmade Paper with Sisal Fibers

SUPPLIES FOR MAKING PAPER

Water
Scrap Papers and sisal twine separated into thin fibers
Plastic tub like a storage tub
Kitchen blender – get one from the thrift store, because you won’t be making smoothies with it again.
Mould & Deckle* (a screen attached to a frame)
Wood boards OR sponge & rolling pin
White felt, pellon, or other absorbent material

CUT UP THE PAPER

Cut or rip up your paper into about 1 inch squares.
Soak your paper for a few hours or overnight.

Drawing, printmaking, and watercolor papers are best because they are generally made from stronger fibers (such as cotton rag, and not chemically treated tree fiber). Your fiber/scrap choice and its characteristics dictate the quality of the final sheet. I have lots of bits and pieces of watercolor paper in my trash bin, and that with the sisal should make it fairly tough. Also, we always buy recycled printer paper, so now it will get recycled again.

STEP 2: BLEND IT & MAKE A TUB OF PULP

Fill the blender three fourths full of water. Throw in a good handful or two of the cut up scrap papers (not too much more, or you’ll burn the blender motor out). Blend until it’s pulp.

Fill up the storage tub with your pulp, about 1/3 to 1/2 way. Add more water to the vat. The more pulp to water, the thicker your paper will be. Stir in some sisal fibers.

STEP 3: PULL SOME SHEETS FROM THE PULP TUB

For this, you’ll need your mould and deckle. It’s basically two frames that are the same size, one with screen attached.

You can find tutorials on how to make your own.

Now, to “pull a sheet” of paper:

Stir your tub of pulp.
Hold the mould screen side up, and place the deckle evenly on top.
Holding them together at a 45 degree angle, dip the mould and deckle to the bottom of the vat and scoop up, holding the mould and deckle horizontally.
As you lift it out of the pulp, give it a quick shake back and forth, and left to right to align the fibers and make a more uniform sheet. Stop shaking before the sheet is fully drained.
Let the water drain to a drip.

STEP 4: COUCHING

(Pronounced coo-ching. It’s a French word, meaning to put to bed.)

‘Couching’ means to transfer the wet sheet from the mould to a flat, absorbent surface. Wool felts are ideal, but thick paper towels, non-fusible interfacing or pellon also work. Set up your felt with a board underneath and soak your couching materials.

Remove the deckle from the mould.
Place a long edge of the mould on the felt.
In smooth motions, place the mold face down, press down, and lift up back toward the long edge.

STEP 5: PRESSING

Option 1: Hand Pressing

Place pellon or paper towel on top of your couched sheet. With a sponge, press gently at first, then firmly. Use a rolling pin to press your paper even more.

Option 2: Board Pressing

Place felt on top of your couched sheet. Couch another sheet, layer another felt, and repeat. Layer one final felt and another wood board when you’ve made a stack. Take the stack outside to a concrete surface and stand on it!

Drying paper on a window. via google images.

STEP 6: DRYING

As a beginner paper maker, these two drying options look the most feasible:

Option 1: Surface Drying

Find a flat, non-porous surface. Smooth wood boards and formica countertops work well.
Take your wet sheet and gently press onto the flat surface. Make sure the edges are pressed down well.
Let the paper dry (1-3 days depending on humidity levels and thickness of the paper).
Peel it off.

Option 2: Exchange Drying

Get some blotters, towels, or other absorbent, dry, flat material.
Make a sandwich of blotters, wet paper, repeat.
When you’re done, place a wood board or a book on top. Weigh it down with more books or something heavy.
Check it every day and exchange the damp blotters for dry ones until your handmade paper is dry.

Thanks to paperslurry.com for most of these directions.

Now I’ll get to work following these directions, and make thick paper.

We’ll update you next week on how it goes, because this is not an instant gratification process.

A How-to: Make Thick Paper From Recycled Scrap Paper