The Aylesford Newsprint Story
The Aylesford Newsprint Story
The Aylesford Newsprint Story
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<strong>The</strong> <strong>Aylesford</strong> <strong>Newsprint</strong> <strong>Story</strong><br />
An Introduction
CONTENTS<br />
History 02<br />
Recycled Fibre 04<br />
Making Paper 08<br />
Wrapping Up 12<br />
Moving On 13<br />
Sales and Marketing 14<br />
Technical Services 15<br />
Research and Development 16<br />
Environment 16<br />
Specification<br />
IBC<br />
Alan McKendrick Chief Executive<br />
Mission Statement<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> aims to be the natural<br />
choice for buyers of premium quality newsprint<br />
in Europe.<br />
Let’s start at the beginning<br />
Its product is made exclusively by recycling<br />
paper, using skilled, highly trained people<br />
and the most advanced technology available.<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> strives to provide<br />
an unrivalled service to customers and seeks<br />
to work in partnership with local authorities<br />
and communities in the collection of used<br />
paper for recycling.<br />
Did you know...<br />
<strong>Aylesford</strong> <strong>Newsprint</strong><br />
supplies 1% of the<br />
worlds newsprint -<br />
by only using<br />
recovered paper.<br />
Darryl Jackson Apprentice<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> | 01
<strong>Newsprint</strong> has been manufactured<br />
in <strong>Aylesford</strong> since 1922. <strong>The</strong> site, now<br />
synonymous with <strong>Aylesford</strong> <strong>Newsprint</strong><br />
Limited, was acquired in 1917 with building<br />
work commencing in 1920. Within a few<br />
years the mill was employing some<br />
1500 people.<br />
During the second world war, because pulp<br />
could not be imported, waste paper was<br />
used, but this ceased after the war was over,<br />
but in the 1960s work recommenced with<br />
the use of recycled fibre.<br />
In 1968 20% recycled fibre was first used<br />
in the production of newsprint, gradually<br />
increasing to 100% in 1984. Since that time<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> has continued to be<br />
a leader in newsprint production.<br />
In 1990 the site was purchased by the<br />
Swedish paper making group SCA and<br />
in 1993, following formation of the joint<br />
venture company by SCA Forest Products<br />
and Mondi, <strong>Aylesford</strong> <strong>Newsprint</strong> Limited was<br />
incorporated to invest over £300 million in<br />
an industry leading development.<br />
<strong>The</strong> new mill at <strong>Aylesford</strong>, was built to house<br />
the state of the art paper machine PM14<br />
to manufacture Renaissance newsprint,<br />
produced exclusively from 100% recycled<br />
fibre, in conjunction with our existing paper<br />
machine PM13.<br />
<strong>The</strong> company strives to maintain its ongoing<br />
commitment for optimum operational<br />
standards, which is supported by a<br />
dedicated sales team, working alongside<br />
our professional and highly experienced<br />
technical service department.<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> is underpinned by<br />
a formal and recognised environmental<br />
policy embracing a commitment to<br />
continuous improvement in its manufacturing<br />
and production processes. Up to date training<br />
for all is provided and a strong safety culture<br />
is maintained for its employees and visitors,<br />
all with the aspiration of sustaining a safe<br />
and secure future for the company, its<br />
employees and the production of Renaissance.<br />
Our History<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> is a joint venture company<br />
owned by two blue chip companies, SCA Forest<br />
Products and Mondi, and is steeped in the<br />
tradition of innovative paper making.<br />
Liz Williamson Sales Administrator Jo Mason Sales Administrator David Lansdowne Sales Administrator<br />
Did you know...<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> recycles<br />
over 90% of the water<br />
it uses in the process.<br />
02 | <strong>Aylesford</strong> <strong>Newsprint</strong> <strong>Aylesford</strong> <strong>Newsprint</strong> | 03
Recycled Fibre<br />
Did you know...<br />
Our RCF store has a capacity<br />
of 10,000 tonnes. <strong>The</strong> suppliers<br />
include local authorities, waste<br />
management companies<br />
and community groups.<br />
Chris Chapman RCF Operator<br />
04 | <strong>Aylesford</strong> <strong>Newsprint</strong> <strong>Aylesford</strong> <strong>Newsprint</strong> | 05
<strong>The</strong> demand for recycled newsprint continues<br />
to increase, encouraged not only by statutory<br />
legislation, but also by incentives of the U.K.<br />
Government to increase and enhance public<br />
awareness in all aspects of recycling; taking<br />
into account the shortage of landfill sites.<br />
Public involvement is sought by seeking<br />
co-operation in the drive to preserve energy,<br />
water and other materials. <strong>The</strong> recycling<br />
of waste paper is a vitally important aspect<br />
to this programme and we at <strong>Aylesford</strong><br />
<strong>Newsprint</strong> continue to support such an<br />
initiative with the production of our 100%<br />
recycled newsprint branded Renaissance.<br />
In another life Renaissance newsprint could<br />
have originated from completely different<br />
publications. We recycle one in seven of the<br />
U.K.’s newspapers and magazines –<br />
a staggering total of 500,000 tonnes<br />
recovered each year.<br />
At present we have 2,000 blue banks for<br />
collection of newsprint and magazines in<br />
the southern part of England and we work<br />
in partnership with over 100 Local Authorities<br />
to support the collection of waste paper.<br />
<strong>The</strong> old adage Waste Not Want Not brings<br />
a new meaning to used newspapers and<br />
magazines as this can provide us with the<br />
raw material necessary for our process. Major<br />
source of supplies are the kerbside collections<br />
made directly with Local Authorities and<br />
through Waste Management Companies<br />
and Paper Merchants. A high percentage<br />
of the 500,000 tonnes we recycle comes<br />
from household collection. Amongst other<br />
sources is the collection made of publishers<br />
returns and pressroom rejects which makes<br />
a significant contribution in maintaining the<br />
best balance of material reprocessed in the<br />
mill towards the continuance of recycling<br />
waste paper.<br />
Kerbside collections, Greenford<br />
Newspapers and magazines conveyed to Fibre Preparation Plant<br />
Recycled Fibre<br />
Yesterday’s news can still make tomorrow’s<br />
front pages.<br />
Gemma Barratt Recycling Area Manager<br />
Did you know...<br />
We have 2,000 blue banks<br />
for collection of newsprint<br />
and magazines in the<br />
southern part of England<br />
Flotation Cells<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> | 07
Making paper<br />
Did you know...<br />
Paper Machine 14 produces<br />
500,000 miles of premium<br />
quality Renaissance<br />
newsprint each year.<br />
08 10 | <strong>Aylesford</strong> <strong>Newsprint</strong> <strong>Aylesford</strong> <strong>Newsprint</strong> | 09 11
<strong>The</strong> quality and mix of the raw material<br />
determines the quality of our final<br />
manufactured product and is an important<br />
factor in sourcing material. We do not accept<br />
paper from any collection where there is a<br />
risk of glass contamination as glass fragments<br />
causes damage to our paper fibre cleaning<br />
and screening process. <strong>The</strong> quality of paper<br />
resulting from co-mingled collections simply<br />
does not meet our minimum standards.<br />
<strong>The</strong> 30/70 mix of used magazines and<br />
newspapers (PAMs) used by <strong>Aylesford</strong><br />
<strong>Newsprint</strong> is one of the key constituents<br />
which go towards making Renaissance<br />
a premium quality newsprint. Only strong<br />
fibres are used in the manufacture of<br />
Renaissance and we maintain an ongoing<br />
analysis of the consistency of the fibres in<br />
recycled paper to ensure that our paper<br />
achieves the best properties required for<br />
printing in today’s modern pressrooms.<br />
<strong>The</strong> raw material is mixed with water and<br />
soap in our high consistency pulpers where<br />
contaminants such as CD cases, flip flops and<br />
other magazine “freebies” are removed.<br />
We are working continually to find better<br />
solutions for the disposal of such items.<br />
After the pulpers the raw material travels<br />
through to our Fibre Preparation Plant for<br />
a 14 stage screening and cleaning process,<br />
initially removing any staples, adhesives<br />
or other substances which can cause the<br />
phenomenon of “stickies” in the finished<br />
product. <strong>The</strong> pulp then passes through<br />
our flotation cells to remove the ink and<br />
then progresses through various cleaning<br />
stages before being sent through to our<br />
paper machines to begin the process of<br />
manufacturing Renaissance newsprint.<br />
Soft calendaring surface treatment ensures<br />
that the roughness of the newsprint<br />
is controlled to minimise the problems<br />
associated with low and high roughness.<br />
Low roughness inhibits ink absorption and<br />
increases the potential of “rub-off”.<br />
Our final product is newsprint produced<br />
on 9.4 metre wide 40 tonne jumbo reels<br />
for cutting to customer requirements.<br />
Renaissance newsprint offers customers<br />
a bright, clean and strong sheet, qualities<br />
essential for printability, endurance and<br />
customer satisfaction, in weights of between<br />
42.5gsm and 55gsm.<br />
<strong>The</strong> ultimate test for any newsprint is the<br />
way it looks, its brightness and its ability<br />
to reproduce excellent quality colour images<br />
on both sides of the sheet.<br />
We at <strong>Aylesford</strong> <strong>Newsprint</strong> believe that<br />
Renaissance newsprint can meet this criteria<br />
knowing that each process has been designed<br />
to maximise its performance on the presses,<br />
and offer the end user a product to achieve<br />
excellent printability.<br />
Making Paper<br />
<strong>The</strong> ultimate test for any newsprint is the<br />
way it looks, its brightness and its ability<br />
to reproduce good quality colour images<br />
on both sides of the sheet.<br />
Checking forming fabric<br />
Keeping an eye on the process<br />
Paul Redsell Production Planner<br />
Did you know...<br />
Barry Williamson Senior Production Planner<br />
Our secondary product can be<br />
used in aggregates, cement<br />
replacement, compost and even<br />
animal bedding.<br />
Stranger than Fiction:<br />
Some of the more bizarre objects detected in our recovered<br />
paper have been a sheep’s head, live ammunition, a family<br />
of live hamsters, engine parts, wedding rings, umbrellas,<br />
training shoes, golf balls, shoes etc., to the more normal<br />
things such as beer cans, carrier bags and bin liners.<br />
Taking quality control samples<br />
10 | <strong>Aylesford</strong> <strong>Newsprint</strong> <strong>Aylesford</strong> <strong>Newsprint</strong> | 11
At the end of the advanced manufacturing<br />
process reels are wound to customer<br />
specification and automatically wrapped and<br />
bar-coded. <strong>The</strong> reels then travel by conveyor<br />
belt to the high bay warehouse, operated<br />
and maintained by sophisticated technology.<br />
By the use of automatically guided cranes<br />
each reel is stored in its own bay. This method<br />
of storage avoids contact stacking of the reels<br />
and they remain untouched by human hand<br />
until delivery is required.<br />
Reel stock and retrieval is fully automated<br />
and no suction or clamps are used during<br />
the handling at these stages. <strong>The</strong> controlled<br />
environment ensures humidity levels are<br />
kept constant to maintain moisture levels<br />
during storage.<br />
<strong>The</strong> entire system is computer controlled<br />
using a sophisticated bar code reading system.<br />
Situated in the South of England and<br />
connected to the continent by an integrated<br />
distribution network of road, rail and sea,<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> is perfectly placed for<br />
delivery throughout Europe. <strong>The</strong> Channel<br />
Tunnel is only 35 miles away and we can<br />
deliver newsprint to anywhere in Northern<br />
Europe. Smooth running delivery is<br />
guaranteed by our fully automated despatch<br />
system, which uses computerised handling<br />
devices to select reels and load them<br />
automatically onto the specialised fleet<br />
of lorries. <strong>Aylesford</strong> <strong>Newsprint</strong> can offer<br />
a flexible just in time delivery with reel sizes<br />
adjusted at short notice giving increased<br />
flexibility, with customers enjoying the<br />
knowledge that they do not have to waste<br />
capital by maintaining large stocks of<br />
newsprint.<br />
Did you know...<br />
In 2006 we travelled<br />
1,710,540 miles delivering<br />
our product in the UK<br />
and Europe.<br />
Dual purpose vehicles<br />
are used to improve the<br />
environmental effects<br />
of our transport<br />
system.<br />
Tracy Edwards Logistics Coordinator<br />
Wrapping Up<br />
<strong>The</strong> wrapping station<br />
Moving On<br />
Reels are moved into the high bay warehouse<br />
Reels ready for despatch<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> | 13
<strong>The</strong> Sales & Marketing department<br />
of <strong>Aylesford</strong> <strong>Newsprint</strong> embraces the<br />
administration and planning of customers’<br />
orders. We have an ongoing commitment to<br />
our customers to provide an efficient, friendly<br />
and helpful service in the areas of both sales<br />
administration and technical service.<br />
<strong>The</strong> support we give is just a phone call or visit<br />
away and our valued customer relationships<br />
are regarded most highly and take priority<br />
in the day to day and future considerations<br />
of our business.<br />
<strong>The</strong> Sales Team<br />
Customer service is a key element of the<br />
business at <strong>Aylesford</strong> <strong>Newsprint</strong>.<br />
This bespoke service starts from the<br />
experienced and dedicated sales office<br />
team who control orders during each stage<br />
– from the initial order being received,<br />
right through to final delivery. Using the<br />
sophisticated mill wide computer system they<br />
monitor every aspect of the order process<br />
and our Sales Team pride themselves on the<br />
excellent customer relationships and service<br />
they provide on a daily basis.<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> ensures that staff<br />
dealing with customers are highly trained,<br />
experienced and qualified to deal with<br />
any query.<br />
From our customers’ perspective, we believe<br />
that this commitment is evident from their<br />
first contact with the Sales Department who<br />
act at the heart of the organisation, with its<br />
contiguous sales administration, production<br />
planning, and customer technical service team<br />
endeavouring to ensure that the customers’<br />
requirements remain paramount throughout<br />
each process.<br />
<strong>The</strong> marketing side of the department<br />
is responsible for all promotional material,<br />
embracing the imagery and branding<br />
of the company.<br />
Our highly competent team are experienced<br />
in all printing processes being technically<br />
proficient in every aspect and area of paper<br />
manufacture, providing an efficient and<br />
effective technical support system.<br />
Responding to any questions, they can give<br />
advice on all areas of practice from routine<br />
information on the technical properties of<br />
a particular reel to specialist assistance on<br />
the best way to use Renaissance newsprint<br />
in conjunction with different presses and<br />
inking systems.<br />
<strong>The</strong> Customer Technical Service Team is fully<br />
supported by a flexible management system,<br />
skilled technicians and a highly experienced<br />
Research and Development Department.<br />
With the experience and ability to make<br />
immediate decisions on behalf of the<br />
company, members of this team are able<br />
to give a quick reaction to any customers’<br />
needs with response times shortened<br />
by the use of our in house Research and<br />
Development Department.<br />
Within the mill, control of the manufacturing<br />
process is maintained through <strong>Aylesford</strong><br />
<strong>Newsprint</strong>’s innovative operating system –<br />
Paper Quality Management System (PQMS)<br />
providing all the answers to any query from<br />
product specification to planned delivery<br />
time. Information stored on the individual<br />
barcode printed on each wrapper, allows the<br />
Customer Technical Service Team to retrieve<br />
all relevant data by reference to any particular<br />
order or isolated reel.<br />
PQMS provides technicians with the facility,<br />
when having analysed paper manufactured,<br />
to place detailed reports directly onto the<br />
system. An immediate follow up by Research<br />
and Development allows decisions to be<br />
made swiftly and efficiently to maintain the<br />
continuous process of paper production.<br />
Sales & Marketing<br />
Customer service is a key element of the<br />
business at <strong>Aylesford</strong> <strong>Newsprint</strong>.<br />
Terry Worby Marketing Manager<br />
Mike Pankhurst Technical Service Manager<br />
Bruce Lord Customer Technical Service<br />
Technical Service<br />
Support with technical advice is always<br />
available at any hour of the day or night<br />
and is a fundamental component of the<br />
quality of service available for all of our<br />
Renaissance customers.<br />
Tom Sefto Customer Technical Service<br />
Bob Boast Sales and Marketing Director<br />
14 | <strong>Aylesford</strong> <strong>Newsprint</strong><br />
Mike Pankhurst with Duncan Gray - Operations Director, Kent Messenger Group<br />
Control room at Trinity Mirror Printing, Watford<br />
<strong>Aylesford</strong> <strong>Newsprint</strong> | 15
Research and Development<br />
Research and Development people work<br />
closely with our customers to continuously<br />
improve quality and efficiency.<br />
• Environmental management system<br />
• Technical claims investigations<br />
• Contacts with research organisations such<br />
as SCA-Research, PIRA, UMIST and STFI<br />
• Chemical safety research<br />
• <strong>Newsprint</strong> quality specification<br />
• Product & Process Development<br />
• Consultations and contacts with regulatory<br />
authorities<br />
<strong>The</strong> Environment<br />
From raw material to delivered finished<br />
product, every production and delivery<br />
aspect is monitored from an environmental<br />
perspective.<br />
• Renaissance is made from 100% recycled<br />
fibre, with the benefit of reducing landfill<br />
• <strong>The</strong> <strong>Aylesford</strong> <strong>Newsprint</strong> mill uses 60% less<br />
energy per tonne than producing newsprint<br />
from virgin fibre<br />
• We recycle over 90% of water used in<br />
manufacturing newsprint<br />
• Our modern water treatment process<br />
provides high quality treated water<br />
• Our process residues are combusted in a<br />
purpose designed boiler fitted with modern<br />
emission controls, producing up to 30%<br />
of the Mill’s thermal energy requirement<br />
• Our secondary product can be used in<br />
aggregates, cement replacement, compost<br />
and animal bedding<br />
• We are using dual purpose vehicles<br />
to improve the overall efficiency and<br />
environmental effects of our transport<br />
system<br />
Accreditations<br />
• Environmental Standard ISO 14001<br />
• Quality Standard ISO 9002<br />
• Investor in People<br />
Site Information<br />
• 100 acre site at <strong>Aylesford</strong>, Kent<br />
• Paper Machine 14 (PM14) -<br />
120 metres long, 10 metres wide and<br />
operating at 1650 metres per minute.<br />
Capacity 300,000 tonnes per annum<br />
• Paper Machine 13 (PM13) -<br />
90 metres long, 5.4 metres wide and<br />
operating at 900 metres per minute.<br />
Capacity 90,000 tonnes per annum<br />
• Gas-powered combined heat and power<br />
plant (owned by Npower Cogen, part<br />
of the RWE Group) situated on mill land<br />
and operated by our people<br />
• De-Inking and pulping plant 500,000 tonnes<br />
per annum capacity of recovered paper<br />
• Biological Water Treatment Plant<br />
TARGET VALUES<br />
Grammage (gm 2 )<br />
Caliper (µm)<br />
Density (kg/m 3 )<br />
Moisture Content (%)<br />
Filler Content (%)<br />
Parker Print Surf (µm)<br />
Air Permeance (µm/Pas)<br />
Tensile Strength MD (kN/m)<br />
Stretch MD (%)<br />
TEA (J/m 2 )<br />
Opacity (%)<br />
Luminance (%)<br />
Purity (%)<br />
42.5<br />
64<br />
660<br />
10.0<br />
8.5<br />
4.0-4.5<br />
4.5<br />
2.5<br />
1.0<br />
15.0<br />
93.5<br />
64.0<br />
4.5<br />
45.0<br />
68<br />
660<br />
10.0<br />
8.5<br />
4.0-4.5<br />
4.0<br />
2.7<br />
1.0<br />
17.0<br />
94.0<br />
64.0<br />
4.5<br />
48.8<br />
74<br />
660<br />
10.0<br />
8.5<br />
4.0-4.5<br />
3.3<br />
3.0<br />
1.0<br />
19.0<br />
95.0<br />
64.0<br />
4.5<br />
52.0<br />
74<br />
700<br />
10.0<br />
8.5<br />
4.0-4.5<br />
3.0<br />
3.1<br />
1.1<br />
22.0<br />
96.0<br />
64.0<br />
4.5<br />
55.0<br />
79<br />
700<br />
10.0<br />
8.5<br />
4.0-4.5<br />
2.5<br />
3.4<br />
1.1<br />
25.0<br />
96.5<br />
64.0<br />
4.5<br />
Dominant Wavelength (nm)<br />
575<br />
575<br />
575<br />
575<br />
575<br />
Additional Information<br />
Specification<br />
<strong>The</strong> values given are set values and variations occur. Optical<br />
values measured by Elrepho 2000, calibrated against master<br />
STFI Elrepho (authorised by ISO).<br />
Designed by 2Cs Communication +44 (0)1473 622263<br />
Photography by Roddy Paine Photographic<br />
Studio +44 (0)1892 534825<br />
Printed by Dexter Graphics +44 (0)1322 2888 880<br />
Printed on Greencoat Plus Velvet<br />
• 80% recycled post-consumer fibre<br />
• 10% TCF (Totally Chlorine Free) virgin fibre<br />
• 10% ECF (Elemental Chlorine Free) fibre<br />
• FSC certification<br />
• NAPM recycled certification<br />
Water Treatment Plant
<strong>Aylesford</strong> <strong>Newsprint</strong> Limited<br />
<strong>Newsprint</strong> House<br />
Bellingham Way<br />
<strong>Aylesford</strong><br />
Kent ME20 7DL<br />
T: +44 (0) 1622 796000<br />
F: +44 (0) 1622 796001<br />
Sales Administration:<br />
An experienced team is available to<br />
respond to all your enquiries regarding<br />
the purchase, administration and delivery<br />
of newsprint.<br />
Sales enquiries:<br />
T: +44 (0) 1622 796000<br />
F: +44 (0) 1622 796001<br />
Customer Technical Service:<br />
Our technical service team is available 24<br />
hours, 7 days a week to respond to any<br />
technical enquiry or problem.<br />
Hotline:<br />
T: +44 (0) 1622 796002<br />
Environment report:<br />
For a copy of our latest environment report, please call:<br />
T: +44 (0) 1622 796002<br />
Alternatively download a PDF from our website<br />
www.aylesford-newsprint.co.uk