Favini_come si produce la carta_jumbo roll

How paper is produced

13 Nov

Posted in Graphic Specialities

In Favini we transform cellulose fibre into a material that is able to give form to the packaging, shoppers, catalogues, corporate identity and creative ideas of brands from the world of design, fashion and luxury. The material we are talking about is paper: versatile, recyclable and sensory.

Favini paper can be used for the creation of various products that we encounter in everyday life.

We find it on the desks of designers and students used as notebooks to capture the ideas and sketches of creative concepts. In perfumeries and fashion stores, it is used to protect and personalise the best perfumes, cosmetics, footwear and accessories with packaging that catches the eye. On the city streets we see it in the hands of the fashionistas and shop obsessed and beyond, since the paper shoppers are reusable and recyclable. But for what else?

Thanks to its versatility it is perfect for printing product and exhibition catalogues, art books, folders, business cards, menus, brochures and invitations.


The paper production process in Favini papermill in Rossano Veneto

Various web sites tell the story of how paper mills transform tree cellulose into paper. One such example is the Focus Junior, which explains how paper is made.

How paper is made at Favini

Let’s look at the various steps: from hydrapulper to the continuous machine web, on to the storage warehouse for the sheet reams and reels.

Il pulper, dove viene miscelato il mix di ingredienti per produrre la carta costituito al 95% da acqua.

The hydrapulper, where the mix of ingredients is combined to produce paper made up of 95% water.

The hydrapulper mixes various ingredients with water: virgin tree cellulose, post-consumer recycled fibre, fibres from annual plants (cotton, bamboo and bagasse), pre-consumer waste such as cutting trimmings. These different fibre types will give specific characteristics to the paper.

Another possible ingredient, which characterizes Favini’s know-how, are the specially milled particles created and developed at the Rossano Veneto (VI) mill site of the by-products from agro-industrial processing: coffee, kiwi, corn, almonds, hazelnuts, lavender, cherries, grapes, citrus fruits, olives.

In addition to these elements used to produce the ecological Crush paper, Favini uses other by-products for special production items such as bran (for more information about CartaCrusca for Barilla case history) and residues of leather manufacturing to obtain Remake (more information about the paper created from upcycling ).

Find out more about these ecological papers which have marked the history of Favini in the article “The story of creative reuse in Favini: the ecological papers created by upcycling“.

Water, a key element in the production of paper

Water is one of the principal raw materials used in the paper production process and it has multiple functions within a paper mill: water is used as the solution to suspend the fibres and other paper manufacturing ingredients, in the coating recipe and as a heating fluid. For this reason, Favini has very careful management programme to reduce waste, focus on efficiency in use, as well as recovery and reuse.

Negli ultimi anni (2009-2016) grazie al piano di miglioramento nell’utilizzo di questa risorsa è stato risparmiato il 29% di acqua. Scopri di più nella sezione Consumi Idrici del Sustainability Channel.

In the last years (2009-2017) thanks to an efficient use of this resource 39% of water were saved. Discover more in water consumption page of the Sustainability Channel.

From the mixture in the pulper to the paper machine

From the hydrapulper the paper slurry goes to the colouring tank. Favini produces numerous coloured papers in high quality grades, for example Burano (read the article Inspirations from Venice), as well as papers with customized colours.

La tina di miscelazione dove vengono aggiunte le cariche inorganiche (carbonato di calcio), l’amido, la colla e i coloranti.

The mixing tank where the inorganic fillers (calcium carbonate), the starch, the sizing agent and the dyes are added.

In R&D laboratories of Favini paper mill we develop customized colours on request for some of the most demanding brands,  notable and distinguished in the mind of the consumer for their specific brand colour. Once approved, the custom coloured paper is manufactured.

The papers, both in the regular colour palette and the customized versions, are produced on the paper machine. The pulp slurry passes from the vats in which the last ingredients are mixed then pass through the head box to flow evenly across the moving paper wire and flat bed table.

For each type of paper to be produced and based on its final use, a specific recipe is followed, studied and tested in the laboratory before manufacture.

The wire of a paper machine acts like a sieve to drain away the excess water.

The wire of a paper machine acts like a sieve to drain away the excess water.

From the flat table the wire of paper passes through the wet presses

From the flat table the wire of paper passes through the wet presses

In this phase when the mixture is still mainly water, the surface of the paper can be felt marked with special treatment.

Nella seccheria, la carta, facendo un percorso a S attraverso i cilindri essiccatori, si stira e si asciuga mediante evaporazione dell’acqua.

In the dryer, the paper, making an S-path through the heated dryers, is ironed and dried by evaporation of the water.

In the middle of the drying section, the size press spreads a finishing treatment to improve the appearance and printability of the paper, it is also at this point that it is possible to optimize the surface for wet toner digital printing (HP Indigo).

Il nastro di carta viene arrotolato attorno a un’anima in acciaio dando luogo alla bobina madre

The paper web is wound on to a steel core forming a jumbo roll

The post-production processes of paper

The appearance and functionality of the paper can be changed after production. For example, in Favini there is an embossing department where the surface of the newly produced paper passes through two rollers which give a three-dimensional texture and modify its finish. Discover the several designs offered by Favini:

Thanks to the surface finish, an embossed paper can appear to the eye like a canvas or have a leather look or perhaps have a geometric design. The tactile aspect of the paper is enhanced by modifying the flat surface into a slightly 3D structure. This gives the paper a higher multi-sensory aspect.

The paper produced including the embossed finishes, will then be cut into sheets and packed, it is protected by a special protective wrapping that keeps the contents humidity controlled and dirt and contaminant free, it then moves finally into storage.

From Favini warehouse, the paper is ready to be shipped and used! Are you undecided about which paper is the most suitable to realize your graphic idea? Visit

Favini stock

Are you looking for graphic design inspiration of printed items and items made on paper? Every week on Favini’s official social media, you will find new ideas on packaging, catalogues and shoppers made from the graphic paper that is most suitable for the customer’s needs. In addition, you will find design ideas that inspire on menus, brochures, invitations to events, fashion shows, weddings and private parties, art exhibition private views.

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