Nov. 04, 2024
Centuries ago, sacks made from jute and burlap were the primary means of holding goods. While sturdy, these materials were time-consuming and costly to produce. In contrast, paper bags are lightweight and significantly more economical to manufacture.
Kraft paper bags gained popularity when inventors developed the technology for mass production. Francis Wolle patented the first paper bag-making machine in the mid-19th century. In 1868, Wolle and his brother established the Union Paper Bag Machine Company, which built a plant capable of producing 1,000 feet of paper per minute.
Years later, inventor Margaret Knight, who worked for the Columbia Paper Bag Company, noted that Wolle's envelope-like design was inefficient. To improve this, she created the square-bottomed bag design and developed a machine that facilitated the widespread commercialization of paper bags.
Since then, paper bags have remained a staple in the market. Thanks to technological advancements, producers can now manufacture paper bags more quickly, efficiently, and with less waste. Below is an overview of how commercial paper bags are processed today.
The wood received at a pulp mill varies in shape and size. It may arrive as round-wood bolts (short logs) with bark or as chips from debarked wood.
For round wood, debarking is necessary, typically achieved by tumbling the wood in large steel drums with wash water. If chemical digestion is required for pulping, debarked wood bolts are processed in a chipper. The chips are then sized, cleaned, and stored for further processing.
The chips are stored in a large pressure cooker (digester) and treated with kraft pulping chemicals. Using steam at precise temperatures, the chips are digested to separate the fibers, which also dissolves lignin and other extractives that can weaken or discolor the paper.
Some digesters run continuously, while others process batches at a time. After digestion, the cooked pulp is discharged into a pressure vessel. Steam and volatile materials are removed, and the heated pulp is reintroduced into the chemical recovery cycle. At this stage, the pulp is screened, cleaned, and excess water is removed in preparation for papermaking.
Raw pulp, containing significant lignin, must be bleached to produce white or light-colored paper. The order of bleaching is determined by factors such as cost of chemicals, pulp type, and pulp condition.
This process further purifies the fibers through chlorination and oxidation. Ultimately, dissolved lignin is extracted from the fibers' surfaces using sodium hydroxide.
The bleached pulp enters the paper mill, where it is mixed with water. The pulp solution undergoes a series of rotating and stationary blades to refine the mixture. This process results in clean-cut, or "fibrillated," fiber ends, which bind tightly, enhancing the paper's strength.
Fillers like calcium carbonate and clay are then added to improve the paper's opacity and density. Dyes and optical brighteners are incorporated to enhance the paper's texture. This final mixture is fed into the paper machine, where water is squeezed out, and the paper is dried and pressed.
Prepared sheets of paper are stacked and then cut to customer specifications, determining the shape and design of the paper bag at this stage.
The sheets are printed using either conventional or digital printing presses. As they pass through, the client-specified design is stamped onto the paper. Typically, fast-drying solvent or water-based inks are used to achieve high-quality prints at speed.
After shearing, specific details for paper bag handles are applied. For bags with rope handles, eyelet punching occurs, and the handles are attached. If the bag has cut-out holes for handles, this too is done at this stage.
The paper is then pleated to facilitate consistent folding and sticking of various bag sections, ensuring uniform assembly.
Clients sometimes require extra durability, so sheets of paper are pasted together for a double layer, enhancing thickness. A machine presses the sheets to create a sturdy, long-lasting bond.
The manufacturing process nears completion. All separately processed pieces, including front, back, and side flaps, are assembled.
Typically, manufacturers employ a tubing machine, which draws in, folds, and bonds the components with adhesive, operating at speeds of 150-250 feet per minute.
In some designs, an additional layer of paper is added to the bottom for enhanced strength, preventing tearing when carrying heavier items.
Finally, finishing touches, such as attaching rope handles, are completed.
Bagitan Packaging specializes in manufacturing professional paper bags, food packaging, and foil packaging for wholesale, retail, and redistribution. Our customizable packaging consists of 100% recyclable materials, making it ideal for brands that aim to offer sustainable options to customers. We handle long-term bulk supply and ship worldwide.
Visit our website at bagitanpackaging.com to learn more, or reach out to us at [protected] to discuss your packaging needs.
Brown paper bags are packaging essentials, but how are they made, and are they genuinely eco-friendly?
Paper bags have been a staple of shopping for centuries. From brown paper bags to white paper bags, various types have woven into our daily lives without us even realizing it.
Have you ever wondered how a paper bag is made? Or when they first came into use? This guide details how paper bags are made today.
While often taken for granted, paper bags have a long history. The first paper bag was invented in the 1850s in the United States. The earliest brown paper bags appeared in the 1880s, but it was in the 1850s that Francis Wolle, a U.S. school teacher, invented the first machine for producing paper bags.
Subsequently, Wolle and his brother established the Union Paper Bag Machine Company and created a paper packaging plant capable of producing a significant quantity of paper in one minute. That very plant is still operational today! Although Wolle invented the machine, the iconic square-bottomed paper bag design we recognize was developed by Luther Childs Crowell in the late 1800s.
Find out more at Bage Machinery.
Who would have imagined that the simple brown paper bag would remain essential over 150 years later?
Today's paper bag-making process has advanced from Wolle's initial designs, yet the core principle remains similar. Each paper bag produced requires approximately one gallon of water. The manufacturing journey begins with paper pulp, which consists of thin wood shavings sourced from trees.
Paper pulp is derived from trees that have been dried for a minimum of three years. The bark is removed, cut into 1-inch strips, and then cooked under intense pressure and heat to form the pulp.
This pulp is pressed into flat sheets or rolls of paper, which are then cut to size (usually twice the finished bag height) and folded. The two parallel open sides are glued together, either by pressing or by heating and pressing. At this point, a simple flat paper bag is produced (similar to those used in sweet shops). For more complex designs like flat-bottomed bags, additional folds allow the finished bag to stand upright. Handles are crafted separately and attached with glue.
While it may seem obvious that paper bags are made of paper, the reality is more complex. Depending on the style and intended use, various paper types can be utilized. Standard brown paper bags typically use kraft paper and can be produced in various colors.
Laminated kraft paper also creates paper bags, featuring a plastic coating on the interior to prevent moisture seeping through—a wise choice for food packaging.
Kraft paper bags come in many colors and weights; generally, brown paper bags are made from 60gsm paper and are available in various sizes. With increasing ecological awareness, many paper bags are now produced from recycled kraft paper, often using robust 110gsm kraft paper for environmentally friendly packaging solutions. Today, paper bags are commonly crafted using a blend of raw and recycled materials.
Disposing of paper bags is quick, easy, and environmentally friendly.
The three main disposal methods are:
Being made of paper allows for recycling, which enables the material to be reused, typically in the form of new paper bags.
To recycle a standard paper bag, it is shredded, boiled, and repurposed into pulp, which is then formed into new sheets of paper, restarting the manufacturing cycle. For personal disposal, composting is a viable option. After setting up a compost bin with garden waste and kitchen scraps, paper bags can be added for decomposition. Furthermore, reusable paper bags can be utilized multiple times before recycling or composting.
If you choose to reuse, you do not have to strictly keep the bags in their original format. Besides using them as packaging, they can protect delicate items and line household objects like pet trays.
Generally, paper bags are biodegradable, making them an excellent choice for composting, as mentioned earlier.
Due to the nature of paper pulp derived from wood chips, the final kraft paper consists of cellulose fibers easily broken down by bacteria in compost bins.
For a paper bag to be fully biodegradable, it must be free from ink, plastic coatings, and other contaminants.
Paper bags are widely recognized as an eco-friendly packaging option for good reason.
Their recyclability is a significant environmental benefit. While paper bag production necessitates cutting down trees, most new paper bags are made from a mix of recycled and raw materials, resulting in reduced impact on forests. The use of recycled paper in production also conserves energy, diminishing greenhouse gas emissions from manufacturing plants.
Furthermore, paper bags can be reused multiple times before their final disposal, further enhancing their ecological benefits. Although some aspects of the paper bag manufacturing process can harm the environment, utilizing paper bags remains significantly more eco-friendly than plastic alternatives.
Paper bags serve multiple purposes, from carrying groceries or purchased items to packed lunches and gift-giving.
Recently, many people have chosen paper bags over plastic ones. Here are several reasons to prefer paper bags:
Having learned how paper bags are made and their environmental benefits, you may want to purchase some for yourself.
As sustainability becomes increasingly critical, more people are searching for paper bags. Fortunately, they are easily accessible, including from providers like Bestpac. Bestpac produces high-quality paper bags and sleeves for bakery and patisserie use.
Our bags are biodegradable, sustainable, and recyclable, ensuring that we only use the highest quality materials and production processes. For more information on our paper bags and finding the perfect paper packaging solution, our experts are available to assist. You can contact them here.
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