Types of Synthetic Paper and Manufacturing Methods

Synthetic paper is manufactured using synthetic resin which is derived from petroleum as its primary material. Its characteristics are similar to those of plastic film and appearance to that of regular paper. It possesses several qualities similar to that of paper made primarily from wood pulp, especially its white and opaque appearance as well as its printing and processing capabilities.

According to their manufacturing method, resin-based synthetic papers have been divided into two broad categories which are as follows:-

1.    Film synthetic paper
2.    Fiber synthetic paper.

Several manufacturing methods exist for both the categories. Let us look at them one by one.

 Manufacturing methods for Film Synthetic Paper

a)    Internal Paper Manufacturing Method
 
        
Synthetic paper manufacturers add filling material and additives to the synthetic resin. The mixture is fused and kneaded in an extrude.  A film is formed by extruding the material through a die slit. The relatively thin fused resin pushed through the die slit can be treated in one of two ways-

1. Non-oriented film method- Here the output resin is hardened by cooling and prepared for commercialization.
2. Bi axial oriented film method- Here the output resin is temporarily cooled and then heated to re-soften the mixture. It is then stretched in the longitudinal and cross directions, forming a film. During stretching, tiny holes (micro-voids) may or may not be allowed to form resulting in two different kinds of products.

b)    Surface Coating Method

In this method a layer of pigment coating is added to the plastic film (including synthetic paper produced by the internal paper-manufacturing method above). This method imparts properties like whiteness, opacity, and suitability for writing and
printing.

c)    Surface Treatment Method

Physical or chemical treatment of the synthetic resin film surface results in qualities such as suitability for writing and printing or opacity using this method.

Manufacturing methods for Fiber Synthetic Paper

a)    Synthetic Pulp Paper Method

Resin fibers are replaced with pulp made primarily from synthetic fibers.


b)    Sp-unbound Paper Method

Synthetic resin is dissolved and injected through a nozzle lining up endless fibers formed as like synthetic fabrics. The fibers are fused thermally in some areas, creating inter-fiber bonding. The light-scattering property of the fibers imparts whiteness and opacity to the paper. The synthetic paper produced by this method has superior strength, but it is not as smooth and is of somewhat lower suitability for writing and printing.
 
Synthetic paper manufacturers employ all the above methods to manufacture synthetic paper. However, since film synthetic paper is commonly used and remains in demand, its manufacturing processes are generally followed.

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