Chapter II: Application of Light-Gas (35)

PAPER-HANGINGS, called more properly by the French, _papiers peints_. The art of making paper-hangings, _papier de tenture_, has been copied from the Chinese, among whom it has been practised from time immemorial. The English first imported and began to imitate the Chinese paper-hangings; but being exposed till very lately to a high excise duty upon the manufacture, they have not carried it to that extent and pitch of refinement which the French genius has been enabled to do, unchecked by taxation. The first method of making this paper was stencilling; by laying upon it, in an extended state, a piece of pasteboard having spaces cut out of various figured devices, and applying different water colours with the brush. Another piece of pasteboard with other patterns cut out was next applied, when the former figures were dry, and new designs were thus imparted. By a series of such operations, a tolerable pattern was executed, but with no little labour and expense. The processes of the calico printer were next resorted to, in which engraved blocks of the pear or sycamore were employed to impress the coloured designs.

Paper-hangings may be distinguished into two classes; 1. those which are really painted, and which are designed in France under the title of _papiers peints_, with brilliant flowers and figures; and 2. those in which the designs are formed by foreign matters applied to the paper, under the name of _papier tontisse_, or flock paper.

The operations common to paper-hangings, of both kinds, may be stated as follows:--

1. The paper should be well sized.

2. The edges should be evenly cut by an apparatus like the bookbinder’s press.

3. The ends of each of the 24 sheets which form a piece, should be nicely pasted together; or a Fourdrinier web of paper should be taken.

4. Laying the grounds, is done with earthy colours or coloured lakes thickened with size, and applied with brushes.

An expert workman, with one or two children, can lay the grounds of 300 pieces in a day. The pieces are now suspended upon poles near the ceiling, in order to be dried. They are then rolled up and carried to the apartment where they are polished, by being laid upon a smooth table, with the painted side undermost, and rubbed with the polisher. Pieces intended to be satined, are grounded with fine Paris plaster, instead of Spanish white; and are not smoothed with a brass polisher, but with a hard brush attached to the lower end of the swing polishing rod. After spreading the piece upon the table with the grounded side undermost, the paper-stainer dusts the upper surface with finely powdered chalk of Briançon, commonly called talc, and rubs it strongly with the brush. In this way the satiny lustre is produced.

THE PRINTING OPERATIONS.

Blocks about two inches thick, formed of three separate boards glued together, of which two are made of poplar, and one (that which is engraved) of pear-tree or sycamore, are used for printing paper-hangings, as for calicoes. The grain of the upper layer of wood should be laid across that of the layer below. As many blocks are required as there are colours and shades of colour. To make the figure of a rose, for example, three several reds must be applied in succession, the one deeper than the other, a white for the clear spaces, two and sometimes three greens for the leaves, and two wood colours for the stems; altogether from 9 to 12 for a rose. Each block carries small pin points fixed at its corners to guide the workman in the insertion of the figure exactly in its place. An expert hand places these guide pins so that their marks are covered and concealed by the impression of the next block; and the finished piece shows merely those belonging to the first and last blocks.

In printing, the workman employs the same _swimming-tub_ apparatus which has been described under block printing (see CALICO-PRINTING), takes off the colour upon his blocks, and impresses them on the paper extended upon a table in the very same way. The tub in which the drum or frame covered with calf-skin is inverted, contains simply water thickened with parings of paper from the bookbinder, instead of the pasty mixture employed by the calico-printers. In impressing the colour by the block upon the paper, he employs a lever of the second kind, to increase the power of his arm, making it act upon the block through the intervention of a piece of wood, shaped like the bridge of a violin. This tool is called _tasseau_ by the French. A child is constantly occupied in spreading colour with a brush upon the calf-skin head of the drum or sieve, and in sliding off the paper upon a wooden trestle or horse, in proportion as it is finished. When the piece has received one set of coloured impressions, the workman, assisted by his little aid called a _tireur_ (drawer), hooks it upon the drying-poles under the ceiling. A sufficient number of pieces should be provided to keep the printer occupied during the whole at least of one day, so that they will be dried and ready to receive another set of coloured impressions by the following morning.

All the colours are applied in the same manner, every shade being formed by means of the blocks, which determine all the beauty and regularity of the design. A pattern drawer of taste may produce a very beautiful effect. The history of Psyche and Cupid, by M. Dufour, has been considered a masterpiece in this art, rivalling the productions of the pencil in the gradation, softness, and brilliancy of the tints.

When the piece is completely printed, the workman looks it all over, and if there be any defects, he corrects them by the brush or pencil, applying first the correction of one colour, and afterwards of the rest.

A final satining, after the colours are dried, is communicated by the friction of a finely polished brass roller, attached by its end gudgeons to the lower extremity of a long swing-frame; and acting along the cylindrical surface of a smooth table, upon which the paper is spread.

The _fondu_ or rainbow style of paper-hangings, which I have referred to this place in the article CALICO-PRINTING, is produced by means of an assortment of oblong narrow tin pans, fixed in a frame, close side to side, each being about one inch wide, two inches deep, and eight inches long; the colours of the prismatic spectrum, red, orange, yellow, green, &c., are put, in a liquid state, successively in these pans; so that when the oblong brush A, B, with guide ledges _a_, _b_, _c_, is dipped into them across the whole of the parallel row at once, it comes out impressed with the different colours at successive points _e_, _e_, _e_, _e_, of its length, and is then drawn by the paper-stainer over the face of the woollen drumhead, or sieve of the swimming tub, upon which it leaves a corresponding series of stripes in colours, graduating into one another like those of the prismatic spectrum. By applying his block to the _tear_, the workman takes up the colour in rainbow hues, and transfers these to the paper. _f_, _f_, _f_, _f_ show the separate brushes in tin sheaths, set in one frame.

At M. Zuber’s magnificent establishment in the antient château of Rixheim, near Mulhouse, where the most beautiful French _papiers peints_ are produced, and where I was informed that no less than 3000 blocks are required for one pattern, I saw a two-colour calico machine employed with great advantage, both as to taste and expedition. Steam-charged cylinders were used to dry the paper immediately after it was printed, as the colours, not being so rapidly absorbed as they are by calico, would be very apt to spread.

The operations employed for common paper-hangings, are also used for making flock paper, only a stronger size is necessary for the ground. The flocks are obtained from the woollen cloth manufacturers, being cut off by their shearing machines, called _lewises_ by the English workmen, and are preferred in a white state by the French paper-hanging makers, who scour them well, and dye them of the proper colours themselves. When they are thoroughly stove-dried, they are put into a conical fluted mill, like that for making snuff, and are properly ground. The powder thus obtained is afterwards sifted by a bolting-machine, like that of a flour mill, whereby flocks of different degrees of fineness are produced. These are applied to the paper after it has undergone all the usual printing operations. Upon the workman’s left hand, and in a line with his printing table, a large chest is placed for receiving the flock powders: it is seven or eight feet long, two feet wide at the bottom, three feet and a half at top, and from 15 to 18 inches deep. It has a hinged lid. Its bottom is made of tense calf-skin. This chest is called the _drum_; it rests upon four strong feet, so as to stand from 24 to 28 inches above the floor.

The block which serves to apply the adhesive basis of the velvet-powders, bears in relief only the pattern corresponding to that basis, which is formed with linseed oil, rendered drying by being boiled with litharge, and afterwards ground up with white lead. The French workmen call this mordant the _encaustic_. It is put upon the cloth which covers the inverted swimming tub, in the same way as the common colours are, and is spread with a brush by the _tireur_ (corruptly styled _tearer_ by some English writers). The workman daubs the blocks upon the mordant, spreads the pigment even with a kind of brush, and then applies it by impression to the paper. Whenever a sufficient surface of the paper has been thus covered, the child draws it along into the great chest, sprinkling the flock powder over it with his hands; and when a length of 7 feet is printed, he covers it up within the drum, and beats upon the calf-skin bottom with a couple of rods to raise a cloud of flock inside, and to make it cover the prepared portion of the paper uniformly. He now lifts the lid of the chest, inverts the paper, and beats its back lightly, in order to detach all the loose particles of the woolly powder.

By the operation just described, the velvet-down being applied every where of the same colour, would not be agreeable to the eye, if shades could not be introduced to relieve the pattern. To give the effect of drapery, for example, the appearance of folds must be introduced. For this purpose, when the piece is perfectly dry, the workman stretches it upon his table, and by the guidance of the pins in his blocks, he applies to the flock surface a colour in distemper, of a deep tint, suited to the intended shades, so that he dyes the wool in its place. Light shades are produced by applying some of his lighter water-colours.

Gold leaf is applied upon the above mordant, when nearly dry; which then forms a proper gold size; and the same method of application is resorted to, as for the ordinary gilding of wood. When the size has become perfectly hard, the superfluous gold leaf is brushed off with a dossil of cotton wool or fine linen.

The colours used by the paper-hangers are the following:--

1. _Whites._ These are either white-lead, good whitening, or a mixture of the two.

2. _Yellows._ These are frequently vegetable extracts; as those of weld, or of Avignon or Persian berries, and are made by boiling the substances with water. Chrome yellow is also frequently used, as well as the _terra di Sienna_ and yellow ochre.

3. _Reds_ are almost exclusively decoctions of Brazil wood.

4. _Blues_ are either prussian blue, or blue verditer.

5. _Greens_, are Scheele’s green, a combination of arsenious acid, and oxide of copper; the green of Schweinfurth, or green verditer; as also a mixture of blues and yellows.

6. _Violets_ are produced by a mixture of blue and red in various proportions, or they may be obtained directly by mixing a decoction of logwood with alum.

7. _Browns, blacks, and grays._ Umber furnishes the brown tints. Blacks are either common ivory or Frankfort black; and grays are formed by mixtures of prussian blue and Spanish white.

All the colours are rendered adhesive and consistent, by being worked up with gelatinous size or a weak solution of glue, liquefied in a kettle. Many of the colours are previously thickened, however, with starch. Sometimes coloured lakes are employed. See LAKES.

PAPER, MANUFACTURE OF. (_Papeterie_, Fr.; _Papiermacherkunst_, Germ.) This most useful substance, which has procured for the moderns an incalculable advantage over the antients, in the means of diffusing and perpetuating knowledge, seems to have been first invented in China, about the commencement of the Christian era, and was thence brought to Mecca, along with the article itself, about the beginning of the 8th century; whence the Arabs carried it, in their rapid career of conquest and colonization, to the coasts of Barbary, and into Spain, about the end of the 9th or beginning of the 10th century.

By other accounts, this art originated in Greece, where it was first made from cotton fibres, in the course of the tenth century, and continued there in common use during the next three hundred years. It was not till the beginning of the 14th century that paper was made from linen in Europe, by the establishment of a paper-mill in 1390, at Nuremberg in Germany. The first English paper-mill was erected at Dartford by a German jeweller in the service of Queen Elizabeth, about the year 1588. But the business was not very successful; in consequence of which, for a long period afterwards, indeed till within the last 70 years, this country derived its supplies of fine writing papers from France and Holland. Nothing places in a more striking light the vast improvement which has taken place in all the mechanical arts of England since the era of Arkwright, than the condition of our paper-machine factories now, compared with those on the Continent. Almost every good automatic paper mechanism at present mounted in France, Germany, Belgium, Italy, Russia, Sweden, and the United States, has either been made in Great Britain, and exported to these countries, or has been constructed in them closely upon the English models.

Till within the last 30 years, the linen and hempen rags from which paper was made, were reduced to the pasty state of comminution requisite for this manufacture by mashing them with water, and setting the mixture to ferment for many days in close vessels, whereby they underwent in reality a species of putrefaction. It is easy to see that the organic structure of the fibres would be thus unnecessarily altered, nay, frequently destroyed. The next method employed, was to beat the rags into a pulp by stamping rods, shod with iron, working in strong oak mortars, and moved by water-wheel machinery. So rude and ineffective was the apparatus, that forty pairs of stamps were required to operate a night and a day, in preparing one hundred weight of rags. The pulp or paste was then diffused through water, and made into paper by methods similar to those still practised in the small hand-mills.

About the middle of the last century, the cylinder or engine mode, as it is called, of comminuting rags into paper pulp, was invented in Holland; which was soon afterwards adopted in France, and at a later period in England.

The first step in the paper manufacture, is the sorting of the rags into four or five qualities. They are imported into this country chiefly from Germany, and the ports of the Mediterranean. At the mill they are sorted again more carefully, and cut into shreds by women. For this purpose a table frame is covered at top with wire cloth, containing about nine meshes to the square inch. To this frame a long steel blade is attached in a slanting position, against whose sharp edge the rags are cut into squares or fillets, after having their dust thoroughly shaken out through the wire cloth. Each piece of rag is thrown into a certain compartment of a box, according to its fineness; seven or eight sorts being distinguished. An active woman can cut and sort nearly one cwt. in a day.

The sorted rags are next dusted in a revolving cylinder surrounded with wire cloth, about six feet long, and four feet in diameter, having spokes about 20 inches long, attached at right angles to its axis. These prevent the rags from being carried round with the case, and beat them during its rotation; so that in half an hour, being pretty clean, they are taken out by the side door of the cylinder, and transferred to the engine, to be first washed, and next reduced into a pulp. For fine paper, they should be previously boiled for some time in a caustic lye, to cleanse and separate their filaments.

The construction of the _stuff-engine_ is represented in _figs._ 785, 786. _Fig._ 785. is the longitudinal section, and _fig._ 786. the plan of the engine. The large vat is an oblong cistern rounded at the angles. It is divided by the partition _b_, _b_, and the whole inside is lined with lead. The cylinder _c_, is made fast to the spindle _d_, which extends across the engine, and is put in motion by the pinion _p_, fixed to its extremity. The cylinder is made of wood, and furnished with a number of blades or cutters, secured to its circumference, parallel to the axis, and projecting about an inch above its surface. Immediately beneath the cylinder a block of wood _k_ is placed. This is mounted with cutters like those of the cylinder, which in their revolution pass very near to the teeth of the block, but must not touch it. The distance between these fixed and moving blades is capable of adjustment by elevating or depressing the bearings upon which the necks _e_, _e_, of the shaft are supported. These bearings rest upon two levers _g_, _g_, which have tenons at their ends, fitted into upright mortises, made in short beams _h_, _h_, bolted to the sides of the engine. The one end of the levers _g_, _g_, is movable, while the other end is adapted to rise and fall upon bolts in the beams _h_, _h_, as centres. The front lever, or that nearest to the cylinder _c_, is capable of being elevated or depressed, by turning the handle of a screw (not seen in this view), which acts in a nut fixed to the tenon of _g_, and comes up through the top of the beam _h_, upon which the head of the screw takes its bearing. Two brasses are let into the middle of the levers _g_, _g_, and form the bearings for the shaft of the engine to turn upon. The above-mentioned vertical screw is used to raise or lower the cylinder, and cause it to cut coarser or finer, by enlarging or diminishing the space between the fixed cutters in the block and those in the cylinder.

To the left hand of _i_, _fig._ 785., is a circular breasting made of boards, and covered with sheet lead; it is curved to fit the cylinder very truly, and leaves but very little space between the teeth and breasting; at its bottom, the block _k_ is fixed. The engine is supplied with water from a pump, by a pipe, which delivers it into a small cistern, near to and communicating with the engine. A stopcock cuts off or regulates the supply of water at pleasure, and a grating covered with hair-cloth is fixed across that small cistern, to intercept any filth that may be floating in the water; in other cases a flannel bag is tied round the nose of the stopcock, to act as a filter.

The rags being put into the engine filled with water, are drawn by the rapid rotation of the cylinder between the two sets of cutters, whereby they are torn into the finest filaments, and by the impulsion of the cylinder they are floated over the top of the breasting upon the inclined plane. In a short time more rags and water are raised into that part of the engine vat. The tendency in the liquid to maintain an equilibrium, puts the whole contents of the cistern in slow motion down the inclined plane, to the left hand of _i_, and round the partition _b_, _b_, (see the arrow), whereby the rags come to the cylinder again in the space of about 20 minutes; so that they are repeatedly drawn out and separated in all directions till they are reduced to the appearance of a pulp.

This circulation is particularly useful, by turning over the rags in the engine, causing them to be presented to the cutter at different angles every time; otherwise, as the blades always act in one direction, the comminution would not be so complete. The cutting is performed as follows: The teeth of the block are set somewhat obliquely to the axes of the cylinder, as shown by _fig._ 787.; but the teeth of the cylinder _c_ itself are set parallel to its axis; therefore the cutting edges meet at a small angle, and come in contact, first at the one end, and then towards the other, by successive degrees, so that any rags coming between them, are torn as if between the blades of a pair of forceps. Sometimes the blades _k_ in the block are bent to an angle in the middle, instead of being straight and inclined to the cylinder. These are called elbow plates; their two ends being inclined in opposite directions to the axis of the cylinder. In either case, the edges of the plates of the block cannot be straight lines, but must be curved, to adapt themselves to the curve which a line traced on the cylinder will necessarily have. The plates or blades are united by screwing them together, and fitting them into a cavity cut into the wooden block _k_. Their edges are bevelled away upon one side only.

The block is fixed in its place by being made dovetailed, and truly fitted into the bottom of the cistern, so that the water will not leak through its junction. The end of it comes through the woodwork of the chest, and projects to a small distance on its outside, being kept in its place by a wedge. By withdrawing this wedge, the block becomes loose, and can be removed in order to sharpen the cutters, as occasion may be. This is done at a grindstone, after detaching the plates from each other.

The cutters of the cylinder, are fixed into grooves, cut in the wood of the cylinder, at equal distances asunder, round its periphery, in a direction parallel to its axis. The number of these grooves is twenty, in the machine here represented. For the _washer_, each groove has two cutters put into it; then a fillet of wood is driven fast in between them, to hold them firm; and the fillets are secured by spikes driven into the solid wood of the cylinder. The _beater_ is made in the same manner, except that each groove contains three bars and two fillets.

In the operation of the cylinder, it is necessary that it should be enclosed in a case, or it would throw all the water and rags out of the engine, in consequence of its great velocity. This case is a wooden box _m_, _m_, _fig._ 785., enclosed on every side except the bottom; one side of it rests upon the edge of the vat, and the other upon the edge of the partition _b_, _b_, _fig._ 786. The diagonal lines _m_, _r_, represent the edges of wooden frames, which are covered with hair or wire cloth, and immediately behind these the box is furnished with a bottom and a ledge towards the cylinder, so as to form a complete trough. The square figures under _n_, _n_, in _fig._ 785., show the situation of two openings or spouts through the side of the case, which conduct to flat lead-pipes, one of which is seen near the upper _g_ in _fig._ 786., placed by the side of the vat; the beam being cut away from them. These are waste pipes to discharge the foul water from the engine; because the cylinder, as it turns, throws a great quantity of water and rags up against the sieves; the water goes through them, and runs down to the trough under _n_, _n_, and thence into the ends of the flat leaden pipes, through which it is discharged. _o_, _o_, _fig._ 785., are grooves for two boards, which, when put down in their places, cover the hair sieves, and stop the water from going through them, should it be required in the engine. This is always the case in the beating engines, and therefore they are seldom provided with these waste pipes, or at most on one side only; the other side of the cover being curved to conform to the cylinder. Except this, the only difference between the washing engine and the beater, is that the teeth of the latter are finer, there being 60 instead of 40 blades in the periphery; and it revolves quicker than the washer, so that it will tear out and comminute those particles which pass through the teeth of the washer. In small mills, when the supply of water is limited, there is frequently but one engine, which may be used both for washing and beating, by adjusting the screw so as to let the cylinder down and make its teeth work finer. But the system in all considerable works, is to have two engines at least, or four if the supply of water be great. The power required for a 5 or 6 vat mill, is about 20 horses in a water-wheel or steam engine.

In the above figures only one engine is shown, namely, the _finisher_; there is another, quite similar, placed at its end, but on a level with its surface, which is called the _washer_, in which the rags are first worked coarsely with a stream of water, running through them to wash and open their fibres; after this washing they are called _half-stuff_, and are then let down into the bleaching engine, and next into the _beating_ engine, above described.

By the arrangements of the mill gearing, the two cylinders of the _washer_ and _beater_ engines make from 120 to 150 revolutions per minute, when the water-wheel moves with due velocity. The beating engine is always made to move, however, much faster than the washing one, and nearly in the ratio of the above numbers.

The vibratory noise of a washing engine is very great; for when it revolves 120 times per minute, and has 40 teeth, each of which passes by 12 or 14 teeth in the block at every revolution, it will make nearly 60,000 cuts in a minute, each of them sufficiently loud to produce a most grating growling sound. As the beater revolves quicker, having perhaps 60 teeth, instead of 40, and 20 or 24 cutters in the block, it will make 180,000 cuts in a minute. This astonishing rapidity produces a coarse musical humming, which may be heard at a great distance from the mill. From this statement, we may easily understand how a modern engine is able to turn out a vastly greater quantity of paper pulp in a day than an old mortar machine.

The operation of grinding the rags requires nice management. When first put into the washing engine they should be worked gently, so as not to be cut, but only powerfully scrubbed, in order to enable the water to carry off the impurities. This effect is obtained by raising the cylinder upon its shaft, so that its teeth are separated considerably from those of the block. When the rags are comminuted too much in the washer, they would be apt to be carried off in part with the stream, and be lost; for at this time the water-cock is fully open. After washing in this way for 20 or 30 minutes, the bearings of the cylinder are lowered, so that its weight rests upon the cutters. Now the supply of water is reduced, and the rags begin to be torn, at first with considerable agitation of the mass, and stress upon the machinery. In about three or four hours, the engine comes to work very smoothly, because it has by this time reduced the rags to the state of _half-stuff_. They are then discharged into a large basket, through which the water drains away.

The bleaching is usually performed upon the _half-stuff_. At the celebrated manufactory of Messrs. Montgolfier, at Annonay, near Lyons, chlorine gas is employed for this purpose with the best effect upon the paper, since no lime or muriate of lime can be thus left in it; a circumstance which often happens to English paper, bleached in the washing engine by the introduction of chloride of lime among the rags, after they have been well washed for three or four hours by the rotation of the engine. The current of water is stopped whenever the chloride of lime is put in. From 1 to 2 pounds of that chemical compound are sufficient to bleach 1 cwt. of fine rags, but more roust be employed for the coarser and darker coloured. During the bleaching operation the two sliders _o_, _o_, _fig._ 785., are put down in the cover of the cylinder, to prevent the water getting away. The engine must be worked an hour longer with the chloride of lime, to promote its uniform operation upon the rags. The cylinder is usually raised a little during this period, as its only purpose is to agitate the mass, but not to triturate it. The water-cock is then opened, the boards _m_, _m_ are removed, and the washing is continued for about an hour, to wash the salt away; a precaution which ought to be better attended to than it always is by paper manufacturers.

The half-stuff thus bleached, is now transferred to the beating engine, and worked into a fine pulp. This operation takes from 4 to 5 hours, a little water being admitted from time to time, but no current being allowed to pass through, as in the washing engine. The softest and fairest water should be selected for this purpose; and it should be administered in nicely regulated quantities, so as to produce a proper spissitude of stuff for making paper.

For printing paper, the _sizing_ is given in the beating engine, towards the end of its operation. The size is formed of alum in fine powder, ground up with oil; of which mixture about a pint and a half are thrown into the engine at intervals, during the last half-hour’s beating. Sometimes a little indigo blue or smalt is also added, when a peculiar bloom colour is desired. The pulp is now run off into the stuff chest, where the different kinds are mixed; whence it is taken out as wanted. The chest is usually a rectangular vessel of stone or wood lined with lead, capable of containing 300 cubic feet at least, or 3 engines full of stuff. Many paper-makers prefer round chests, as they admit of rotatory agitators.

When the paper is made in single sheets, by hand labour, as in the older establishments, a small quantity of the stuff is transferred to the working-vat by means of a pipe, and there diluted properly with water. This vat is a vessel of stone or wood, about 5 feet square, and 4 deep, with sides somewhat slanting. Along the top of the vat a board is laid, with copper fillets fastened lengthwise upon it, to make the mould slide more easily along. This board is called the bridge. The maker stands on one side; and has to his left hand a smaller board, one end of which is made fast to the bridge, while the other rests on the side of the vat. In the bridge opposite to this, a nearly upright piece of wood, called the ass, is fastened. In the vat there is a copper, which communicates with a steam pipe to keep it hot; there is also an agitator, to maintain the stuff in a uniform consistence.

The moulds consist of frames of wood, neatly joined at the corners, with wooden bars running across, about an inch and a half apart. Across these, in the length of the moulds, the wires run, from fifteen to twenty per inch. A strong raised wire is laid along each of the cross bars, to which the other wires are fastened; this gives the laid paper its ribbed appearance.

The water-mark is made by sewing a raised piece of wire in the form of letters, or any figured device, upon the wires of the mould, which makes the paper thinner in these places. The frame-work of a _wove_ mould is nearly the same; but instead of sewing on separate wires, the frame is covered with fine wire cloth, containing from 48 to 64 meshes per inch square. Upon both moulds a _deckel_, or movable raised edge-frame, is used; which must fit very neatly, otherwise the edges of the paper will be rough.

A pair of moulds being laid upon the bridge, the workman puts on the deckel, brings the mould into a vertical position, dips it about half way down into the stuff before him, then turning it into a horizontal position, covers the mould with the stuff and shakes it gently. This is a very delicate operation; for if the mould be not held perfectly level, one part of the sheet will be thicker than another. The sheet thus formed has, however, no coherence; so that by turning the mould, and dipping the wire cloth surface in the vat, it is again reduced to pulp if necessary. He now pushes the mould along the small board to the left, and removes the deckel. Here another workman called the _coucher_ receives it, and places it at rest upon the ass, to drain off some of the water. Meanwhile the _vat-man_ puts the deckel upon the other mould, and makes another sheet. The coucher stands to the left side of the vat, with his face towards the vat-man or maker, on his right is the press furnished with felt cloths, or porous flannels; a three-inch-thick plank lies before him on the ground. On this he lays a cushion of felts, and on this another felt; he then turns the paper wire mould, and presses it upon the felt, where the sheet remains. He now returns the mould by pushing it along the bridge. The maker has by this time another sheet ready for the coucher; which, like the preceding, is laid upon the ass, and then couched or inverted upon another felt, laid down for the purpose.

In this way, felts and paper are alternately stratified, till a heap of six or eight quires is formed, which is from 15 to 18 inches high. This mass is drawn into the press, and exposed to a force of 100 tons or upwards. After it is sufficiently compressed, the machine is relaxed, and the elasticity of the flannel makes the rammer descend (if a hydraulic press be used) with considerable rapidity. The felts are then drawn out on the other side by an operative called a _layer_, who places each felt in succession upon one board, and each sheet of paper upon another. The coucher takes immediate possession of the felts for his further operations.

Two men at a vat, and a boy as a layer or lifter, can make about 6 or 8 reams in 10 hours. In the evening the whole paper made during the day, is put into another press, and subjected to moderate compression, in order to get quit of the mark of the felt, and more of the water. Next day it is all separated, a process called parting, and being again pressed, is carried into the loft. Fine papers are often twice parted and pressed, in order to give them a proper surface.

The next operation is the drying, which is performed in the following way. Posts about 10 or 12 feet high are erected at the distance of ten feet from each other, and pierced with holes six inches apart; two spars with ropes stretched between them, at the distance of 5 inches from one another, called a treble or tribble, are placed about 5 feet high between these posts, supported by pins pushed into the holes in the posts. The workman takes up 4 or 8 sheets of paper, and puts them upon a piece of wood in the form of a T; passing this T between the ropes, he shifts the sheets upon them, and proceeds thus till all the ropes are full. He then raises the treble, and puts another in its place, which he fills and raises in like manner. Nine or ten trebles are placed in every set of posts. The sides of the drying-room have proper shutters, which can be opened to any angle at pleasure.

When the paper is dry, it is taken down, and laid neatly in heaps to be sized. Size is made of pieces of skin, cut off by the curriers before tanning, or sheep’s feet, or any other matter containing much gelatine. These substances are boiled in a copper to a jelly; to which, when strained, a small quantity of alum is added. The workman then takes about 4 quires of paper, spreads them out in the size properly diluted with water, taking care that they be equally moistened. This is rather a nice operation. The superfluous size is then pressed out, and the paper is parted into sheets. After being once more pressed, it is transferred to the drying-room, but must not be dried too quickly. Three days are required for this purpose. When the paper is thoroughly dry, it is carried to the finishing-house, and is again pressed pretty hard. It is then picked by women with small knives, in order to take out the knots, and separate the perfect from the imperfect sheets. It is again pressed, given to the finisher, to be counted into reams, and done up. These reams are compressed, tied up, and sent to the warehouse for sale. A good finisher can count 200 reams, or 96,000 sheets in a day.

Hot pressing is executed by placing a sheet of paper between two smoothed pasteboards, alternately, and between every 50 pasteboards a heated plate of iron, and subjecting the pile to the press. This communicates a fine smooth surface to writing-paper.

The grain of the paper is often disfigured by the felts, when they are too much used, or when the loose fibres do not cover the twisted thread. The two sides of the felt are differently raised, and that on which the fibres are longest is applied to the sheets which are laid down. As the felts have to resist the reiterated action of the press, their warp should be made stout, of long combed wool, and well twisted. The woof, however, should be of carded wool, and spun into a soft thread, so as to render the fabric spongy, and capable of imbibing much water.

This operose and delicate process of moulding the sheets of paper by hand, has for nearly thirty years past been performed, in many manufactories, by a machine which produces it in a continuous sheet of indefinite length which is afterwards cut into suitable sizes, by the PAPER-CUTTING MACHINE.

In 1799, Louis Robert, then employed in the paper works of Essonne in France, contrived a machine to make paper of a great size, by a continuous motion, and obtained for it a patent for 15 years, with a sum of 8000 francs from the French government, as a reward for his ingenuity. The specification of this patent is published in the second volume of _Brevets d’Invention expirés_. M. Leger-Didot, then director of the said works, bought Robert’s machine and patent for 25,000 francs, to be paid by instalments. Having become proprietor of this machine, which, though imperfect, contained the germ of a valuable improvement in paper-making, M. Didot came over with it to England, where he entered into several contracts for constructing and working it.

Meanwhile M. L. Didot having failed to fulfil his obligations to Robert, the latter instituted a law-suit, and recovered possession of his patent by a decision dated 23d June, 1810. Didot then sent over to Paris the Repertory of Arts, for Sept. 1808, which contained the specification of the English patent, with instructions to a friend to secure the improved machines described in it, by a French patent. The patent was obtained, but became inoperative in consequence of M. L. Didot failing to return to France, as he had promised, so as to mount the patent machine within the two years required by the French patent law. It was not till 1815, that M. Calla, machine-maker at Paris, constructed the paper apparatus known in England by the name of Fourdrinier’s, and which, on the authority of the _Dictionnaire Technologique_, was very imperfect in comparison of an English-made machine imported about that time into France. _La construction de ces machines, qui n’offre pourtant rien de difficile, est restée jusqu’à ce jour exclusivement dans les mains des Anglais_, is the painful acknowledgment made in 1829, for his countrymen, by the author of the elaborate article Papeterie in that national work. If there be nothing difficult in the construction of these machines, the French mechanicians ought to be ashamed of forcing their countrymen to seek the sole supply of them in England; for the principal paper works in France, as those of MM. Canson, Montgolfier, Thomas Varenne, Firmin Didot, Delcambre, De Maupeon, &c., are mounted with English-made machines.

The following, for example, are a few of the paper-mills in France which are mounted with the self-acting machines of Messrs. Bryan Donkin & Co.:--

Messrs. Canson, at Annonay.
M. de la Place, at Jean d’Heures, Bar-le-duc.
Société anonyme, at Sainte Marie, under M. Delatouche.
Echarcon près Mennecy, (Seine et Oise).
Firmin Didot, Mesnil sur l’Estrée.
M. F. M. Montgolfier, à Annonay.
Muller, Bouchard, Ondin and Co’s., at Gueures, near Dieppe.
MM. Richard et Comp. à Plainfoing.
M. Callot-Bellisle; Vieuze et Chantoiseau.
M. Bechétaile, near St. Etienne, at Bourg Argental.

It deserves particularly to be remarked, to the honour of English mechanism, that the proprietors of the first five of the above works received gold medals at the last exposition of their papers at the Louvre, and all the rest received medals either of silver or bronze.[37]

[37] Rapport de Jury Central, par M. Le Baron Charles Dupin, vol. ii.
p. 278; Paris, 1836.

The following is a true narrative of the rise and progress of the paper automaton.

M. Leger Didot, accompanied by Mr. John Gamble, an Englishman who had resided for several years in Paris, obtained permission from the French government, in 1800, to carry over the small working model of Robert’s continuous machine, with the view of getting the benefit of English capital and mechanical skill to bring it into an operative state upon the great scale. Fortunately for the vigorous development of this embryo project, which had proved an abortion in France, they addressed themselves on the one hand, to a mercantile firm equally opulent and public spirited, and on the other, to engineers distinguished for persevering energy and mechanical resource. A first patent was granted to Mr. Gamble on the 20th of April 1801, and a second, for certain improvements upon the former, on the 7th of June 1803. In January 1804, Mr. Gamble, for certain considerations, assigned these two patents to Messrs. Henry and Sealy Fourdrinier, the house above alluded to, who were at that period, and for several years afterwards, the most considerable stationers and paper-makers in Great Britain. By an act of parliament passed on the 4th of August 1807, Mr. Gamble’s privilege of 14 years from April 1801, was prolonged to 15 years after the date of the act, being an extension of about 7 years upon the original patent.

The proprietors showed good reasons, in the enormous expense of their experiments, and the national importance of the object, why the patent should have been extended 14 years from the latter date, and would have obtained justice from parliament in this respect, but for an unworthy artifice of Lord Lauderdale in the House of Lords. “He, and he only, was the person who took the objection,” and, by introducing a regulation in a standing order of the House of Lords, that none but the original inventor should have an extension, though Mr. H. Fourdrinier was the inventor substantially of the operative machine, he defeated the honourable intentions of his brother peers, whose committee said, “We will give seven years, and Mr. Fourdrinier may apply again, if it should turn out that the seven years that we propose to give to Mr. Fourdrinier should not give sufficient time to afford any chance of his receiving any remuneration for the expense that he has incurred in introducing this invention.” The bill passed in the House of Commons for 14 years, but it was limited by this _ruse_ of Lord Lauderdale to 7, “who put the standing order upon the books (of the upper house) which prevented Messrs. Fourdrinier from having any benefit from the invention.”[38]

[38] See this shabby piece of diplomacy unveiled in the Minutes of
Evidence taken before the Select Committee of the House of Commons on
Fourdrinier’s patent; May, 1837.

In February 1808, Mr. Gamble, after losing both his time and money savings during eight years of irksome diligence, assigned over to Messrs. Fourdrinier the whole right of his share in the patent to which he was entitled under the act of parliament.

Dartford in Kent, which had been long conspicuous as the seat of a good manufactory of paper and paper moulds, was selected by the proprietors of the patent as the fittest place for realizing their plans; and happily for them it possessed, in Mr. Hall’s engineering establishment, every tool requisite for constructing the novel automaton, and in his assistant Mr. Bryan Donkin, a young and zealous mechanist, who, combining precision of workmanship with fertility of invention, could turn his local advantages to the best account. To this gentleman, aided by the generous confidence of Messrs. Fourdrinier, the glory of rearing to a stately manhood the helpless bantling of M. L. Didot is entirely due. In 1803, after nearly three years of intense application, he produced a self-acting machine for making an endless web of paper, which was erected at St. Neot’s, under the superintendence of Mr. Gamble, and performed in such a manner as to surprise every beholder.

Since that important era Mr. Donkin has steadily devoted his whole mind and means to the progressive improvement of this admirable apparatus; and has, by the unfailing regularity, precision, promptitude, and productiveness of its work, earned for himself a place along with Watt, Wedgewood, and Arkwright, in the temple of mechanical fame.

“_La France_,” says a late official eulogist of her arts, and interpreter of her sentiments, “ne craint plus la rivalité des autres peuples pour la fabrication des divers genres de papiers et de cartons.”[39] After this boast, one would not expect to hear him immediately confess that in 1823 his country possessed only one manufactory of the _papier continu_, containing one of the Fourdrinier machines made at London by Mr. Donkin, for M. Canson, at Vidalon-les-Annonay; that in 1827 there were only 4 of these machines in France, and that in 1834 there were not many more than a dozen. He justly observes, that “this mode being more economical, more rapid, and more powerful, will become henceforth the only one which can be practised without loss. Then will disappear the antient system of hand-work, which likewise involved the inconveniences, we may say dangers, resulting from combinations among the operatives. The machine-made papers possess many advantages: they can receive, so to speak, unlimited dimensions; they preserve a perfectly uniform thickness throughout all their length; they may be fabricated in every season of the year; nor do they require to be sorted, trimmed, and hung up in the drying-house, operations which occasioned great waste, amounting to no less than one defective sheet out of every five. The continuous paper at one time retained the impression of the wire-wove web on its under side; a defect from which it has been freed by a pressure apparatus of Mr. Donkin, recently imported from England by M. Delatouche.”

[39] Rapport de Jury Central, sur les Produits de l’Industrie
Française exposé en 1834, par Le Baron Charles Dupin, Membre de
l’Institut, Rapporteur-général et Vice President du Jury Central; ii.
278.

It appears from documents presented to a committee of the House of Lords in 1807, that the Messrs. Fourdrinier had, by that time, withdrawn from their stationery business the large sum of 60,000_l._, to further the object of their patent; so many difficulties did they encounter in bringing the machinery to its then comparatively complete state, and so little encouragement or support did they receive from the paper manufacturers throughout the kingdom.

The patentees laid a statement before the public in 1806, containing the following comparative estimate of the expense attending seven vats, and that attending a machine employed upon paper sized in the engine, performing the same quantity of work as seven vats, at the rate of 12 hours daily.

A MACHINE.

+-------------------------+-------+-----------+----------+-----------+
| | Day. | Week. | Month. | Year. |
| +-------+-----------+----------+-----------+
| |_s. d._|_£ s. d._|_£ s. d._|_£ s. d._|
|2 Journeymen | 3 6 | 2 2 0 | 8 8 0 |109 4 0 |
|2 Ditto | 2 6 | 1 10 0 | 6 0 0 | 78 0 0 |
|2 Finishers | 3 6 | 2 2 0 | 8 8 0 |109 4 0 |
|2 Dry workers | 3 6 | 2 0 | 8 8 0 |109 4 0 |
| Parters (none) | | | | |
| Fire (none) | | | | |
| Felting | | | | 24 0 0 |
| Washing, ditto | | | | 5 0 0 |
| Wire | | | |200 0 0 |
|1 Man, to keep in repair}| | | | |
| the mill and machine }| | | |100 0 0 |
|- | +-----------+----------+-----------+
|9 Total | | 7 16 0 |31 4 0 |734 12 0 |
+-------------------------+-------+-----------+----------+-----------+
| _£ s. d._ |
|Expense of 7 vats per annum (see next page), is 2,604 12 0 |
|A machine doing 7 vats’ work, is, per annum 734 12 0 |
| ---------------- |
| Balance saved by the machine per annum _£_1,870 0 0 |
+--------------------------------------------------------------------+
|_N. B._--There are other advantages, to the amount of full 400_l._ |
|per annum, of which manufacturers are well aware, although not taken|
|into this calculation. |
+--------------------------------------------------------------------+

SEVEN VATS.

+---------------------+-------+----------+-----------+-------------+
| | Day. | Week. | Month. | Year. |
| +-------+----------+-----------+-------------+
| |_s. d._|_£ s. d._ | _£ s. d._ | _£ s. d._|
|7 Vatmen, at | 3 3 | 6 16 6 | 27 6 0 | 354 18 0 |
|7 Couchers | 3 1 | 6 9 6 | 25 18 0 | 336 14 0 |
|7 Layers | 3 1 | 6 9 6 | 25 18 0 | 336 14 0 |
|3 Finishers | 4 0 | 3 12 0 | 14 8 0 | 187 4 0 |
|6 Dry-workers | 3 1 | 5 11 0 | 22 4 0 | 288 12 0 |
|3 Men to go to press,| | | | |
| &c. | 2 6 | 2 5 0 | 9 0 0 | 117 0 0 |
|7 Parters (women) | 1 4 | 2 16 0 | 11 4 0 | 145 12 0 |
| Fire | | 7 0 0 | 28 0 0 | 364 0 0 |
| Felting | | | | 140 0 0 |
| Washing ditto, oil,| | | | |
| soap, fire, &c. | | 1 11 6 | 6 6 0 | 81 18 0 |
| Moulds | | | | 140 0 0 |
|1 Man, and expenses }| | | | |
| of repairing, in }| | | | |
| keeping in order 7}| | | | |
| vats, vat-presses,}| | | | |
| &c. }| | | | 112 0 0 |
| | +----------+-----------+-------------+
|Total 41 persons. | |42 11 0 |170 4 0 |2,604 0 0 |
+---------------------+-------+----------+-----------+-------------+

In the same statement, it was shown that the expense of making paper by hand is 16_s._ per cwt., whereas by their machine it is only 3_s._ 9_d._; so that upon 432,000 cwts. the quantity annually made in Great Britain and Ireland (as founded upon the fact that one vat can make 480 cwts. of paper, and that there were 900 vats in the kingdom), the annual saving by the machine would be 264,600_l._, or 345,600_l._ - 81,000_l._