Roll Processing Dept

Paper Machine
No1 Paper Machine Page

Roll Processing comprised of both the 175 Super Calendar- aka 'The Big Stack' and Double Drum winder upstairs- on the main machine floor.

Downstairs, the "fractional" rewinders, 80 inch Appleton super calendar, 74 inch Holyoke calendar, plus Jagenberg Micro embosser and Lamb roll wrapper.

More details about the 175 Super Calendar 'Stack' and Double Drum rewinder can be found on the No 1 paper machine floor page.

Depicted in the very upper left photo is 'Ferk' standing next to the 175 Super Calendar 'Stack'. Ferk came out from Wisconsin Rapids, Wisconsin in November of 1964 to help with the start-up of the Shasta Mill. Ferk worked up through the calendar progression starting as a 175 first helper. Shortly thereafter, he trained on the Double Drum as operator.

The Union and Company then came to an agreement in regard to how the progressions were to be established. Ferk then moved into the 80 inch super calendar operator position. Up until he retired in December of 1998, Ferk had held the position of senior Shasta Mill 175 Super Calendar 'Stack' operator.

According to Ferk, the bottom 'Stack' roll or 'king roll' weighed approximately 40,000 lbs or about twenty tons. It must have been a job in order to set it into place when the 175 super calendar was first installed in 1964. Ferk went on to explain that an empty spool in which the reel of paper was wound upon weighed about 1,800 lbs to 1 ton each. A full reel of paper, including spool weighed between 18,000 to 20,000 lbs or about ten tons.

If the crane hooks did not catch properly on the spool notches and the load was then picked up, a full reel of paper may then come loose while in transit. Ferk noted that a reel of paper did on occasion become dislodged from the crane hooks and due to it's extreme weight, would crack the thick concrete machine floor below from the impact.

Depicted in the lower left photo is Chris L.- 1st helper (left) and Joe C.- 175 'Stack' operator (right) at the 1st helper station on the 175 super calendar.

Jerry J. the 175 'Stack' operator is depicted in the lower right photo inspecting a reel of paper at the 175 super cal.

Chris and Jerry are two of the main organizers of the annual Shasta Mill employees' picnic and reunion which is held at the Anderson River park each August.

Greg S., the 80 inch super calendar operator is depicted in the left photo operating the Appleton 80 inch calendar.

The 74 inch calendar sat just to the right of the 80 inch calendar.

The German designed and manufactured Jagenberg Micro Embosser was the last major investment made downstairs in the Roll Processing Department.

The right photo depicts the Lamb roll wrapper and roll line where rolls of paper would be processed and wrapped prior to being stored in the warehouse.

Located next to the Lamb roll wrap line, the Embosser was installed in late 1986-early 1987.

Right photo depicts the roll guard located on the ejector at the end of the Jagenberg Micro Embosser.

The role of the embosser was to place a certain finish onto the paper as the paper ran through the equipment.

Depicted in the above left photo is one of the micro embosser crews led by operator Duane E. and his helpers Pam O. and Bill W.

Pam and Duane are also depicted in the above right photo. Lower right photo is of the side view of the roll ejector system on the Shasta Mill Jagenberg Micro Embosser.

Even though the employees worked hard and were conscientious about producing a superior product for our many customers, there was still time to celebrate a birthday or other special occasion. The bottom series of photos depict micro embosser operator Betty U's birthday party which her crew gave her at the micro embosser. Remember, our mill coworkers were like a second family!

As a side note, in the left photo, one of the fractional rewinders is depicted as the employees were celebrating Betty's birthday. The fractionals would reprocess rolls with defects. Operators would then remove the damage or defect, then splice the paper and finish rewinding the roll. The salvaged roll would then be placed onto the Roll Line to be wrapped and sent out into the warehouse.

Thank you credits go to Glen L., Pam O., Greg S. and Yvonne for providing several of the photos on this page.