Forming a Sheet of Paper

In order to form a sheet of paper, papermakers use two tools: a mould and a deckle. The mould is a frame (usually rectangular in shape) covered in a fine mesh screen. The deckle does not have a screen and fits over the mould like a frame. The purpose of the deckle is to contain the pulp and give the sheet of paper an even edge. However, no matter how tightly the deckle fits, some pulp will always leak under the frame, giving handmade paper its characteristic feathery "deckle edge".

The papermaker fits the mould and deckle together, and deckle-side-up, submerges the entire unit in the pulp. He/she then lifts the mould out, shaking it gently back and forth in order to distribute the fibres evenly. Once the water drains through the screen, the deckle is removed and a newly formed "waterleaf" is left on the screen. Waterleaf refers to the wet pulp on the screen that has yet to be pressed and dried. The mould is then gently tipped over and the waterleaf turned onto a curved board covered in wool felt. This process is called couching, from the French word "coucher" - to lay down.

A second piece of felt is then placed on top, sandwiching the paper. This bundle is then placed between two wooden boards, and put in a screw press. After the excess water has been pressed out, the paper is removed and hung on a rack to dry. Later the paper sheets are heat-pressed or sent through a series of metal rollers ("calendering") in order to flatten and smooth the surface of the paper.

More on how paper is made

• From Plant to Pulp
• Types of Pulps
• Forming a Sheet of Paper
• Additives in Paper



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