Lesson video

Hi there everyone, and welcome to your design and technology lesson for today.

My name is Mr. Booth.

Thank you very much for joining me.

Today, we are in our technical principles unit and we are looking at reforming manufacturing processes with a focus on papers and boards.

Today's outcome, I want you to be able to explain and compare small scale and industrial reforming processes for papers and boards.

We have five key words I want you to keep a lookout for today.

The first one is reform.

Reshaping a material into a new form without changing its basic chemical structure.

We have recycle.

Convert waste into reusable materials.

Upcycle turning old or unwanted materials or products into something useful.

We have mould, a hollow shape, which can be used to form materials, and also a former, which is a solid object.

A material is manipulated around to create a specific shape.

Three learning cycles in today's lesson, the first is all about small scale reforming processes for papers and boards.

So let's get going.

Reforming processes change the shape or structure of a material without changing its chemical structure.

We don't completely break the chemical structure of that material down, we just reform it.

For papers and boards, reforming involves reshaping or redistributing pulp fibers to create new products, often enhancing properties or extending the materials' lifespan.

This process is used to improve the uniformity, the strength, and the overall quality of whatever products we're making.

The materials we make that product out of.

Quick check for understanding.

Which of the following best describes a reforming process for papers and boards? Is it A, cutting card into smaller pieces? B, die cutting a packaging net.

C, applying a varnish to paper to protect it.

Or D, reshaping or redistributing pulp fibers.

Pause the video now.

Have a go at this.

Come back to me when you've got your answer.

It is of course D.

We are reshaping or redistributing pulp fibers.

Now if we look at small scale reforming processes, small scale example of reforming paper and boards includes making handmade paper, which is essentially making recycled paper.

It's a very similar process.

Now let's have a look at how we would do this.

Now this is a great activity for you to be able to do either in the classroom or even if you are at home.

So the first thing you need to do is collect used pieces of paper and cut or rip them into smaller pieces.

We then need to submerge the paper pieces into warm water for a few hours, or even better if you can leave them overnight.

We need to allow the water to start reverting the paper back into pulp and you'll see that happening if you run your fingers through it.

We need to blend the pulp to achieve a smooth mixture.

So you can use a handheld blend for that, but just be very careful how you do that.

And then we need to dilute the pulp by adding it to another container with more water in.

Once we've done that, we need to mix the diluted pulp mixture to distribute the pulp evenly throughout it.

Let's have a quick check.

What is produced when you mix pieces of paper with water? Is it A, slop.

B, paste.

C, pulp; or D, slush? Pause the video now, have a go at this, and come back to me when you've got your answer.

It is, of course, C pulp.

So let's continue with our paper making process.

What we then need to do is use a cloth and slide it underneath the pulp mixture.

This acts as a mesh screen.

We then lift the cloth and the pulp outta the container, and then allow the pulp to dry and harden.

It can be rolled to remove excess water, and when it's dry, we can peel the reformed paper off the cloth.

Now while the pulp is still damp, we can shape the pulp.

We can shape that paper to form something different.

Now, the first way we can do that is using a former.

So if we get a solid object such as a can, an empty food can, what you can do is you can manipulate it around that and it will set in that shape once dry.

Or what we can do is use a mould, which we need a hollow shape, and then we can force it into that shape and it will take that shape again once it's dry.

And for this example, it's a small plastic cup.

Another example of small scale reforming of paper and boards is of course papier mache.

I'm sure you are probably made papier-mache in some time in your life.

Now, tissue paper and PVA glue is often used very, very popular in primary school design and technology.

But it's made basically by soaking paper in glue or some kind of paste mixture and then layering it over a former or pressing it into a mould.

Once dry, it hardens to a solid shape and can be painted or decorated.

And you can see we've got two ways of doing this.

You can even use newspaper or kitchen roll and PVA glue if you don't wanna use tissue paper.

Now, creative and detailed designs can be used, meaning making card and other craft materials to manufacture a former.

And here we have some fantastic examples from art.

So here we have a rabbit character and a former, you can see on the left-hand side.

And then we have the finished papier mache product, which has been painted for a finish.

And, again, here we have what I think looks like a dodo, but again, the former and then the finished papier mache product at the end.

Quick check for understanding.

What is made by soaking paper and glue or paste mixture, and layering it over a former? Pause the video now.

Have a go at this.

Come back to me when you've got your answer.

It is, of course, papier mache.

So here's your first task on small scale reforming processes.

Task A: The first thing I want you to do is explain what a reforming process is and give one example related to paper and boards.

Next, describe how recycled paper and board can be reformed from pulp into a usable material.

And finally, list three benefits of the reforming process papier mache.

Pause the video now.

Have a go at these.

Come back to me when you've got your answers.

So how did you get on? Let's have a look at some sample answers.

So the first question was, I wanted you to explain what a reforming process is and give one example related to paper and boards you might have written something like a reforming process changes the shape or structure of paper or boards without altering its chemical structure.

A reforming process for paper on board is making paper by hand, which produces recycled paper.

The second one, describe how recycled paper and board can be reformed from pulp into a reusable material.

So the first step is tear the paper, rip all paper into small pieces, so it can blend, soak the pieces in water, and then blend into a mushy pulp.

Then scoop out the pulp, pull the pulp into a tub of water, and dip in a screen or cloth to catch up all the pulp.

Number four, remove the water, let the water drain, then gently roll to remove more water.

Dry the paper, let it dry, completely peel and use, carefully peel off your new sheet of handmade paper.

The next task was to list three benefits of the reforming process, papier mache.

Let's have a look at those.

So one of them could be you could use a wide variety of papers including newspaper.

So you are extending the life of those materials.

You can decorate the design after it is hardened and you can create detailed designs by making formers.

Well done with that task.

Let's move on to the next learning cycle.

So for this learning cycle, we're now gonna be looking at industrial reforming processes.

Industrial reforming is used to create paper and board products on a large scale using automated methods.

These methods ensure speed, mass production is faster than manual processes, especially when it's fully automated.

Accuracy: Machines produce consistent, precise parts over and over again.

The parts are identical and it can be repeated.

Quick check for understanding which of the following is a key benefit of using automation for industrial paper and boards reforming? Is it A, it requires no adhesives or heat? Is it B, it ensures speed and consistent quality.

Is it C, it creates unique one-off products, or is it D, It uses hand tools for precise cuts.

Pause the video now.

Have a go at this and come back to me when you've got your answer.

It is of course B.

It ensures speed and consistent quality.

An industrial reforming process is pulp moulding.

This is a manufacturing process that uses recycled paper pulp, just like we saw in our first learning cycle to form shaped products using mould.

It's commonly used to make eco-friendly packaging and disposable items, and you will have seen some of these.

For example, egg cartons, drinks holders, which I'm sure you've got your coffee in, and also packaging inserts to protect packaging during transportation.

Let's have a look at the industrial process of pulp moulding and you'll see it's very similar to what we did in learning cycle one.

First of all, waste paper is soaked, blended, and turned into pulp.

The pulp is then poured or vacuum formed into a shape mould.

The mould pulp is pressed to remove excess water and refine the shape.

The mould product is dried in ovens or naturally, and then trimming or shaping is done for a final product.

Very similar to what we did in learning cycle one.

I'm sure you'll agree.

So now let's look at an illustrated version of this process.

So first of all, we create our pulp.

We then have a mould the shape of the product that we want to create.

The pulp is poured into the mould, it's heated and pressed, and then dried, released and trimmed to get our final product.

Another check for understanding.

Identify the packaging product that has been made using the industrial reforming process of pulp moulding.

Is it image A, image B, or image C? Pause the video now.

Have a go at this.

Come back to me when you've got your answer.

It is of course C.

And this product is actually a shoe insert that you might find when you buy new shoes to keep them in shape.

Now, bonding involves joining layers of paper and cardboard together using heat adhesives or other methods to form a strong or more functional material.

Bonding can be completed in many different ways.

We can have adhesive bonding, so this is using glue such as PVA, but you can also use starch or even hot melt adhesives.

We stick these layers of paper and board together using these adhesives.

This is very common in things like lamination, corrugated board or even book binding.

We also have heat ceiling used with coated or synthetic papers.

Heat melt a layer of plastic or wax to bond the sheets together, and then this is very common in the food packaging industry.

Corrugated cardboard lamination is the process of bonding flat sheets of paper, which we call the liners to a fluted or that wavy layer using adhesives to create strong multi-layered cardboard.

And, of course, I'm sure you've all seen corrugated cardboard before, but this gives the structure material, its strength and cushioning and it's commonly used with packaging and shipping boxes.

And I'm sure you've seen an example in your own homes that gets delivered every week through your letterbox.

We also have foam board.

Now this is made by bonding a layer of foam between two outer layers of paper.

The common uses for board are signage, mounting photos or prints to give them a little bit more structure.

Architectural models are often made out of foam board and also school presentation displays.

And that's what it looks like.

I mean, again, I'm sure you've seen some of these examples.

Now onto your next task.

Task B, where we look at industrial reforming processes.

First of all, industrial reforming processes is used to create paper and board products on a large scale using automated methods.

What does this ensure? That's the first question.

The next one, explain the bonding process and give an example of material that has been bonded.

And the third question, use diagrams to explain the process of making pulp moulded packaging.

Pause the video now.

Have a go at these tasks.

Come back to me when you've completed them.

So how did you get on? Let's have a look at some feedback answers.

So first of all, industrial reforming is used to create paper and board products on a large scale using automated methods.

What does this ensure? Well, these methods ensure speed, mass production is faster than manual processes.

Accuracy, machines produce consistent and precise parts and products every single time, and also consistency.

Identical parts can be made repeatedly 24 hours a day.

The next question was I wanted you to explain the bonding process and give an example of material that has been bonded.

So as we know, bonding involves joining layers of paper or cardboard together using adhesives or other methods to form a stronger or a more functional material.

For example, foam board.

And the next one was using diagrams. I want you to explain the process of making pulp moulded packaging.

So you could have used the diagram that we saw earlier in the learning cycle.

We, first of all, we make our pulp.

We then have a shaped mould that is matches our final product.

We then have pulp poured into that mould.

We heat, it's heated and pressed, dried, released, and then trimmed to the product that we want.

Well done with that task.

We're now onto our final learning cycle, and this is all about conserving resources.

We know we need to conserve resources, and this is exactly the same for papers and boards.

Even though papers and boards are renewable.

It still takes time, energy, and land to grow those resources.

Now we can conserve paper and board resources by recycling processed, used timber into new materials.

For example, manufactured boards or being very creative by upcycling, using timber without the major processing.

Recycling is the process of converting waste into reusable materials.

Recycling paper and board reduces the effects of deforestation and saves the energy required to process raw timber.

It also prevents waste material from going into landfill or incineration or burned.

Sometimes your recycled materials will not get recycled.

They might be incinerated.

Waste paper and boards can be recycled and reformed into other products.

A quick check for understanding which of the following is a benefit of recycling paper and boards? Is it A, to increase landfill waste? B, it adds strength to material.

C, it reduces tree felling; or D, it saves energy.

Pause the video now.

Have a go at this and come back to me when you've got your answer.

It is of course C and D.

It reduces tree felling, reducing deforestation, and also it saves energy.

Now this is the paper recycling process.

So let's have a little closer look at each of these stages.

So first of all, we have paper collection.

Now you probably do this yourself.

I have a blue bin outside my house that I put all my waste paper in, so it's a very similar process to that.

We then need to de-ink that paper, take all the ink off the paper that you find on it.

We then clean the paper.

We then go back into our paper making process that you have seen already in this learning cycle.

So we make the pulp first.

We then make it the paper by rolling it out and then we have our recycled paper.

A pretty simple process, but as you can see, no trees were felled.

We didn't start from scratch, so we've saved a significant amount of energy.

Now upcycling is the process of taking discarded or unwanted materials or sometimes even products, and then creatively transforming them into something useful or attractive.

Unlike recycling, upcycling does not require breaking the material down.

It usually preserves its current form.

You can usually tell what that material was once you've upcycled it.

And here we have a lovely example.

We've got a paper pot maker.

So by using the paper pot maker and newspaper, you can create biodegradable pots for seedlings.

Isn't that great? Another check for understanding.

What is the process of taking discarded or unwanted materials and creatively transforming them into something useful or attractive? Pause the video now.

Have a go at this and come back to me when you've got your answer.

It is of course, upcycling, which is different to recycling.

So let's have a look at some benefits of upcycling.

It reduces waste and landfill.

It saves energy.

There's no processing required.

It gives old materials a new purpose and a longer life.

And here have some fantastic examples of products that have been upcycled, but I'm sure you can still see what those products originally were.

We're now onto your final task.

Task C, all about conserving resources.

I want you to describe two environmental benefits of recycling papers and boards.

I want you to explain the difference between recycling and upcycling paper using an example, and then finally, I want you to draw a diagram that explains the process of recycling paper to create recycled paper.

Pause the video now.

Have a go at these tasks and come back to me when you've completed them.

So let's have a look at some feedback.

So the first question I asked you to answer was describe two environmental benefits of recycling papers and boards.

And you might have answered something similar to this.

Recycling paper and boards reduces the number of trees that need to be fell and cuts down on the amount of waste sent to landfill.

It also uses less energy than producing new paper-based products.

The second question, I wanted you to explain the difference between recycling and upcycling paper using an example.

Recycling involves returning paper back to pulp form and then processing it into more paper-based products.

Upcycling, reuses paper in its current form, such as turning magazine pages into beautiful decorations.

And then, finally, I wanted you to draw a diagram that explains the process of recycling paper to create recycled paper.

And, hopefully, you drew something very similar to this.

And what's important is that you've got the six different stages on there as well, which I'm sure you did.

Well done with that.

So that brings us to the end of today's lesson where we've been looking at reforming manufacturing processes for papers and boards.

Let's have a quick summary.

First of all, reforming involves reshaping a material into a new form without changing its basic chemical structure.

Small scale production methods can be used to reform materials.

A mould is a hollow shape for forming materials.

While a former is a solid shape around which materials are shaped, reforming materials on a larger scale requires different techniques.

Recycling and upcycling save resources, reduce waste, and give new life to all materials.

Well done.

You've been absolutely fantastic today.

I look forward to seeing you all next time.

Bye-bye.