Where do dream workbooks

I am asked periodically. And yet, how do you manage to get to certain enterprises, who are behind you, what is the strength, etc.? And fairy tales are not here, I just work a lot and really love our industry. But by example, I’ll still share it. Many of us have children of school age, every September there is a question, what to take a child to school, what to buy, so that he gets only fives and is a great clever girl. I confess that I personally am a shopaholic, many are even jealous of my Light, I really like to go shopping and, of course, I also chose notebooks for Stas school. And then I just mechanically looked, and who makes them, and decided to write what they say I want to visit you. And they took me and did not refuse. So, friends, we are transported from Perm to the village of Polotnyany Plant (better known, because it was here that the Goncharov estate belonged, the family of which belonged to Natalya Nikolayevna, Pushkin's wife), Dzerzhinsky District, Kaluga Region, 35 km from the regional center. It is in this historical place that Polotnyano - Factory Paper Manufactory LLC is located, which produces dream notebooks.How is everything there, I’ll show you today.

Polotnyano - Factory paper manufactory is one of the oldest industrial enterprises in our country. He blessed her on the path of paper leadership, Peter I himself, by releasing, on occasion, his nominal decree of March 7, 1718 on the creation of a sail-linen factory under the control of Kaluga merchant Timofey Filatov - Karamyshev. In 1725, the factory was built and issued its first products: sailing canvas and writing paper.
2. Main aisle factories. From the series was-became

In 1732 she passed under the wing of Athanasius Goncharov and Grigory Shchepochkin. By the way, at that time it was considered one of the largest in Europe. In their status piggy bank is another fact for pride. In 1775, Empress Catherine II, pleased with the quality of the writing paper produced, allowed the manufacture to be called the “Supplier of the Imperial Majesty’s Court” and water marks, medals and the honorary title of the manufacturer appeared on Goncharov’s writing paper. Few people know, but true. At one time, in 1812, Mikhail Kutuzov located the headquarters of the Polotnyi Zavod plant and most likely could not resist and visited this magnificent factory, and only then defeated the French. Like Kutuzov, the great Russian poet A.S. Pushkin.Acquainted with his bride, Natalia Nikolaevna Goncharova, he repeatedly came to these places. In the future, the Goncharov paper mill was included in the number of enterprises of V. Howard and became part of the joint production under the name "Kondrovsko-Trinity Factories of Howard and Co.".

4. Spassky Gate. They performed the function of the church gate and at the same time the entrance gate to the Goncharovs' estate, in the territory of which our factory is located. The gate is a kind of architectural structure. The abutments of the travel arch support a massive attic, topped with a baroque pediment. The foundations themselves are decorated by squat columns of the Tuscan order, attached to them from four sides - three in each corner.

In 1917, after the Great October Revolution, the manufactory passed into state ownership, and a little later in 1923 was transferred to the Centrobumtrest and became an enterprise of all-union value.
5. Learn, learn and learn again, so did Lenin say, but how to fix knowledge without notebooks ...

During the Great Patriotic War, while it was under occupation, it was almost completely destroyed, and the equipment was partially lost.In 1944, it was gradually restored, and in 1947 a workshop for the production of consumer goods (paper-white goods) was even commissioned.

Gradually transferred to our time. The factory is incorporated, like most enterprises in the 90s, and in a time that is not easy for the country, it finds the strength not only to survive, but to confidently occupy its niche in the Russian market. In 2002, their premium brand notebooks, Magic Lines (magic lines), were introduced to the market, and 2004 - two automatic lines for the production of school and general notebooks were installed at the factory. Since then, the motto of the factory - Only the world level of quality! In 2006, the factory is part of the United Paper Mills holding. That very well stimulates them to further growth and modernization of fixed assets. Two papermaking machines, as well as a corrugated workshop, were reconstructed. As a result, they bring to the market notebooks under the X-SIVE (exclusive) brand, and this is already a super premium segment.

Today Polotnyano - Factory Paper Manufactory is one of the largest factories in our country for the production of corrugated paper and cardboard for flat layers, which again is needed for the production of corrugated cardboard.In addition, it consistently ranks among the three largest notebook manufacturers in Russia. The range of the company is represented by approximately 700 items of paper-clean products. By the way, next year they have a great anniversary, they will be 300 years old, so it turns out that they are very experienced guys in this topic.

9. If the theater begins with the broadcaster, then papermaking with waste paper :).

10. For the manufacture of products of the tetrad workshop, industrial (waste of corrugated cardboard production) and household waste paper are used here.



13. The waste paper received here is first sorted (yes, it turns out it also has a different value) and then from the waste warehouse along the conveyor it is fed to the waste paper dissolution section, where it is mixed with recycled water in the pulper until the pulp is formed.


15. And this is a pulper in action.


17. From the site of waste paper dissolution, the paper pulp enters the grinding-preparatory department, where it undergoes several stages: cleaning, sorting, fractionation and grinding. Unfortunately, most of the processes are simply hidden from human eyes, but on the other hand, we don’t lose much. Go ahead.

18.Then, the prepared and cleaned paper pulp is fed to the paper machine, where the formation of a sheet of paper takes place.

19. This canvas is initially dehydrated, you see, the closer to the paper machine it is drier and drier. Next, it is pressed and dried on the drying cylinders, heated by steam.

20. One of two paper machines.


22. The formation of finished rolls is carried out on a slitting machine.
23. And here is their second paper machine. By the way, very soon the paper-making machine No. 1 will be sent to a sanatorium, its reconstruction is scheduled for 2018.


25. Warehouse of finished products. This is how the corrugation paper looks like. By the way, the mass of such rolls is about 1 640 kg, and the length of the web is more than 1 600 m.

In the year of ecology, I especially want to mention their desire to think first of all about the environment than about your wallet. So in 2016, they completed their first stage of a large-scale technical reconstruction project of wastewater treatment plants. A “Deltafloat-56” flotation trap and a “P 2000” filter press were launched.


The launch of this flotation complex has significantly improved the quality of wastewater and ensure their compliance with all established standards.

29.And nevertheless, I promised you to show the tetrad production, not a question, we are already in the tetrad workshop.

30. The workshop for the production of notebooks produces paper and paper products: student’s and general notebooks, notebooks, business notebooks, drawing albums, notebooks, kits for artistic creativity, etc. The structure of the shop includes 2 sections. At the moment we are at station number 1 where the notebooks are produced directly.

A high-performance German line for the production of notebooks Will (280 SL, 100 beats per minute) and an automatic line for the production of notebooks "PWT 84" are installed here. These lines are also equipped with role-based samokanalami for the production of 12-sheet notebooks in the "green" cover. Here we got them.
31. The initial rolls of paper received here are unwound.

32. Then the colorful apparatuses apply various patterns on one or both sides of the paper web. The maximum speed of ruling of automatic lines for the production of notebooks "WILL-8050" and "WILL-8049" is 500 m / min.


34. Next comes the time for the cross-cutting section, where the Unit cuts off individual sheets from the paper web. Cutting is carried out at a right angle to the direction along the paper.


36. Cascade feed station.She slides the sheets, cut by a cross-cutting machine, up and down steps. At the next stage, the balance is made, the sheets are collected in a pile, their number depends on the release of a specific product.

37. Next comes the time cover. For her responsible machine for tabs and cover the cover with a roll. This machine can wind material for covers and tabs from a roll through a system with “floating” rollers and a device for deflecting a paper web. The built-in colorful device serves for a monochromatic or two-colorful printing on a paper cloth. The cross-cutting unit cuts the cover sheets, which are then applied to the passing stacks of paper.


39. So, the tetrad "wedding" has happened, now it is time to fasten them with rings, of course with wire clips. To do this, they do not need to go to the registrar office, everything will be done for them by the local stapling station.

40. Stacks of paper coming from the counting station are straightened and stapled along the middle axis in the stapling station and forwarded to the folding section. Stapling heads are located above the paper web at the level of paper movement. The pulling mechanism feeds the wire into the stitching heads.In the sewing head, the wire is cut with knives along the length.



43. Next, the folding process takes place (ie, folding sheets in notebooks of a certain volume and format) and after that they go through the Roller pressing section of the roots and enter the Cutting Station, where sheets of sheets are already cut into notebooks of the finished format. That's all, nothing complicated, especially if everything is responsible for automation.

44. In the workshop, student notebooks and general notebooks are made using as a cover paper cover sheets and printing covers on a clip - 12, 18, 24, 40, 48, 60, 80, 96 sheets, drawing albums on a clip.

Just an interesting fact. By the way, the very name “notebook” comes from the word “four”. There are several possible explanations. One of them is that in the libraries of medieval universities books, for the convenience of students, were divided into four parts, in the absence of typography, this was simply irreplaceable, these parts were called quarters - notebooks ... There are versions with an earlier history. It may have come to us from ancient Greece, where students wrote with pointed chopsticks on wax-coated tablets.You can't write a lot on one thing, and apparently by experiment, they came to the conclusion that the four tablets are the very thing and here it is a notebook. Such student notebooks even survived to our times.

But there is another version of the origin of the notebook itself, and the words “notebook”. Again the ancient world. Egypt, papyrus, with all its positive properties, it had a big disadvantage, it can not be folded, it just breaks. And also the Egyptians made an embargo on his export. I had to look for an alternative. Here and Alexander of Macedon tried with their campaigns. So in the Greek city of Pergamum in Asia Minor, people took over from the Persians and improved the technology of making hides, this material for the letter was called parchment, thanks to the city of origin. At first, scrolls similar to papyrus were also made from parchment, and then they were taken and folded in four — that was what was called the “tetrad”. Several of these notebooks, stitched together, are already conditionally similar to modern notebooks.

So what are so good exactly the notebooks from the TFBM. For example, here in this series that we bought with Stas there is an important element - Kongrev (named after its developer William Kongrev), i.e.multi-level convex embossing (the picture does not convey this theme very much, but it feels very unusual and pleasant to the touch, believe me). In this embossing, a matrix (upper mirror cliche) and a counter-matrix (punch) are used. This method embossed only sheet material that is able to change its shape. The material, clamped for a short time between the die and the die, takes the form of a cliché and remains in that position. The result is a beautiful three-dimensional three-dimensional print.

It is the PSBM that was the first to use the technology of multi-level embossing on the covers of notebooks of the Magic Lines series to create an extra volume of the image. Each stamp is manually engraved at different levels to give the design a natural look. Therefore, we can safely shout that the PZBM notebooks are reasonably called HAND MADE notebooks! Eh, they would know what a cool assortment they have for girls, but that’s another story .... It’s great that progress has come and we have a choice in this subject for every taste and budget.

49. I already wrote above that next year they have a great anniversary, they will turn 300 years old, so for this matter, now works are under way to restore the historic building for the paper museum.So next year, the first paper museum in Russia, “Buzeon”, will work here. I think it is very interesting and I hope that I will definitely find the time and come here again, which is what you want.


51. For my part, I want to express my gratitude to the company “Polotnyano - Factory Paper Manufactory” for the warm welcome! And to all other representatives of the business, we with Valentina Mironova, the general director of the factory, we also recommend taking the path of openness and inviting bloggers more often, let the whole world know that there is production in Russia and it is the best.

R. S. Dear owners and shareholders, representatives of the press services of companies, marketing departments and other interested parties, if your company has something to show, “How this is done and why this is so!”, We are always happy to participate. Feel free to email usand tell us about yourself by inviting us to visit you.

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