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There are two methods of sheet formation:

1/ Dipping method (for fine/thin paper). The pulp is diluted with water and put into a masonry trough or vat. The lifting mould (mesh on a wooden frame) is then dipped into the trough, shaken evenly and lifted out with the pulp on it. The consistency of the pulp in the tank should be kept constant.

2/ Lifting method (all paper and card). A fixed measure of the pulp is poured evenly onto a mould, which is clamped between two wooden deckles (frames) in a water tank and dipped. The mould is then raised, using a lever mechanism, to drain the excess water.

Couching. After the sheet formation is completed, the wet paper is transferred onto a cloth/felt sheet and a stack of interleaved sheets is built up.

Pressing. A hydraulic press is used to remove the excess water from the sheets. Pressing reduces the bulkiness of the paper i.e. the sheets become more compact. This improves the physical properties of the paper and facilitates drying.

Drying. After pressing, between 50 and 65% of moisture remains in the sheets. The sheets are dried by hanging them in open areas of sunlight to remove the rest of the moisture. Solar dryers can speed up this process and reduce the amount of space needed. Colored paper is sometimes dried in the shade to avoid the bleaching effect of the sun.

Cleaning and sizing. Small dirt particles and other foreign matter are removed manually with a sharp instrument. The cleaned sheets are given a coating with starch to improve the physical properties of the paper and prevent feathering. This is called sizing and can be done manually
with a brush or by the dipping method, where the sheets are immersed in a tub of sizing chemicals.

Calendering. The sheets are placed between metallic plates and passed through spring loaded rollers in a calendering machine. This smoothes the paper and enhances the gloss. Cutting. The sheets are neatly cut to the required size using a cutting machine.

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