Modeling a Paper Mill - Part 4.3 New Warehouse Addition

In the last post, I talked about how I added another building within the cellulose portion of the mill.  I had another project on my to-do list, which was to expand the Walthers stock kit warehouse building so that I could load more boxcars with finished product.  When I initially designed the paper mill, the warehouse was to be two Walthers kits joined together, which would allow at least five (5) 50-foot boxcars to be stored for general rail loading and leaving the truck bays intact.  However, two buildings took up a large amount of space, and the paper mill modules were going to be restricted to a 12 linear foot area.  So after running with a warehouse which could only accommodate 3 boxcars, something had to be done.  After all, the paper mill can only survive by increasing it's outflow whenever demand is present.  Remember, it's 1985 on the layout, so consumers are still reading their daily newspaper and the paper mill is constantly busy meeting the demand for paper rolls.  While business has started to see a slight decline in big city newspaper demand, small local and regional papers continue to flourish and demand has increased.

Accordingly, two new tracks were laid into a portion of the grounds which was being used for storage of miscellaneous items and equipment, including a small transformer yard.  The plant manager, after presenting a capital investment plan to the bean counters, was able to procure the funds to add track and place it under roof to avoid those harsh northern Ontario winters.  This meant that the electrical substation had to be moved onto the roof of the warehouse, which while a little bit of a stretch, is not too obvious or out of place.

I had purchased several pieces of laser-scribed basswood several years ago from  Monster Modelworks, but never got around to using them for a project that I had intended to scratch build in N scale.  While maybe the sheets and brickwork are the wrong scale for the purist, I opted to use the three sheets that had been purchased rather than buying sheets in HO scale. After all, the main purpose was to house boxcars, and I wasn't looking to model something exactly like a building that doesn't actually exist on the prototype.

Several weekends ago, I started to take measurements and started to draft what my addition would look like.  As I was doing so, I realized that the addition would likely have to cover the existing windows on the Walthers papermill kit, so I decided to remove the windows and make the addition high enough to accommodate the tallest of boxcars while at the same time covering the windows.  Removing the windows without breaking them took some finessing the plastic from its glue, but everything came out without any significant damage. So after joining the three sections of wood, a little cutting was in order to re-install the plastic windows into the new addition.  

Structure is complete and it's time to think about finishing the roof as well as the area by the doors. I'll add a circular tube at the top of each door to simulate an overhead door.

While I originally was going to install a platform at door height of the boxcars, I opted to install a concrete walkway at ground level and only finish a small portion of the doorways.  Some drums and workers were added, but since you can't see very far into the building, I decided to forego and real detail. Again, the building was built to house boxcars and really meant to be a storage space for loading and unloading purposes.

View from the other side. Tracks in foreground are yard storage of empty boxcars waiting to be loaded and excess tank cars ready for other parts of the Mill. 

Modeling a Paper Mill - Part 4.2 Construction Progress

Between travels for work and time spent this fall preparing the yard and house for the winter months, I have not had as much time to spend on the layout.  However, I have been able to do a little painting and install some scenery materials so that the paper mill doesn't look as bleak and empty as before.  And of course I've had some re-do's, as I wasn't satisfied with the way some of the roadways turned out.  Apparently trying to model a very fine, crushed stone roadway with fine ballast was harder than I previously remembered it to be when just trying to do small roadways.  Large areas that could be a roadway or just an open area just seem to show even the finest of gravels rather than a well worn gravel and dirt roadway that I was trying to achieve.  So between roadways and some ground scenery, some color is appearing and the modules are beginning to take the form that I wanted.

When I had some free evenings and paint was drying in various portions of the two modules, I also dug out some tank kits that I had accumulated for the mill and began to build them.  And of course, all tanks should be set inside some sort of spill containment structure, so I have also been rummaging through the scrap styrene box to fine appropriately sized pieces to build containment structures.  My recent work has been to start adding some pumps and piping; I found some great HO sized pumps on the Shapeways website and will be adding pumps and piping shortly.

Initial construction; still need to add piping to each of the three tanks as well as the 3 tanks in the background

The biggest project undertaken was scratch building a new building within the cellulose portion of the mill.  Based on a general visitor guide I obtained in 2001, I believe that this building is actually part of the bark boiler complex on the Temiscaming mill  I liked it due to some unique angles that are present, as well as the ability to accommodate the placement of several stacks I built using the Walthers refinery kit.  So it has now become part of a background building for the specialty cellulose mill.  For my building, I added a rail unloading shed at ground level, which I'm fairly sure is not present in the prototype, but allows some more spots for tank car off-loading.  It also allowed me to spot some storage tanks in between some of the tracks which will be used as part of the chemical products group alcohol plant.

Start of the specialty cellulose mill. Still need to cut the angled middle and bottom panels. Hardest part was cutting the windows to the correct size. Several catwalks and stairwells will be added to the left side of the Bldg (not shown in picture)

Bldg is now partially done; major components are in place, however, work still needed for the piping and exits along the left side of the Bldg

Windows still need to be worked on and some sort of backing put into place so that the windows and styrene don't deflect and bow; many of the pieces used are leftovers from other projects

Working through some of the details

Additionally, I have been able to ballast most of the track in the paper mill, as well as setting the switches permanently.

Modeling a Paper MIll - Part 3 Rail Services

The Spruce Creek facility receives most of its bulk raw materials via rail.  I have purposely chosen not to include truck operations in my modeling, as I lacked the space to include a large enough loading area for trucks and opted to set my warehouse building at the end of the module, so that I might have more storage track space. 

Rail traffic for the four mills consists primarily of boxcars, chemical slurry tank cars, and chemical tank cars.  When I began to design my mill, one of the first items I noted that the prototype had was a number of storage tracks that were present, either within or outside the mill itself.  The second item was that, with the exception of the Temiscaming mill, each mill had its own or several switcher engines.

Switching Power

One the most interesting aspects of the mill I find is the power used to move the various boxcars and tankcars and the number of movements needed to keep the operations running smoothly.  I chose to replicate my mills power based on the various types of equipment that have been used at my four prototype mills.  The following is a rough list of engines that have been known to operate at the different mills in the area and is simply used to illustrate the variety of power over the years.  

The next decision was how the mill would be switched. Paper mills receive a large number of cars on a daily basis when in operation, which can tie up the local switching crew for the better part of a day or more.   For a start-up operation, this would have strained the resources of the crew, so the decision was reached early on that KLR crews would go to the mill, drop any empties and pick-up the cars ready for transport from the yard, while a two-person yard crew would work at least one shift to move cars within the mill.

I decided to go with similar engines and power requirements as were typically seen at my four example mills.

	Engine #	Type	Notes
Iroquois Falls	1203	S4	Ret. from ONR 1973; sold to Abitibi Pulp & Paper
	1310	RS3	Sold from ONR in 1985 to Abitibi Pulp & Paper
Smooth Rock Falls	104	S4	Mattagami Rail; formerly Quebec Iron & Titanium
Kapuskasing	108	RS23
	109	RS23	Former Devco #201
	168	GP7	Mattagami Rail, ex ACR 168
Temiscaming			No known dedicated engines; services provided by CP and RaiLink via the branch line (Temiscaming Sub.) from Mattawa to Temiscaming, Quebec (approximately 41 miles).

Currently, the Spruce Creek mill is serviced by an S4 (former Boston & Maine ) and a Mattagami GP7 unit.  With the introduction of the SW1200RS by Rapido in 2017, a unit in CN's black and orange paint scheme may become the newest switcher.  Ideally, when funds allow and a model is available, power will be replaced by an Alco RS23.

Inside the Mill

Let me first start off by saying that I firm believer that modeling an industry should be realistic to the prototype but also fun to operate.  After all, who wants to operate on a layout or switch an industry if they’re not having fun.  So I subscribe to the thought following what the prototype has done is the simplest and most realistic way of achieving your goal. This may include modeling only some of the basic buildings one might find in a paper mill, as well as following the general track arrangements, or modeling each and every building if it is needed to support a variety of rolling stock which is received. 

The idea of keeping the track plan simple and close to the prototype became very apparent during a review of my first mill track plan.  My first design was based where I had cited various buildings and where they fit best, rather than based on any logical flow from a manufacturing standpoint.  That was a mistake, as the initial design created the situation where I would need to build a crossing within the facility just so that I could access both my chemical delivery track, as well as the warehouse tracks using different movements.  So it was back to the drawing board and a little more review of the aerial photos I had from several of the northern Ontario mills before planning the track work.    What really jumped out at me was that each of the mills had sufficient yards within or immediately outside of the mill, such that empties and filled cars were shuttled to and from the yard from the active loading or unloading areas.  When switching was completed, the plant switcher was generally returned to its engine house or bay.

Location	# Yard Tracks	Notes
Iroquois Falls	6+	Exterior to Plant; between Cambridge Ave and Ambridge Drive; use of a Wye
Smooth Rock Falls		Unknown within mill; Access via rail along 4th Street
Kapuskasing	5+	Yard tracks adjacent to ONR main; parallel to ONT-11
Temiscaming	6	Yard tracks well south of the mill; Small wye towards south end and near river

Car Loads

Let’s take a look at what the Spruce Creek plant produces, what the various raw materials that are needed, and how often rail cars enter the plant.  Similar to the Temiscaming mill, I modeled operations to include three main mills that manufacture different forest products, including specialty cellulose, high-yield-pulp and coated bleached board (containerboard) as well as a chemical products facility.   The chemical products division produces a variety of products made from spent sulphite liquor (primarily alcohol, resin or lignin based).  

It goes without saying that modeling four operating plants takes up a large amount of space, which typically is not available with a model railroad regardless of which scale you're modeling.  However, I have used photos from the Kapuskasing and Temiscaming mills as backdrop, which is how I incorporate each of the mills.    

The Spruce Creek Pulp and Paper Mill is located on two 2’ by 6’ modules in the center of the room.  Starting from the left side, my buildings include a power plant, the pulp mill, alcohol plant, acid building, kaolin building, specialty cellulose mill, board mill and the warehouse.

High Yield Pulp - the pulp mill is a manufacturing facility that converts wood chips or other plant fibre source into a thick fibre board which can be shipped to a paper mill for further processing. Pulp can be manufactured using mechanical, semi-chemical or fully chemical methods (kraft and sulfite processes). The finished product may be either bleached or non-bleached, depending on the customer requirements.  In our mill, kraft pulp is produced using softwood pulp, while the "B" mill can produce either softwood or hardwood pulp.  Similar to the Boardmill, final products are shipped via both rail and truck.  The Kraft mill also produces large amounts of lignin liquor, a byproduct of the digestion process. This material can be shipped out in tankers, dried, or fed to other bacterias to make yeast.  The Kraft mill also uses other chemicals such as sodium hydroxide (caustic soda) and sulfuric acid. Kaolin (slurry form) is brought in to make glossy paper. Kaolin is often supplemented by calcium carbonate (lime) slurry and titanium dioxide.

The Chemical plant consists of products which are made from the spent sulphite liquor generated within the facility.  The plant can be divided into an alcohol division, resin division and lignin division.  Most of this operation takes place within numerous tanks situated within three central buildings.  Due to their relative size, I chose to model only the fronts of the buildings and blended the building into the photo backdrop.

Refined from wood pulp, specialty cellulose is used in a range of applications across many industries – cosmetics, pharmaceuticals, personal care, food, coatings, electronics and energy.  Specialty cellulose is manufactured in both rolls and bales.  Similar to the chemical plant, this area was modeled using only the front of the building set against the photo backdrop.

The Boardmill Division produces high quality paper and manufactures newsprint for publishers of daily newspapers and commercial printers, as well as controlled bulk paper for mass-market paperback book publishers and commercial printers.  Coated bleach board is a product used for a broad range of commercial printing, publishing and packaging applications.  Newsprint production uses wood fibre obtained from four separate sources, including thermomechanical pulp (TMP), recycled pulp, groundwood pulp and kraft pulp. Kaolin is used to make glossy paper. While chlorine was used to bleach the paper, in recent years it has been replaced by sodium chlorate.

Rail Traffic

One of the other key aspects I looked at when designing my mill was how much traffic did a typical northern Ontario paper receive and could I support anything close to that. For example, both the Kapuskasing and Temiscaming mills generally receive rail traffic at least 5 days per week.  Aerial photographs are readily available for the Kapuskasing mill, and show that it has at least 5 storage tracks which appear to be able to easily hold forty (40) fifty-foot boxcars easily.  There are several additional tracks within the property which can also accommodate 15-20 cars easily per track.  If a typical train load is 20-30 tank cars and boxcars, I knew that there was no way to accommodate that much storage for my modelling. 

Another aspect that goes hand in hand with this was how much yard trackage would I be able to accommodate within two modules, given that this would become the easiest way to move traffic around with the yard switcher.  With the exception of the Temiscaming mill, each of the other mills discussed previously have been supported by a fairly large amount of trackage either on or just off the mill property.  It was very common to see numerous strings of boxcars just waiting to be pushed into the warehouse tracks, however, stored just along the property boundary.  Warehouse tracks were typically designed to support multiple boxcars, with the area under roof supporting at least 3 tracks and it was quite common to see 4-5 boxcars on each track.

The next step was to determine which types of rolling stock would be needed at the mill.  Paper mills take in and also ship out of lot of things, which may typically include: 

Rail Car	Inbound	Outbound
Boxcars	Scrap paper	Paper Rolls, Kraft or bleached paper	Various sized boxcars paper rolls and bundles bleached kraft bundles, scrap paper
Gondolas/Hi-cube Hoppers	Wood Chips
Bulk Head/Pulp Wood Flats	Pulp Wood Logs (cut to lengths of 4 to 6 feet long)
Tank Cars	Kaolin Chlorine  Limestone Slurry Caustic Soda Sodium Hydroxide Sodium Hydrosulfide Sulfuric Acid Lignin liquor	Tall Oil by-product Lignin Liquor Turpentine by -product	Chlorine (pulp bleaching); Clay slurries (note: Kaolin would be used for glossy papers)
Gondola		Scrap Iron
Bulkhead flat cars	10-foot pulpwood		Single-stacked cross-ways
Hopper	Coal, although most facilities burn some sort of wood waste
Covered Hoppers	Salt Cake, Calcium Carbonate, Lime, Sodium Chlorate, Corn Starch		Calcium carbonate – off loaded near the fourdrinier building for coatings; replaces kaolins

 Rail Spurs

 For my operations, I opted to go with the following arrangement:

• Warehouse (1 interior track within the Building; 2 interior tracks in adjacent Bldg.); each track to hold 2-3 boxcars
• Rotary chip dumper (1 track); able to store one hopper
• Chemical Plant (1 track – min. 5 loading/unloading spots)
• Engine House – (single track off of the outbound storage track)
• Yard Tracks (2 tracks, one for outbound cars and one for inbound; able to store 8 cars min.)

Engine house - Iroquois Falls, ONT

Modeling a Paper Mill - Part 2 Operations

This is the 2nd part of my paper mill discussion, and I have tried to explain the thoughts that went into designing the mill and more importantly the amount of traffic it could generate and handle.  You may not realize it, but a paper mill makes a great central industry on a layout. The mill gets inbound shipments of chips from lumber mills, chemicals from everywhere, and ships out boxcars of paper (and trailers for the intermodal trains) to all kinds of satellite industries such as paper converters (cut rolls of paper into various size sheets for copiers, notebooks, ect.), corrugated box plants, newspapers, and printers.  Therefore, rail transportation includes:

• Raw logs to a mill from a log reload offline
• Chips from the lumber mill to the paper mill
• Various types of chemicals from multi-sources that are used in the paper manufacturing process
• Paper from the papermill to a paper converter
• Various chemical by-products which are shipped to numerous types of industries for their own use
• Paper sheets from the converter to a printer
• Coal and other products brought in for power generation

Let me first say that I firmly subscribe to the thought that building a layout by following what the prototype has done is the simplest and most realistic way of achieving your goal. My first mill track plan had some crossover and other trackage that just didn't seem realistic, mostly because it wasn't following what the prototype did.  So it was back to the drawing board.

During the summer of 2001, I had the opportunity to take the family for a trip on the short-lived Timber Train excursion.  Started by the Mattawa Temiscaming Excursion Co., the train was intended to shuttle tourists between Mattawa and Temiscaming, Que. for the day.  The Timber Train used the existing Ottawa Valley RaiLink line, and RaiLink provided the power.  During the stop in Temiscaming, you had the opportunity to walk and shop around the town, or go on a informative tour of the paper mill. Unfortunately, the 7.5 hour journey through the scenery of Ontario and Quebec ultimately did not survive.  When the Timber Train went belly-up, the Adirondack Scenic RR picked up all or most of their cars at bargain-basement prices.  Engines went back into RaiLink service.  But for me, the tour of the paper mill was very much worth the entire trip. Informative from both how paper and pulp is made, but also informative from a railroad operations standpoint.  No wonder the train staff was looking at me kinda funny as the train was entering the mill.  I was the only one at the window trying to photograph every building and track in front of me.  Ultimately armed with knowledge gained from trip as well as observing the other mills I discussed in Part 1, I would pattern the Spruce Creek Pulp & Paper mill after these operations as much as I could.

So let's start with a discussion with what the Spruce Creek plant produces and how it actually is made from the various raw materials which are needed. Similar to the Temiscaming mill, I modeled operations to include three main mills that manufacture different forest products, including specialty cellulose, high-yield-pulp and coated bleached board (containerboard) as well as a chemical products facility.   The chemical products division produces a variety of products made from spent sulphite liquor (primarily alcohol, resin or lignin based).  

Tembec's Temiscaming, PQ operation

Temiscaming - Chemical Division in background; bark & chip storage buildings in foreground

Temiscaming Specialty Cellulose Mill

It goes without saying that modeling four operating plants takes up a large amount of space, which typically is not available with a model railroad regardless of which scale you're modeling.  However, I have used photos from the Kapuskasing and Temiscaming mills as backdrop, which is how I incorporate each of the mills.    

As I mentioned in Part 1, my Spruce Creek Pulp and Paper Mill is located on two 2’ by 6’ modules in the center of the room.  Starting from the left side, my buildings include a power plant, the pulp mill, alcohol plant, acid building, kaolin building, specialty cellulose mill, board mill and the warehouse.

High Yield Pulp - the pulp mill is a manufacturing facility that converts wood chips or other plant fibre source into a thick fibre board which can be shipped to a paper mill for further processing. Pulp can be manufactured using mechanical, semi-chemical or fully chemical methods (kraft and sulfite processes). The finished product may be either bleached or non-bleached, depending on the customer requirements.  In our mill, kraft pulp is produced using softwood pulp, while the "B" mill can produce either softwood or hardwood pulp.  Similar to the Boardmill, final products are shipped via both rail and truck.  The Kraft mill also produces large amounts of lignin liquor, a byproduct of the digestion process. This material can be shipped out in tankers, dried, or fed to other bacterias to make yeast.  The Kraft mill also uses other chemicals such as sodium hydroxide (caustic soda) and sulfuric acid. Kaolin (slurry form) is brought in to make glossy paper. Kaolin is often supplemented by calcium carbonate (lime) slurry and titanium dioxide.

The Chemical plant consists of products which are made from the spent sulphite liquor generated within the facility.  The plant can be divided into an alcohol division, resin division and lignin division.  Most of this operation takes place within numerous tanks situated within three central buildings.  Due to their relative size, I chose to model only the fronts of the buildings and blended the building into the photo backdrop.

Refined from wood pulp, specialty cellulose is used in a range of applications across many industries – cosmetics, pharmaceuticals, personal care, food, coatings, electronics and energy.  Specialty cellulose is manufactured in both rolls and bales.  Similar to the chemical plant, this area was modeled using only the front of the building set against the photo backdrop.

The Boardmill Division produces high quality paper and manufactures newsprint for publishers of daily newspapers and commercial printers, as well as controlled bulk paper for mass-market paperback book publishers and commercial printers.  Coated bleach board is a product used for a broad range of commercial printing, publishing and packaging applications.  Newsprint production uses wood fibre obtained from four separate sources, including thermomechanical pulp (TMP), recycled pulp, groundwood pulp and kraft pulp. 

Part 3 will look at the rail operations inside the mill.