Reflections related to paper machine operation
There used to be 6 paper machines in operation at the mill. However,
the oldest No. 6 machine was not in operation while I worked at the
mill. The machine was so old, that the dryer gears were made out of
wood. In other words, a machine which belonged to the 1800 rather
than the 1900 century. The remaining 5 machines produced so many
different paper grades that today all these grades would never be
produced in a single paper mill. The mill produced newsprint and
rotoprint on two of the machines, the furnish mainly consisting of
groundwood pulp. Two more machines produced many different weights
of unbleached kraft grades such as light and heavy paper bag and
wrapping grades the furnish being mainly sulphate pulp. One machine
was totally dedicated to tissue paper production the furnish being
mainly sulfite pulp.
It took years to become a
proficient paper maker. A paper maker would start in the finishing
room and work his way up through back tending to wet end tending.
The paper machine superintendent was an important person for very
good reasons. The miracles he had to perform with his paper makers
to get a paper slurry to run through the Ocean Falls machines to end
up as finished paper was close to a miracle. When the paper was not
coming off the dry end of the machines, the Mill Manager and other
staff had to stand back and hope that the paper machine boss would
manage to save the mill's profitability for the month.
There is an
abyss between modern pulp and paper operators and the old paper
makers of Ocean Falls, two entirely different species of paper
makers. The modern pulp and paper operator is located in an air
conditioned control room with subdued lighting where the operator is
watching the distributed control system displays. In many cases, the
operator can not see the machine or machines he or she is
controlling. Every conceivable parameter involved in modern paper or
pulp making is monitored by dozens of moisture, temperature,
pressure and flow sensors and their output available to the operator
by the touch of a computer key. Any out-of-range process variation
measured by these sensors is gently and automatically adjusted by
the control systems. The modern paper maker can call up any and all
past events associated with these variations in the form of graphs
or what have you.
A paper machine or a pulp
machine is built in separate sections, each section driven by
separate drives. The relationship of the speed between the sections
is very important and in paper making language called the draw.
Today, variable frequency drives or DC drives control the speed of
these various sections. The speed difference between the sections,
or the draw, can be adjusted very accurately in the control room and
the electrical control systems take care of the rest.
The
paper makers of Ocean Falls had none of these facilities. His
control room consisted of a couple of electrical panels sitting in
the middle of the floor between two paper machines. He would have a
group of ordinary on/off switches, some amp meters and if lucky, a
couple of temperature indicators/recorders in hirntrolling the flow of stock to the headbox.
The noise level between the machines was very high and in the summer
time the temperature in the machine room would be close to that of a
sauna. The concept of hearing protection was not invented at that
time. Due to the heat, the papermakers would often work in their
undershirts since the teeshirts were not invented at that time
either. The paper stock would enter unpressurized headboxes and flow
by gravity onto the wet end.
How
the paper makers managed to get the "tail" as it is called from one
section to the other is also hard to understand. The tail is the
very first strip of paper which has to be threaded through the
machines. The Ocean Falls paper makers would catch the soft, wet
paper strip by hand and throw it into the next section hoping that
it would stay there. Today, there are modern threading systems which
automatically starts the travel of the sheet through the presses,
dryers and calender stacks if paper. When the Ocean Falls paper
maker had to adjust the draw between sections, he would go and turn
a hand wheel on the back of the machine which then would move a belt
on a conically shaped drive pulley.
The
quality control of the paper coming off the machine consisted of the
Backtender running his hand over the paper on the pope reel to check
for wrinkles and he would be tapping the reel with a stick to ensure
that the reel was building up uniformly. The paper quality would
later be further investigated by paper testers. However such
feedback would not come back in time for instant adjustment should
something not be right. Today, many of the paper qualities
are continuously
monitored and backed-up by state-of-the-art laboratory work. The
above description of old versus modern paper making is not an
attempt to belittle the modern operator. There is no comparison
anymore. Paper and pulp produced today is produced at a speed and at
a quality which would have been totally impossible to achieve on the
old machines. The technical expertise of modern operators can not be
compared to the old "hands-on" expert papermakers of the past.
Paper machine drives and
paper machine basement
The No. 1
and 2 paper machines at Ocean Falls were driven by steam engines, a
highly unique type of drive considering that the paper machines were
installed in 1916 and 1917. Again, a leftover technology from the
1800 century when the steam engine was king. Going by memory, the
steam engines were Corlitz, two cylinder, compound engines. In the
middle of the two cylinders, there was a huge flywheel which would
drive a much smaller pulley mounted on a line shaft. The steam
engines were installed in the machine room basement. These pulley
drives were unique because they were rope drives. I believe the rope
was a 1 1/2" diameter manila rope. The rope must have been close to
half a mile long. It was very entertaining when the mill had to
replace a worn-out rope. The operation would take care of nearly
half of all the millwrights in the mill. The rope was so long, that
the rope spool would be located in the far end of the machine room
basement. The millwrights would stand in a long line throughout the
basement and slowly feed the rope unto the flywheel.
I could never have visualized that I one day would have to produce
steam engine diagrams. This task was carried-out by an instrument
which would plot the steam pressure in the cylinders related to
piston travel. Such steam diagrams will indicate the efficiency of
the steam engine and they had to be done on a regular basis. This
was the only way the performance of the engines could be properly
assessed. To calculate the efficiency it was necessary to measure
the area of the enclosed curve produced by this instrument. For this
we used a planimeter, another instrument now belonging in museums.
The line shaft driven by
the small pulley ran the full length of the machine room basement.
The paper machine consisting of a wet end, presses, dryers and
calenders was driven by this line shaft. Conically shaped smooth
pulleys were driving flat belts which would run to the upstairs
machine room operating floor. The belts would drive shorter shafts
also equipped with cone pulleys. A gear box coupled to the upstairs
driveshafts would provide the final speed required of the paper
machine sections. Moving the flat belt on the cone pulleys would
vary the speed of each individual machine section.
Talking about the paper
machine basement brings up another memory. As mentioned earlier, it
was often very difficult to start up the paper machines and
everybody were worried about paper breaks in the dryer sections. A
break in the dryer sections would mean that a lot of paper had to
hauled out by hand, a very time consuming business. At the end of
the paper machines there was a special final paper finishing roll
stack called a calender stack. It would not take much to get a break
at the calender stack. These stacks were quite temperamental. In
order not to have to shut down the machine, there were large
openings in the floor where the paper from the dryer section could
be dropped down to the basement. Sometimes there were real problems
getting the sheet through the calender stack. The last thing the
paper makers wanted was to shut down the whole machine. So they kept
trying and trying. The paper makers often ended up with nearly half
the paper machine room basement full of nice, dry newsprint. When
you looked into the basement you could not even look through it
since the paper went nearly to the ceiling. There was equipment such
as pumps running inside the big mountain of paper. I often feared
that we would get a basement fire but I can not recall the mill
having a basement fire of any consequence. The rejected paper would
by the way be repulped in beaters and recycled.
Beater Room and Groundwood mill
The Ocean Falls paper
mill included a department called a "Beater Room". Today a beater
room is old pulp technology. The "Beaters" of the past are now
replaced by refiners and repulpers. The Beaters were large oval
wooden tubs with a center wall and a large beater roll mounted on
one side of the vat. The beater roll also made of wood was equipped
with numerous steel bars mounted in the surface of the roll. The
beater tub was filled with paper stock or recycled paper waste plus
water. The paper and pulp would be drawn between the beater roll and
the bottom of the tub and would this way circulate many times around
the vat. These beaters were an important part of the stock
preparation process to prepare the paper stock for the paper
machines. The beaters would operate on a batch principle, the stock
being dumped into a beater chest once the paper stock was properly
refined.
As mentioned, the Ocean
Falls mill produced three major grades of pulp stock. Mechanical
pulp, sulphate pulp and sulfite pulp. The sulphate and sulfite pulp
was produced in batch digesters, large cooking vessels. The
mechanical pulp was produced by grinding wood blocks in closed pulp
wood grinders. The original groundwood grinder room was very old
dating back to the beginning of the mill. It employed a very
primitive and manpower intensive process. The original groundwood
grinders were quite small and they were 3 pocket grinders. Each
grinder had three separate pockets which the operator would fill
with with relative small blocks of wood. Each operator had a small
wood pile by the side of his grinder. The operator would load the
grinder by opening a simple plate door. Once the wood was inside the
pocket and the door closed, the operator would open a steam valve on
top of the pocket. The steam pressure would drive a piston down on
top of the wood thus pushing the wood against the large grindstone
running inside the grinder. It was necessary to cool this process
with water to avoid the wood from burning and to provide a final
pulp slurry. The efficiency of the grinding operation was poor based
on wood utilization. Towards the end of the grinding cycle there was
a loss of wood since the very last wood in the pocket could not be
ground properly. The grinders produced a lot of what was called
slivers. These slivers were screened out and sent to a sliver pit.
The groundwood room could
be compared to Dantes inferno due to it's layout, darkness. moisture
and steam escaping from the grinders. The floor of the operating
floor was low and traffic through the grinder room was by catwalks
about 12 feet above the operators. It was always an amazing sight to
see these men working below in all the steam and water spray from
the grinders. Such working conditions would most likely not be
tolerated in any industry today, and rightfully so.
In the middle of 1960
these grinders were replaced with modern "Great Northern" grinders
some driven by a water turbine and others by electric motors. The
feeding of these grinders was now a mechanical process, the blocks
coming in by a large conveyor.
More paper machine
stories
This story also relates
to the paper machine operation. There were times when the paper
makers including the superintendent just could not get the machines
to run properly. They would experience paper breaks all the time. In
desperation, the superintendent would make the claim, that the
machine was misbehaving because it was out of alignment. Every time
there were frequent breaks on one of the paper machine the younger
engineers and draftsmen would get nervous. (We could hear the paper
breaks in our nearby office. Calender breaks are very noisy). Should
the paper boss declare that a machine was out of alignment, it was
the task of the engineers to figure out where it was out of
alignment. For some reason, we were always told that the
misalignment was in the dryer sections. A paper machine dryer
section is a totally enclosed machine section with a large hood
enclosing the dryers. The dryers consist of large, steam heated
steel cylinders which rotates and dries the paper as it travels
through the dryer section. To support the paper there are machine
felts carrying the paper sheet. Having received marching orders, we
would strip down to nothing and jump into a disposable paper
coverall. Time was of essence and we had to enter the dryer sections
soonest possible. The temperature inside the dryer was impossible
high and the dryer rolls were so hot, that we had to jump from one
foot to the other to keep the feet from burning. Under these
conditions we worked for hours with plum bobs and other instruments
checking that all the dryer rolls and smaller rolls within the dryer
section were parallel. It must have been a twice a year
performance. I do not ever recall that our work resulted in the
re-alignment of a dryer roll. By some miracle, the machine always
started up after our sweaty and unpleasant work. I guess we brought
good luck to the paper makers and their machines.
An Ocean Fall's Xmas party
The company would host a Xmas party for the mill operators and the
mill staff every year. These parties would take place in the Martin
Inn ballroom which also had room for dinner tables. They were very
nice parties especially because it was rare to have large parties in
town during the year. Everybody would show up in their best clothes
and some of the men were in tuxedos. I remember one such party. We
had finished our nice Xmas dinner. There was an open bar and it was
very busy. The dancing had started and we were all dancing with
someone else's wife. It must have been around 12:30 or perhaps as
late as 1:00 AM when the big steam whistle over at the mill starting
blowing. We counted the blows of the whistle and thus knew, that
there was a fire in the mill. People who were supposed to respond to
such a problem and also people not supposed to, staggered across the
bridge to the mill to find that there was a fire in the No. 1
machine dryer sections. This was a big fire, a typical dryer fire,
not much flame but lots of smoke. In spite of all the lights being
on in the machine room we could barely find our way around due to
smoke. There were long walkways running high up on the side of the
dryer sections and people were on these walkways with fire hoses. I
must admit, it is one of the most funny things I have seen since
everybody were running around in three-piece suits and tuxedos
dragging fire hoses behind them. We got the fire out but it was too
late to go back to the party and honestly, our clothes would not
have presented themselves well if we had returned. Certainly one
good way to remember a Xmas party at Ocean Falls.
By the way, it was not uncommon to get fires within a dryer section.
The paper dust was everywhere inside the dryer hood in thick layers,
some areas even soaked with lubricating oil. All the steam heated
dryer rolls were supported and running in sleeve bearings which
needed constant lubrication. The paper machine was equipped with a
centralized lubrication system. Should the oil flow fail to one of
the bearings it would not take long before a fire would start due to
the overheated bearing. These fires were stubborn fires to put out
since the fire would glow within the heavy paper dust layers that
could not get enough oxygen to support an open flame. Something else
to consider when fighting a dryer fire was not to spray cold water
on the dryer rolls. The dryer rolls were fabricated of cast steel
and cold water on a hot roll could cause the roll casing to crack
thereby destroying the dryer roll.
Harbour Dredging
The Ocean Falls harbour had to dredged from time to time. The mill
was depositing a fair amount of organic material in the harbour.
This was back in the time where words such as air and water
pollution were fairly new words. A large dredge was brought in from
Vancouver complete with skipper and dredging crew. The dredging crew
was housed I believe in the old, long bunkhouse. To get out to the
dredge, the crew had to walk for about 8 minutes to get down to the
wharf where a boat would take them out to the dredge. The dredging
crew was certainly not used to the heavy rainfall in Ocean Falls and
they were complaining. The crew decided to request that they be
driven by taxi to and from the dock if it was raining. Considering
that there was only one taxi in Ocean Falls and that the walk was
only 5 to 8 minutes, the boss of the dredge said that he would have
to think about their request. A week later the boss called the crew
together. He opened a large box just received from Vancouver. Out of
it, he pulled the most beautifully coloured ladies umbrellas and
handed one to each crew member. This story spread fast in town and
there was a smile on everybody's face every time a dredging crew
member was spotted.
Rain and weather memories
It is difficult to write about Ocean Falls and not to say a few
words about the rain because it was a part of one's life during
periods of the year. As mentioned earlier, Ocean Falls is exposed to
one of the highest yearly rainfalls in North America. Matching
rainfalls can only be found at a few spots in Alaska and on the
Hawaiian island of Kauai. The heavy, steady and daily rain usually
starts towards the end of September or the beginning of October. The
heavy rain is caused by the warm, very moist airflow coming in from
the Pacific Ocean to the west. The mountains are lower out on the
edge of the coast line and they gently rise towards Ocean Falls
where Caro Marion is about 4,000 feet high. I do not know what the
yearly record rainfall is for Ocean Falls. However, there was an
official weather station located at Ocean Falls. The engineering
department was in charge of collecting the daily data and to
transmit this data. I do remember that one of the years we had close
to 200 inches of rain. In metric terms, that is equivalent to 5
meters of rain. Most of the rain falls between the beginning of
October and Christmas and is intermittent during January and
February. Not only is Ocean Falls exposed to endless days of rain,
but the rainfall can be extremely heavy. There have been rainfalls
measuring 8 inches in 8 hours, i.e. 1 inch/hour. Quite often the
rain is accompanied by a westerly storm blowing perhaps 30 to 50
knot. In such conditions the rain comes at you horizontally and not
vertical.
During the rainy season you really did not have to look out of your
windows to see if it was raining before leaving for work. You knew
it was raining. The decision you had to make was; are you going to
leave for work in just your rubber-overs with an umbrella, or are
you going to jump into full rain gear and rubber boots. This
decision did require a quick look outside before you opened the
door. Should you make the wrong decision and not dress properly, you
would be totally soaked before completing your 5 to 10 minutes walk
to the mill. Heavens only know how many times we sat down at our
office desks with the rain water running down our backs. It could
take several hours to dry up properly. Rubber-overs by the way, are
large rubber shoes with zippers into which you can step with your
normal shoes. In Ocean Falls they were an absolute necessity if you
were an office worker.
During heavy rainfalls it was interesting to see whose boat had gone
under during the night when on your way to work in the morning.
Fortunately, it was mainly the smaller boats which suffered such a
fate. All it took was for the boat cover to drop a corner inside the
boat and you would have a perfect water funnel working on your
behalf. We had a small plywood speedboat for a while with two 40 hp
outboards. It had a small cabin but was open in the back. More than
once did I sit in a howling rain storm at 2 or 3 in the morning
bailing water and this in nearly total darkness. We did manage to
drown the boat eventually and our two engine boat became a one
engine boat because of saltwater damage to one of the engines.
The months of January and February would bring colder weather. This
would often result in heavy wet snowfalls but could at other times
be nice dry snow. Ocean Falls could often be bone chilling cold for
a period of several weeks.
During the winter a high pressure area builds-up over Alaska and
Yukon. This high pressure area results in the winds
becoming easterly outflow winds rather than the normal warmer
westerly winds. The winds coming down the mountain side of the
Mount Baldy could be dreadfully cold. The wind would funnel in
between the mill paper machine building and the Hudsons Bay store on
the other side of the mill. The only normal access to the mill was
via a long wooden bridge supported by pilings. It certainly woke you
up in the morning having to cross this bridge.
This bridge brings up another story. One of the engineers at the
mill had been a Lieutenant Commander in the British Navy. It was
stated that he had skippered a British frigate during the second
world war. He had for this reason been on the bridge of many ships.
He told us, that the front surface of the bridge on a war ship was
designed and built to throw the air over and above the heads of the
personnel on the bridge. This would protect them from the ever
present rain and cold air. The front of the bridge railing was built
so that the rail was leaning forward by perhaps 30 degrees. In
addition, a second plate was added to the sloping front supported by
ribs. This design would act as a wind tunnel and at the speed of a
war ship, the wind would be forced high up above the bridge. The
engineer talked the plant engineer and mill manager into copying
this design onto the bridge running from the Townsite to the mill.
By using timbers and plywood a war ship bridge design was added to
the mill bridge. This installation worked perfectly. It was a real
pleasant change from the previous ice cold walks. This surely was
what one would call applied engineering.
The cold spells were often the times where people could not get in
and out of town except by ship. The amphibian and float planes could
not fly either due to icing in the air or icing on the hull or
pontoons when landing. It was actually quite annoying since this
could go on for a week or two. It would stop all business traveling
and mail and newspapers would not arrive daily.
Ham radio and Television in Ocean Falls
There was only one radio station to listen to in Ocean Falls during
the daytime. A small 50 watt repeater transmitter was beaming the
Canadian Broadcast Corporation signal across town. This did have
it's advantage since it was never necessary to move the radio dial
to search for other stations. However, the town had regular
telephone service so outside communication was not a problem. "B.C.
Telephone" had a full time employee in town servicing it's
customers. The telephone signal from Ocean Falls was beamed towards
Calvert Island where the B.C Telephone had a strong repeater
station. There were four very active radio amateurs in town, I was
one of them.
We were all close friends and spent a lot of time
together. There was Bert Barley, a Sulfite mill foreman, Doug
Carson, an instrument mechanic and Ken Smith, a papermaker. Radio
reception and the transmission of signals in Ocean Falls was not
very good due to the many mountains adjacent to the town. To offset
this limitation we spent more time using telegraphy than using
microphones since the telegraphy signal (cw signal) would get out
much more readable. As a result, we were all fast and competent
telegraphy operators. Ken had been a telegraphist in the Canadian
Navy and his telegraphy was as precise as machine telegraphy. Being
able to communicate with the outside world did help to offset some
of the isolation of living in Ocean Falls.
When I arrived in Ocean Falls in 1963 there was no television signal
and subsequently no television sets. It must have been around 1965
when it was decided to get a TV signal into Ocean Falls. For some
reason I ended up assisting with the first trials to establish TV
signal reception in town. The television signal was transmitted from
the town of Terrace north of Ocean Falls and then transmitted by
repeater stations to Ocean Falls. I can still remember sitting on
the top of Goat Mountain with a parabolic receiving antenna and a
signal strength meter. We got to the top of the mountain by using a
Bell helicopter. Never before or later in life have I been exposed
to so many mosquitoes as I was on Goat Mountain. I am sure that the
TV signal strength must have suffered from the density of the
mosquitoes between the transmitting and receiving antennas.
Now suddenly Ocean Falls had a TV signal and everybody proceeded to
buy television sets. A considerable amount of these television sets
were purchased from the local Hudson's Bay store. However, there was
one problem to overcome. There were not anybody in town who could
repair televisions. I decided, it would be good for me to get some
more electronic troubleshooting experience by repairing television.
I approached the manager of the Hudson's Bay company and told him,
that if he would purchase the necessary test equipment, I would
repair the televisions his company had sold. However, I told him
that I would not do any house calls and that all televisions would
have to be brought to my home for repair. We agreed on this
arrangement. I received the necessary test equipment and soon my
basement was filling up with television sets. This partly because I
could only work in the evenings and weekends. Since I believe I was
the first radio/television repairman in town at that time, I also
ended up with a major portion of the towns radios as well as the old
reel-to-reel tape recorders. It was a very steep learning curve
since I had to cover the repairs of whatever make and type of
TV people had purchased. Even worse, the TV signal strength was very
poor even in the best signal reception areas of town. Subsequently,
the horizontal oscillator would not lock-in properly with the result
that the television pictures would be rolling and folding. It was
not easy to explain to people that it was nearly impossible to get
their brand new television working properly. Many of these sets were
of the older type where all other entertainment components were
built into one unit. In other words, it was a total disaster for the
people having such units. I must admit I often felt that the owners
of these non functioning TV sets blamed the repair man for their
dilemma. Not a good feeling if you are the repair man.
References, comments and contact information
Soren H. Bach, worked in the Ocean Falls Engineering Department from
1963 to 1968. The mill was at that time owned and operated by the
Crown Zellerbach Company. Prior to moving to Ocean Falls I worked at
the Elk Falls Mill at Campbell River, B.C. also a Crown Zellerbach
mill. Following Ocean Falls I was employed by the Northwood Pulp
mill in Prince George, B.C. From 1976 to 1998, I worked with the
Pulp and Paper Consulting Engineering Company H.A.Simons Ltd.located
in Vancouver, B.C.. Thus, my total working life of 35 years was
spent in the Pulp and Paper engineering field. I was strongly
influenced by my time in Ocean Falls and the memories of this town
and paper mill follows me forever. I do believe that my family
qualifies as being a part of the "Rain People" from Ocean Falls,
what these residents are often called. However, I also realize that
we were some of the "Newbies" since there were families in town who
had lived there for several generations. Two of our daughters were
born in Ocean Falls.
From an engineering viewpoint, the Ocean Falls Paper mill was most
likely the best training ground anywhere for an engineer who wanted
to specialize in the pulp and paper field. I believe it would be
difficult to locate a similar paper mill anywhere in the world which
could match the Ocean Falls Mill's ability to produce mechanical,
sulfite and sulphate pulp within the same facility. Adding to this,
the complexities of the many different paper grades produced by the
5 paper machines. The Ocean Falls Paper Mill was truly a unique
mill.
Many of the residents of Ocean Falls have read the excellent book
titled "The Rain People". This book written by Bruce Ramsey was
published in 1971. Some of the material in this book is based on
historical material collected by the local Ocean Falls historian
James McKellar. I can highly recommend this book to anybody who have
an interest in the birth and life of the paper mill town called
Ocean Falls. Another recent book written by Paul Jones and published
in 2005 is titled " Out of the Rain". This book depicts the life of
a young boy during the years 1939 to 1949. It describes Mr. Jones's
personal experiences having lived in Vancouver and Ocean Falls. A
part of the book covers his time in the Canadian Navy during the
Second World War. This book is also a very interesting and
entertaining reference book related to Ocean Falls.
Many of the older residents of Ocean Falls have now fallen away.
However, their children or grandchildren will most likely have
an interest in the town from where they or their parents came from.
In 2002 I learned of an addendum which had been published to the
original book "The Rain People" This addendum describes the final
years of the paper mill and the eventual demolition of both town and
paper mill.. For me it was a bit sad to read this section which
covers the final days of Ocean Falls as a paper mill town..
The content of the original book "The Rain People" is informative
with many stories covering the lifestyle of the people living in
this unique and very isolated town. This book makes you feel happy
of having lived in Ocean Falls and it brings out many good and funny
memories. You will have to have been from the "Falls" to really
appreciate the finer points of the anecdotes.
The first major reduction in mill production came in 1968 with the
subsequent large layoff of mill staff. It was planned at that time
to shut down the mill in stages. However, a newly elected Provincial
Government decided to purchase the mill for a minimal sum of money
to continue the operation of the mill thus saving the town from
certain death. Several of the senior mill operators and maintenance
people had already left Ocean Falls but were called back to operate
the mill. Over several years, a valiant effort was made by the local
unions and mill staff to keep the mill operating at a profit.
However, the writing was on the wall for the Ocean Falls mill and
the mill eventually ceased operation due to poor profitability.
Studies were carried out to identify possible solutions for a
different type of mill based on modern processes and modern
equipment. However, quoting the published addendum, investments
could not be located to permit a redesign of the mill thus providing
it with a new future.
It must have been heartbreaking for the people living in Ocean Falls
to realize that the end was near for their town, the mill and their
employment. The long and drawn-out negotiations to keep the mill in
operation resulted in some bitterness of some people towards the
Government of the day and the previous mill owners. This bitterness
was expressed in the addendum to the original book. I guess I would
have liked to retain a happy memory of Ocean Falls gracefully
sliding into the past, as have so many other older pulp and paper
mills located in B.C.and Canada.
The stark reality of the Ocean Falls mill was; that it was one of
the more expensive mills to operate in the Province of B.C. in
spite of the the hydro power savings. The isolated location of the
paper mill resulted in many high cost expenditures not normally
carried by other pulp and paper companies located closer to
civilization. Everything had to be carried to and from the mill by
boat or barge. This included everything and everything. Wood for the
mill, all the mill chemicals and all new mill maintenance equipment
and supplies. The finished paper products had to be shipped out by
barge or ship since there were no roads into Ocean Falls. The cost
of the wood for the mill was high due to long delivery
distances. The mill was frightfully outdated operating paper
machines built in the early 1900 with some machines driven by steam
engines. The mill had to carry the cost of the necessary township
infrastructure, a cost most other pulp and paper mills companies
totally avoid. This meant the provision of housing, heating,
electricity, and the maintenance cost of all buildings and
roads. Due to the isolated location of the mill, it was necessary to
retain a large, versatile maintenance staff. It was essential that
the mill would be in a position to carry out major maintenance
repairs with a minimum of delay in order to avoid production losses.
This again meant the requirements for very well equipped repair
shops. Most pulp and paper mills located closer to large cities rely
on private companies to carry-out many of the large scale and often
specialized equipment repairs. Outside contractors can be brought
in to most mills on short notice should a major maintenance problem
occur.
History has shown, that pulp and paper mills much more modern than
the Ocean Falls mill have had to be shut down permanently. This due
to the very difficult cost environment many mills often operate
within. Mills with quite modern production processes and equipment,
and installed perhaps as late as 1980, have had to shut down. The
Ocean Falls mill was totally devoid of any air and water pollution
control equipment. Such now obligatory systems are high cost items
in any new pulp and paper mill. The Ocean Falls mill would not have
been able to continue operation without such facilities.
In my opinion, the Ocean Falls paper mill town ended it's career in
a noble way, having been the home to so many people since the
beginning of the 1900. From an economic, long term viewpoint, the
Ocean Falls Mill created very good revenue for all involved, the
Provincial Government, Investors, Mill equipment suppliers and the
people who lived and worked in Ocean Falls.
Notes:
All comments, descriptions and explanations related to the Ocean
Falls paper mill and town are solely my own. I am recalling events
in my life which happened 40 years ago Due to my long-standing
interest in the life and history of Ocean Falls I felt I should
communicate some of my memories and share some of my photographs.
The town of Ocean Falls still lives on albeit on a much smaller
scale than that of the past. I send everybody still living in Ocean
Falls my very best regards.
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