Tissue Calendering and Its Influence on Performance and Packaging
Tissue calendering is a finishing process applied during tissue paper production to improve the surface properties of the material. Using a set of heated or unheated rollers; called calender rolls; the tissue web is passed through under controlled pressure to enhance its smoothness, gloss and thickness consistency. While calendering may seem like a technical footnote in the broader tissue production process, its influence on end-product performance and packaging compatibility is significant.
Calendering is used across all major categories of tissue: facial tissue, toilet rolls, kitchen towels, napkins and dispenser systems. It plays a direct role in defining the feel and function of the sheet; contributing to softness, printability and appearance, but also influencing how the tissue performs on high-speed converting and packaging lines.
Calendering in Tissue Production
In tissue production, calendering is often applied post-drying and pre-reeling. The process can be carried out using steel-to-steel, rubber-to-steel or soft-nip configurations, depending on the end use of the tissue. Parameters such as nip pressure, roll temperature, speed differential and dwell time are carefully adjusted to achieve the desired surface characteristics.
Heavily calendered tissue tends to be smoother and more uniform, which benefits printability for branded packs and improves folding accuracy on packaging lines. However, this comes at a trade-off; high levels of calendering compress the sheet, reducing bulk and absorbency. In response, manufacturers balance calendering with sheet structure, ply bonding and embossing to maintain consumer-acceptable softness and volume.
In toilet and kitchen tissue, for instance, too much calendering may yield a glossy finish but reduce tactile softness and perceived value. In facial tissue or napkins, moderate calendering helps reduce linting and improve consistency, especially for multi-colour printing. The process is often tailored to the branding and performance requirements of the target market.
Packaging Implications
From a tissue packaging perspective, calendering influences how tissue behaves in automated lines. Smoother, more uniform tissue sheets reduce friction, feeding issues and dusting, which improves the reliability of infeed, folding and wrapping mechanisms. For interfolded products, surface regularity ensures better stacking and compression control; both critical for maintaining consistent pack height and sealing performance.
Calendered tissue also contributes to dimensional stability. During bundling and cartoning, calendered products show less expansion or deformation, reducing machine jams and improving pack presentation. For this reason, tissue converters working with high-speed cartoners often favour lightly calendered webs that strike a balance between aesthetics and runnability.
On the flip side, over-calendered tissue may introduce problems. Reduced bulk can result in loosely packed bundles, sagging packs or misaligned folds, which require secondary packaging adjustments. Also, if tissue becomes too smooth, it can cause slippage during product handling or stack shifting during palletisation. As such, packaging machinery must be tuned to accommodate the surface characteristics introduced during calendering.
Market and Technical Considerations
The choice to calender; and to what extent; is ultimately a strategic one. It reflects brand positioning, shelf presence, cost-to-serve and end-user expectations. In premium product lines, controlled calendering may be paired with embossing and high-colour print to elevate shelf appeal. In value ranges, light calendering offers machine performance benefits without unnecessary material cost.
Technically, innovations in calendering rolls; such as soft-nip technology, multi-zone heating and variable pressure control; allow finer control of paper finishing. This enables tissue manufacturers to dial in performance specifications for different markets or to respond to raw material variability.
As regulatory and consumer demands increase around sustainability, calendering may also help reduce basis weight while maintaining sheet strength and print quality. By delivering uniform density and smoother surfaces, calendered tissue can support lightweighting strategies without compromising pack integrity.
How We Can Help
Tissue calendering is a precision process with wide-ranging effects. It influences how a product looks, feels, performs in the home and behaves on the production line. Getting it right requires technical understanding, close collaboration between paper makers and packaging engineers and the ability to balance visual and functional priorities in a competitive marketplace.
At Jacob White Packaging, we help manufacturers handle different complex tissue packaging issues. Whether you're adjusting production specifications or scaling packaging performance, our equipment and experience can help you stay ahead. Contact us to find out more.
