Taken my time getting this written up, but thought I'd post my take on this old classic as it's now been partially demolished. As soon as I heard they were finally tearing it down, I dragged my arse up north as I've never gotten around to doing it.
We were pretty thorough, but with the sheer scale of it and Secca being home, parts unfortunately ended up missed. Got most of the good stuff though.
The History
Background
Robert Fletcher & Son Ltd. was a prominent British paper manufacturer with operations in Stoneclough and Greenfield, near Oldham. The company's origins trace back to the early 19th century, initially owned by the Crompton family under the name Ralph Crompton and Nephews, Bleachers and Papermakers. Paper production commenced in 1829 at the Stoneclough mill.
Robert Fletcher joined the firm in 1830, quickly ascending to manage the bleaching department and eventually overseeing the entire mill. Following the death of the last Crompton brother, the principal trusteeship of the company and the option of succession was offered to Fletcher. He was later succeeded by his sons, John and James following his death on 17th May 1865. In 1897, the firm was incorporated as a limited company, employing around 200 people at that time.
The Greenfield Mill
Establishment and Early Operations
The mill's origins can be traced back to around 1780 when it was established as a woollen mill by a Mr. Bottomley. This period marked the early stages of the Industrial Revolution in England, with many mills emerging in the region.
In 1799, a significant flood devastated the area, washing away several mills, including the original structures at Greenfield. Despite this setback, the mill was rebuilt and continued its operations in the textile industry.
Transition to Paper Production
Following its reconstruction, the mill shifted focus from woollen production to paper manufacturing. This transition aligned with the growing demand for paper during the 19th century, driven by increased literacy rates and the expansion of the printing industry.
Acquisition by Robert Fletcher & Sons
Robert Fletcher & Sons, seeking to expand their operations, acquired the Greenfield Mill in 1921. They specialised the mill for the production of cigarette paper, a niche market that the company dominated for many years.
Under Fletcher's ownership, the mill expanded significantly, employing up to 1,000 workers and operating multiple paper machines to meet demand (I've seen reference to seven machines, but these predate the Greenfield Mill acquisition, so presumably that number is specific to the Stoneclough operation).
This facility became integral to the company's operations, benefiting from the high quality water sourced from the surrounding hills, essential for paper manufacturing. This water was originally sourced via pipes from the Chew Valley, with the construction of Dovestone reservoir in 1967 providing a much closer source.
Expansion
During the mid-20th century, as cigarette consumption soared, Fletcher’s expanded the site to include more mechanised and modern production lines. I believe the site operated three modern machines, with each of their outputs significantly exceeding the original seven combined. (Same sources as above, so may not be accurate).
Decline and Closure
Despite its success, the company faced financial challenges in the latter part of the 20th century. In 1986, it was acquired by the Melton Medes conglomerate, under their Swedish Match arm, which temporarily restored profitability. However, by the early 2000s, the business encountered further difficulties, leading to the closure of the Stoneclough mill in 2000. The intention was to prop up the Greenfield Mill, along with creating additional jobs at the site.
The Greenfield mill continued operations for a short period, but ultimately ceased production in July 2001 when the company went into receivership following requests by disgruntled creditors to wind up the business. Supposedly staff arriving for the morning shift were ordered to collect their belongings and leave the site, with the mill subsequently remaining as if the last shift had just finished, slowly decaying into obscurity.
Demolition
Demolition of the site commenced in October 2023, with plans for redevelopment, including new housing, underway. Work does appear to have paused however, I believe mainly due to concerns from locals about the loss of heritage, but it's a bit too late at this point, the only significant building remaining is the Boiler House.
Overview of Cigarette Paper Production
1. Raw Material Preparation:
Early on, linen or flax rags were commonly used as the primary material for cigarette paper. These were cleaned, shredded, and processed into a pulp.
Later in the mill's life, wood pulp (from softwood or hardwood) and cotton linters (the short fibers left after cotton ginning) became the preferred materials due to their finer texture and consistency.
2. Pulping Process:
The raw materials were pulped using Hollander beaters or, in later years, refiners. This process involved breaking down the fibers, mixing them with water, and adding any required chemicals.
For cigarette paper, the pulp needed to be refined to a very fine consistency to achieve the thinness and uniformity required.
3. Bleaching and Additives:
The pulp was bleached to achieve a bright white color and remove impurities.
Additives such as calcium carbonate were introduced to control the paper's porosity, ensuring it burned at the desired rate.
Some papers included faint watermark patterns, achieved using specific rollers.
4. Papermaking:
The pulped and treated fibers were transferred to Fourdrinier machines, which formed the paper. The Fourdrinier machine represents the heart of paper formation, where the process begins.
Forming Section -
The paper pulp (a mix of fibers, water, and sometimes additives) is evenly spread onto the forming fabric or wire at the headbox.
Gravity, suction, and slight vibration help remove water as the pulp moves forward, leaving behind a wet mat of fibers that begins to take the form of paper.
Press Section -
The wet sheet passes through a series of press rollers, squeezing out more water while compacting the fibers. This improves the sheet’s strength and consistency.
Drying Section -
The partially dried sheet then enters a series of steam-heated cylinders, further removing moisture and solidifying the paper. At this stage, the paper is still relatively unrefined and may not have the smooth surface or thickness uniformity required for the final product.
5. Smoothing and Cutting:
Once dried, the paper passed through calendering rollers to ensure it was smooth and uniform in thickness.
Heating and Smoothing -
The paper from the Fourdrinier machine is fed into the calendering rollers. These rollers are often heated, which softens the paper fibers and helps the machine compress the sheet more effectively.
The rollers (usually arranged in a stack) smooth the surface of the paper, improving its texture and appearance. This is especially important for cigarette papers, which need a smooth finish for easy rolling and uniform burning.
Thickness Control -
The pressure between the rollers can be adjusted to control the paper's final thickness and density. A thinner, denser paper would result from higher pressures, ideal for cigarette paper.
Final Adjustments -
If needed, coatings or treatments (e.g., moisture-resistance or burn-control additives) can be applied at this stage. These would be carefully calibrated for cigarette papers to ensure the desired burn rate and texture.
The finished paper was cut to size, typically into large reels for transportation to cigarette manufacturers.
6. Quality Control:
Samples were tested to ensure the paper met strict specifications for thickness, porosity, tensile strength, and burn rate.
The Explore
Explore 1
Made our approach to the site as sneakily as possible, and having remained undetected, we gained entry and started in the older top mill which houses the Bleach and Stock towers. These were used to bleach pulp early in the paper production process.
Chlorine Solution Testing -
Bleach Charges -
Proceeded further into the site, ending up on the top floor of the main mill section. Some lovely decay shots to be had up here.
Avery Scale -
Stacker -
Lockout Panel -
There's some office space and locker rooms as well, and some nice views over the rest of the site from the windows. Also a very good location to keep an eye on Secca's whereabouts.
Started moving down through the levels, there's not much to see and there's very little light. Hell of a lot of water from leaking water pipes, almost as if it's been left like that intentionally with the hopes of degrading the building's structure enough to justify demolishing it.
Reached the lowest level, with access to the main chamber being through a door that's been ripped off it's hinges. Plenty to see in here over two levels, including the digesters.
Potcher Warning -
Gauge Cluster -
Digester In Situ -
Digester Post Demolition -
There is an adjoining room with a few things inside, but I didn't venture very far before turning back from the stench... Presumably it's used as the toilet by visitors because it certainly smelt like it.
We continued onwards, reaching some of the most photogenic sections of the site. Even after 20 odd years being abandoned, everything is still in pretty good condition with some lovely decay.
Beaters -
Control Panel -
Fire Alarm -
A couple of us moved into the service tunnel behind this section while the others got their shots. Couple of interesting things for me, including some gauges. Checked out a large switch room as well, although the lack of a roof and everything of value being stripped meant there wasn't much of note to see.
Met the others, had a quick snack break and carried on into the room with the older Fourdrinier Machinery. Made good use of the elevated sections for some shots and proceeded carefully, wary of our proximity to Secca at this point.
Fourdrinier Machine -
We moved into the large open area with the counterbalances where the roof has unfortunately started to collapse. Less work for the demo crews I suppose.
Found the small canteen on an upper level with a view out over the shop floor.
Canteen -
Counterbalance Trucks -
Machinery -
Control Panel -
Found a different staircase and headed up, finding an admin area and the medical bay, which proved very interesting.
There's some rather old employee files in a cabinet in a corridor, dating from the late 30s-40s.
Also found some blueprints in an adjoining room. Had a quick look in what appeared to be a meeting room, making sure to stay low due to the windows not being boarded up, Secca is directly below.
We didn't find the boardroom here, which was a tad confusing, as we couldn't see any other way to the upper levels. Turns out the separate staircase is hidden in the dark area adjacent to the large room which we didn't know about, so it ended up being missed unfortunately.
We weren't sure where to go from here, so we discussed options and decided to keep going as we hadn't located the lab yet. Went back on ourselves and followed the service tunnel from earlier to the end, coming out in what looked like a small area for deliveries.
Continued...
We were pretty thorough, but with the sheer scale of it and Secca being home, parts unfortunately ended up missed. Got most of the good stuff though.
The History
Background
Robert Fletcher & Son Ltd. was a prominent British paper manufacturer with operations in Stoneclough and Greenfield, near Oldham. The company's origins trace back to the early 19th century, initially owned by the Crompton family under the name Ralph Crompton and Nephews, Bleachers and Papermakers. Paper production commenced in 1829 at the Stoneclough mill.
Robert Fletcher joined the firm in 1830, quickly ascending to manage the bleaching department and eventually overseeing the entire mill. Following the death of the last Crompton brother, the principal trusteeship of the company and the option of succession was offered to Fletcher. He was later succeeded by his sons, John and James following his death on 17th May 1865. In 1897, the firm was incorporated as a limited company, employing around 200 people at that time.
The Greenfield Mill
Establishment and Early Operations
The mill's origins can be traced back to around 1780 when it was established as a woollen mill by a Mr. Bottomley. This period marked the early stages of the Industrial Revolution in England, with many mills emerging in the region.
In 1799, a significant flood devastated the area, washing away several mills, including the original structures at Greenfield. Despite this setback, the mill was rebuilt and continued its operations in the textile industry.
Transition to Paper Production
Following its reconstruction, the mill shifted focus from woollen production to paper manufacturing. This transition aligned with the growing demand for paper during the 19th century, driven by increased literacy rates and the expansion of the printing industry.
Acquisition by Robert Fletcher & Sons
Robert Fletcher & Sons, seeking to expand their operations, acquired the Greenfield Mill in 1921. They specialised the mill for the production of cigarette paper, a niche market that the company dominated for many years.
Under Fletcher's ownership, the mill expanded significantly, employing up to 1,000 workers and operating multiple paper machines to meet demand (I've seen reference to seven machines, but these predate the Greenfield Mill acquisition, so presumably that number is specific to the Stoneclough operation).
This facility became integral to the company's operations, benefiting from the high quality water sourced from the surrounding hills, essential for paper manufacturing. This water was originally sourced via pipes from the Chew Valley, with the construction of Dovestone reservoir in 1967 providing a much closer source.
Expansion
During the mid-20th century, as cigarette consumption soared, Fletcher’s expanded the site to include more mechanised and modern production lines. I believe the site operated three modern machines, with each of their outputs significantly exceeding the original seven combined. (Same sources as above, so may not be accurate).
Decline and Closure
Despite its success, the company faced financial challenges in the latter part of the 20th century. In 1986, it was acquired by the Melton Medes conglomerate, under their Swedish Match arm, which temporarily restored profitability. However, by the early 2000s, the business encountered further difficulties, leading to the closure of the Stoneclough mill in 2000. The intention was to prop up the Greenfield Mill, along with creating additional jobs at the site.
The Greenfield mill continued operations for a short period, but ultimately ceased production in July 2001 when the company went into receivership following requests by disgruntled creditors to wind up the business. Supposedly staff arriving for the morning shift were ordered to collect their belongings and leave the site, with the mill subsequently remaining as if the last shift had just finished, slowly decaying into obscurity.
Demolition
Demolition of the site commenced in October 2023, with plans for redevelopment, including new housing, underway. Work does appear to have paused however, I believe mainly due to concerns from locals about the loss of heritage, but it's a bit too late at this point, the only significant building remaining is the Boiler House.
Overview of Cigarette Paper Production
1. Raw Material Preparation:
Early on, linen or flax rags were commonly used as the primary material for cigarette paper. These were cleaned, shredded, and processed into a pulp.
Later in the mill's life, wood pulp (from softwood or hardwood) and cotton linters (the short fibers left after cotton ginning) became the preferred materials due to their finer texture and consistency.
2. Pulping Process:
The raw materials were pulped using Hollander beaters or, in later years, refiners. This process involved breaking down the fibers, mixing them with water, and adding any required chemicals.
For cigarette paper, the pulp needed to be refined to a very fine consistency to achieve the thinness and uniformity required.
3. Bleaching and Additives:
The pulp was bleached to achieve a bright white color and remove impurities.
Additives such as calcium carbonate were introduced to control the paper's porosity, ensuring it burned at the desired rate.
Some papers included faint watermark patterns, achieved using specific rollers.
4. Papermaking:
The pulped and treated fibers were transferred to Fourdrinier machines, which formed the paper. The Fourdrinier machine represents the heart of paper formation, where the process begins.
Forming Section -
The paper pulp (a mix of fibers, water, and sometimes additives) is evenly spread onto the forming fabric or wire at the headbox.
Gravity, suction, and slight vibration help remove water as the pulp moves forward, leaving behind a wet mat of fibers that begins to take the form of paper.
Press Section -
The wet sheet passes through a series of press rollers, squeezing out more water while compacting the fibers. This improves the sheet’s strength and consistency.
Drying Section -
The partially dried sheet then enters a series of steam-heated cylinders, further removing moisture and solidifying the paper. At this stage, the paper is still relatively unrefined and may not have the smooth surface or thickness uniformity required for the final product.
5. Smoothing and Cutting:
Once dried, the paper passed through calendering rollers to ensure it was smooth and uniform in thickness.
Heating and Smoothing -
The paper from the Fourdrinier machine is fed into the calendering rollers. These rollers are often heated, which softens the paper fibers and helps the machine compress the sheet more effectively.
The rollers (usually arranged in a stack) smooth the surface of the paper, improving its texture and appearance. This is especially important for cigarette papers, which need a smooth finish for easy rolling and uniform burning.
Thickness Control -
The pressure between the rollers can be adjusted to control the paper's final thickness and density. A thinner, denser paper would result from higher pressures, ideal for cigarette paper.
Final Adjustments -
If needed, coatings or treatments (e.g., moisture-resistance or burn-control additives) can be applied at this stage. These would be carefully calibrated for cigarette papers to ensure the desired burn rate and texture.
The finished paper was cut to size, typically into large reels for transportation to cigarette manufacturers.
6. Quality Control:
Samples were tested to ensure the paper met strict specifications for thickness, porosity, tensile strength, and burn rate.
The Explore
Explore 1
Made our approach to the site as sneakily as possible, and having remained undetected, we gained entry and started in the older top mill which houses the Bleach and Stock towers. These were used to bleach pulp early in the paper production process.
Chlorine Solution Testing -
Bleach Charges -
Proceeded further into the site, ending up on the top floor of the main mill section. Some lovely decay shots to be had up here.
Avery Scale -
Stacker -
Lockout Panel -
There's some office space and locker rooms as well, and some nice views over the rest of the site from the windows. Also a very good location to keep an eye on Secca's whereabouts.
Started moving down through the levels, there's not much to see and there's very little light. Hell of a lot of water from leaking water pipes, almost as if it's been left like that intentionally with the hopes of degrading the building's structure enough to justify demolishing it.
Reached the lowest level, with access to the main chamber being through a door that's been ripped off it's hinges. Plenty to see in here over two levels, including the digesters.
Potcher Warning -
Gauge Cluster -
Digester In Situ -
Digester Post Demolition -
There is an adjoining room with a few things inside, but I didn't venture very far before turning back from the stench... Presumably it's used as the toilet by visitors because it certainly smelt like it.
We continued onwards, reaching some of the most photogenic sections of the site. Even after 20 odd years being abandoned, everything is still in pretty good condition with some lovely decay.
Beaters -
Control Panel -
Fire Alarm -
A couple of us moved into the service tunnel behind this section while the others got their shots. Couple of interesting things for me, including some gauges. Checked out a large switch room as well, although the lack of a roof and everything of value being stripped meant there wasn't much of note to see.
Met the others, had a quick snack break and carried on into the room with the older Fourdrinier Machinery. Made good use of the elevated sections for some shots and proceeded carefully, wary of our proximity to Secca at this point.
Fourdrinier Machine -
We moved into the large open area with the counterbalances where the roof has unfortunately started to collapse. Less work for the demo crews I suppose.
Found the small canteen on an upper level with a view out over the shop floor.
Canteen -
Counterbalance Trucks -
Machinery -
Control Panel -
Found a different staircase and headed up, finding an admin area and the medical bay, which proved very interesting.
There's some rather old employee files in a cabinet in a corridor, dating from the late 30s-40s.
Also found some blueprints in an adjoining room. Had a quick look in what appeared to be a meeting room, making sure to stay low due to the windows not being boarded up, Secca is directly below.
We didn't find the boardroom here, which was a tad confusing, as we couldn't see any other way to the upper levels. Turns out the separate staircase is hidden in the dark area adjacent to the large room which we didn't know about, so it ended up being missed unfortunately.
We weren't sure where to go from here, so we discussed options and decided to keep going as we hadn't located the lab yet. Went back on ourselves and followed the service tunnel from earlier to the end, coming out in what looked like a small area for deliveries.
Continued...
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