EP1181227A4

EP1181227A4 - Paper sorting system

Info

Publication number: EP1181227A4
Application number: EP00928574A
Authority: EP
Inventors: Michael R Grubbs; Garry R Kenny; Paul G Gaddis
Original assignee: ADVANCED SORTING TECHNOLOGIES LLC; ADVANCED SORTING TECHNOLOGIES
Current assignee: ADVANCE SORTING TECHNOLOGIES LLC
Priority date: 1999-04-29
Filing date: 2000-04-28
Publication date: 2004-10-20
Anticipated expiration: 2020-04-28
Also published as: EP1181227B1; EP1181227A1; ATE470636T1; WO2000066465A1; WO2000066465A9; DE60044530D1; AU4679100A

Abstract

The present invention includes devices and methods for handling and sorting paper. Devices for accelerating and spreading paper from a paper input (14) to a sensor (23) are disclosed. Operably thin layers of paper are passed through a sensor at cost effective feed rates. One embodiment of the invention includes a spreader (24) positioned to receive paper (12) from the input and an inclined feed section (18) downstream of the spreader. The inclined feed section includes first and second inclined conveyors (50, 52) to further accelerate and spread the paper. A feed accelerator (84) is operably positioned to receive paper from the second inclined conveyor. The feed accelerator further accelerates and separates the paper. The feed accelerator feeds the paper to the sensor which is operably connected to an ejector (92) downstream of the sensor. Targeted paper is ejected from the paper stream and product paper continues downstream to a product conveyor (102).

Description

DESCRIPTION PAPER SORTING SYSTEM

TECHNICAL FIELD The present invention relates to paper handling. Select embodiments of the invention are particularly well-suited for use in the waste paper recycling industry.

BACKGROUND ART Environmental campaigns and recycling in many offices have generated a supply of recyclable waste paper. However, waste paper sorting is still currently performed almost entirely by manual sorting. This is time consuming and expensive. Thus, heretofore it has generally been more economical to use raw paper material than sort and process recyclable waste paper.

Numerous automated waste separation techniques are known. However these systems are designed for recovery of non-ferrous metals, aerospace alloys, municipal waste, mixed recyclables and plastic containers. Paper sorting presents unique problems not overcome by prior art separation techniques.

The unique problems encountered when attempting to sort waste paper is due to the relatively light weight and flexible nature of pieces of paper. These characteristics make it difficult to supply paper to a sorting sensor. Even when waste paper has been supplied to a sensor, it has not been supplied at a sufficient feed rate, e. g. pieces per hour (PPH), to be cost effective. Prior art sensors operate on the basis of an eddy current created by the waste stream as it passes through the sensor, diffusion of light transmission through the waste e. g. transparent glass, and the like. These techniques are inapplicable to sorting waste paper because the paper has no metallic components and the paper is opaque to light. Thus, not only must an effective paper sorting sensor be designed, an effective paper handling system must be designed to supply waste paper in sufficient feed rates to the effective paper sorting sensor. Prior art paper handling techniques have been unsatisfactory in overcoming these obstacles.

DISCLOSURE OF THE INVENTION

The present invention relates to paper handling and sorting methods and devices. One embodiment of the present invention is for a paper handling system for handling paper fed to the system. The system includes a paper input adapted to receive paper and the system includes a product output. Operably positioned between the paper input and the product output is an acceleration means for distributing and accelerating the paper.

Another embodiment of the present invention is a paper handler adapted for use with a sorting machine which includes a sensor for sorting paper. The handler includes a paper input for receiving the paper and a product output positioned downstream of the paper input. The handler also includes a feed accelerator having an acceleration conveyor operably positioned to feed the paper through the sensor.

Another embodiment of the present invention is a paper sorting machine comprising a paper input and a spreader positioned to receive paper from the paper input. An inclined feed section is downstream of the spreader. The inclined feed section includes a first and a second inclined conveyor. The second inclined conveyor is downstream of the first inclined conveyor. A feed accelerator is operably positioned to receive paper from the second inclined conveyor. The feed accelerator includes an accelerator conveyor having a sensor end. A sensor is operably positioned to sense paper passing over the accelerator conveyor sensor end. An ejector is positioned downstream of the sensor. A product conveyor is downstream of the ejector and a product output is downstream of the product conveyor.

Accordingly, the present invention includes methods of handling paper which include distributing clumps of paper into operably thin layers of paper. Preferably the methods include accelerating the paper as the paper is transported downstream. In some embodiments this is accomplished by progressively increasing the speed at which the paper is transported downstream until the paper is passed through a sensor, or other operative component sensing or performing an operation on the paper.

Accordingly an object of the present invention is to provide means and methods for achieving a cost effective recycled machine grade paper fraction from a paper waste stream.

Another object of the present invention is to provide means for achieving automated sortation on a cost effective basis.

Another object of the present invention is to provide means for achieving improved consistency and repeatability in the quality of recycled waste paper.

Another object is to reduce labor requirements for sorting waste paper.

Another object of the present invention is to provide means and methods to accelerate and spread paper to operably thin layers to achieve an effective sort.

A further object of the present invention is to perform the sort at high speeds. An object of the present invention is to incorporate automated sortation into a paper handling system to achieve consistent grades of premium paper from waste paper.

Other and further objects, features and advantages of the invention will be readily apparent to those skilled in the art upon a review of the following disclosure when taken in conjunction with the accompanying drawings.

Fig. 1 shows a paper sorting system according to the present invention. Fig. 2 depicts the system shown in Fig. 1 receiving clumps of paper, ejecting targeted paper, and delivering product.

Fig. 3 depicts an elevated side view the spreader included in Fig. 1. A paper input is shown on the right and discharge chutes depend from the spreader. Fig. 3 shows the spreader in its preferred inclined orientation.

Fig. 4 shows a simplified schematic plan view of the spreader shown in Fig. 3 with the paper input removed. A plurality of rotatable shafts including a plurality of discs on each shaft is depicted. The discs are oriented at zero degrees and forty-five degrees on alternating shafts.

Fig. 5 depicts an elevated side view of a rubber tipped disc. The disc is shown oriented at zero degrees.

Fig. 6 depicts a plan view of the spreader shown in Fig. 4 wherein three sets of the rotatable shafts are rotated at progressively increasing speeds. Clumps of paper are shown being fed and accelerated on the rotatable shafts.

Fig. 7 shows a somewhat schematic elevated side view of the spreader shown in Fig. 3. Fig. 7 shows the spreader in an optional non-inclined orientation. Clumps of paper are shown being fed into the product input and accelerated downstream. An end-on view of three sets of rotatable shafts, which are rotating at increasing speeds, is shown.

Fig. 8 shows an enlarged view of the two inclined conveyors included in Fig. 1. The first inclined conveyor is positioned to feed into the second inclined conveyor.

Fig. 9 shows a simplified enlarged view of the first inclined conveyor shown in Fig. 8. The first inclined conveyor is shown accelerating underlying layers of paper and feeding the paper to the second inclined conveyor. Air supplied through a set of louvers pins the paper to the inclined conveyor belt and fluffs, and further spreads, the paper as it cascades off of the end of the first inclined conveyor.

Fig. 10 depicts an enlarged view of the acceleration conveyor, sensor and product conveyor shown in Fig. 1.

Fig. 11 depicts the acceleration conveyor of Fig. 10 without the sensor and without the product conveyor.

Fig. 12 shows a schematic view of the structure shown in Fig.

10. Paper is shown pinned to the acceleration belt to feed the paper through the sensor at a predetermined speed substantially equal to the belt speed. Targeted paper is shown being ejected from the system and product paper is shown being conveyed away.

Fig. 13 shows an enlarged view of a product removal apparatus of the paper handler shown in Fig. 1. The product removal apparatus is shown downstream of the sensor and acceleration belt.

Fig. 14 depicts a schematic view of the product removal apparatus shown in Fig. 13. Paper is shown being pulled through the product removal conveyor and pinned to the product conveyor by an air flow generated by an air-assist means. An airlock including a rotating seal is shown de-entraining product.

Fig. 15 schematically depicts the air flow system used with the paper sorting system of Fig. 1. BEST MODE FOR CARRYING OUT THE INVENTION

The present invention relates to methods and apparatus for handling, in particular sorting, paper. The invention will be best understood by reference to the attached drawings wherein like reference numerals refer to like components.

Fig. 1 shows an elevated side view of one embodiment of the present invention for a paper handling or sorting system 10. Referring to Fig. 2, the paper handling system 10 is adapted to handle paper 12 fed into the system. The system 10, in the embodiment shown in Fig. 2, comprises a paper input 14 adapted to receive the paper 12, and a product output 16. The system 10 includes acceleration means 18 for distributing and accelerating the paper 12. The acceleration means 18 is operably positioned between the paper input 14 and the product output 16. As is further explained below, the acceleration means 18 includes several separate components including spreader 26, inclined conveyors 50 and 52, and acceleration conveyor 84.

In some embodiments, the system 10 comprises an ejection output 20 between the paper input 14 and the product output 16. A sensor means 22 for determining whether paper should be routed to the ejection output 20 or the product output 16 is included in the system 10 shown in Fig. 2. Generally the acceleration means 18 accelerates the paper 12 from a first speed proximate the paper input 14 to a second higher speed proximate sensor means 22.

In some embodiments the paper 12 is fed from a pit conveyor (not shown) to the paper input 14 at a rate of ten to thirty feet per minute. This may be via a lift conveyor (not shown) which transfers mixed waste paper from the pit conveyor to the paper input 14. In order to effectively eject sensed target paper, it is important that the paper 12 pass through the sensor means 22 at a predetermined speed. The sensor means 22 includes a sensor 23. In some embodiments the predetermined speed at which the paper 12 passes through the sensor 23 is 1000 or 1200 feet per minute. One goal is to accelerate the paper 12 from a first speed at which it enters the system 10 to a greater speed and pass it through the sensor at the greater speed. Thus, the paper may be accelerated from 10 ft./min. to 1200 ft./min. Another goal is to spread and separate the paper in order to achieve a more effective and efficient sort. Thus, in one embodiment the acceleration means includes the spreading means or spreader 24 for distributing and spreading paper 12. The paper 12 generally enters the system in clumps at the paper input 14.

THE SPREADER

Fig. 3 shows an elevated side view of the spreader 24 shown in Fig. 2. Fig. 4 shows a simplified or schematic plan view of the spreader 24 shown in Fig. 3. In the embodiment of Fig. 3, the spreader 24 is shown in its preferred inclined orientation with the frame and thus the paper flow path being at an angle 25 which is in the range of 10° to 20°, and is preferably in the range of 14° to 16°. The spreader 24 includes a plurality of rotatable shafts 28. Each rotatable shaft 28 includes a plurality of discs 30. Fig. 5 shows an elevated side view of a disc 30. In the embodiment shown in Fig. 5 the disc 30 is a bulged triangular disc which includes rubber tips or edges 32. Other effective disc configurations will be apparent to those with skill in the art. The rubber tip 32, which is urethane in one preferred embodiment, helps grip the paper 12 and accelerate paper 12 which is contacting the discs 30 ahead of other paper 12 not yet contacting the discs 30. Other disc friction enhancing embodiments will be apparent to those with skill in the art.

As noted, Figs. 4, 6 and 7 are somewhat schematic illustrations of the arrangement of the disc 30. Fig. 7 illustrates an alternative orientation of spreader 24 in a non-inclined position. Although the spreader 24 will operate successfully in the non-inclined position of Fig. 7, it has been found to be preferable to incline spreader 24 as shown in Fig. 3. The inclination of the spreader aids in the separation and spreading of the paper, as it allows top layers to slide back over bottom layers.

In actual construction, the discs 30 are typically formed from one-quarter inch thick urethane sheet material. Adjacent discs are typically separated by a spacer plate (not shown) having a thickness on the order of one to two inches.

Figs. 6 and 7 show plan and elevated side views, respectively, of the spreader 24 in which paper 12 is spread and accelerated by the rotatable shafts 28 and discs 30.

The plurality of rotatable shafts 28 comprise bulged triangular discs 30. The bulged triangular discs 30 are rotated 45 degrees relative to the remainder of the bulged triangular discs 30. As shown in Fig. 6 every other shaft includes a point of the disc 30 projecting out of the page. This is shown in Fig. 7 as well.

Fig. 6 shows paper 12 flowing downstream in the direction of arrows 31 from the paper input 14 toward the product output 16.

Downstream is defined as the direction from the paper input 14 toward the product output 16. As shown in Fig. 6, the plurality of rotatable shafts 28 are generally transverse to the flow of paper 12.

The triangular shaped discs 30 function to vibrate and undulate the paper stream as it flows across discs 30. This is accomplished by the tips of the discs 30 impacting the paper stream at regular time intervals between impacts as the paper travels downstream

Fig 7 shows an elevated side view of the spreader 24 The plurality of shafts 28 comprises at least two sets of shafts including a first set of shafts 34 operating at a first speed 36 The first speed 36 is indicated by the rotation arrows shown in Figs 6 and 7 The plurality of shafts 28 also includes a second set of shafts 38 operating at a second speed 40. As shown m Figs 6 and 7, the second speed 40 is higher than the first speed 36 This is indicated by use of an increased number of rotation arrows for increased speeds Also depicted in Figs. 6 and 7 is a third set of shafts 42 operating at a third speed 44.

In one embodiment the first 34, the second 38, and the third 42 set of shafts rotate at progressively increasing speeds In one embodiment the first set of rotatable shafts 34 rotates at a tip speed of approximately 155 feet per minute; the second set of rotatable shafts 38 rotate at a tip speed of approximately 280 feet per minute; and the third set of rotatable shafts 42 operate at a tip speed of approximately 386 feet per minute.

These progressively increasing speeds of the first, second and third sets of shafts are accomplished by a drive means 43 including a drive motor 47 driving a gear box 49 which in turn is drivingly connected to one of the shafts 28 (see Fig. 3). The various shafts each carry two sprockets (not shown) on their outer ends, and the sprockets of adjacent shafts are connected by drive chains (not shown). The desired relative speeds of the various shafts are controlled by the selection of the size of the sprockets attached to each shaft. Thus if it is desired to double the speed of one shaft relative to the adjacent shaft, the two shafts carry sprockets one of which has twice the number of teeth as the other, the two sprockets being connected by a chain.

Undersized material will fall between the shafts 28 and discs 30. Removable canvas chutes 45 direct this undersized material to bins (not shown). Thus, the spreader 24 also functions as a trommel, or a sifter.

THE INCLINED CONVEYORS

Referring to Fig. 2 the acceleration means 18 includes a plurality of inclined conveyors 50 and 52 located downstream of the spreader 24.

Fig. 9 shows a schematic enlarged view of the inclined conveyors 50 and 52. In Fig. 9 the first inclined conveyor 50 operates at a first inclined conveyor speed 54. The second inclined conveyor 52 operates at a second inclined conveyor speed 56. Preferably the second inclined conveyor speed 56 is higher than the first inclined conveyor speed 54. The increase in speed from one conveyor to another facilitates spreading, thinning, and acceleration of the paper 12. Fig. 7 shows an embodiment wherein the spreader 24 comprises a spreader output 58. Proximate to the spreader output 58, the spreader 24 operates at an output speed 60. Preferably the first inclined conveyor speed 54 is higher than the spreader output speed 60. The speed at which the paper travels downstream is thus progressively increased.

Typically the first and second inclined conveyors 50 and 52 are inclined, relative to a horizontal floor 62, at an angle 64 in the range of ten degrees to thirty-five degrees (10° to 35°). The incline of the conveyors provides means for top layers of paper 66 to slide off of bottom layers of paper 68. This further spreads the paper into thinner layers. Preferably the inclination angle 64 of first and second inclined conveyors 50 and 52 is about twenty-five degrees (25°).

Preferably the conveyor 50 comprises a belt 70 including rough top material 72. In some embodiments, the conveyor belting is vulcanized seamless rough top rubber material. The rough top material 72 helps grip the bottom layers of paper 68 and accelerate them to a speed substantially equivalent to the speed of the inclined conveyor belt. The material further helps to spread the bottom layers of paper 68 apart from the top layers of paper 66. The bottom layers of paper 68 are being pulled or carried along the belt 70 at a greater speed than the top layers of paper 66, while the top layers of paper 66 slide down off of the bottom layers of paper 68 due to gravity. Other conventional belting material to effectuate objectives of the present invention will be apparent to those of skill. In some embodiments the inclined conveyor 50 comprises a belt

70 and assist means 74. The assist means 74 is for pinning the paper 12 to the belt 70. In the embodiment shown in Fig. 9, air 76 flows through a set of louvers 78 positioned above the belt 70. The air flows downward against paper 68 to assist in pinning paper 68 to belt 70. The louvers 78 may be adjusted, opened, closed, or oriented, by a louver handle 80. They may be automatically adjusted as well as manually adjusted. The air 76 is controlled through an air knife 82.

Also the air assist means 74 provides a means for fluffing the paper as it cascades off the first inclined conveyor 50 onto the second inclined conveyor 52.

Any paper which adheres to of conveyor 50 and carries over the discharge end thereof will be directed to canvas chute 83 which transfers material from a drop-out opening to container on the floor. It is noted that each of the conveyors described herein has close fitting sidewalls enclosing it on each side, so that paper cannot fall off the side of the conveyor.

In some embodiments the inclined conveyors will have variable frequency drives. Provisions may be made for a portion of sidewalls of a conveyor to be removable for replacement of the belting. Access ports for cleaning out jams that might occur at transfer points between conveyors may be incorporated. Viewing windows may be provided to allow material flow to be observed during operations. In some embodiments a uniform, metered feed stream of waste paper will be accepted from a typical input feed system. Multiple stages of high-speed rough-top inclined conveyors may be positioned in series to accelerate and distribute the in feed waste paper as it is being transported to an automated sensing/ejection system. It is important to note that components of the paper handling system need not be aligned in a straight line as shown in Fig. 2. It will be apparent to those with skill in the art that bends and angles may be incorporated where appropriate. Intermediate transport or delivery conveyors may be incorporated where appropriate as well.

THE ACCELERATION CONVEYOR AND PRODUCT

CONVEYOR

The system 10 shown in Fig. 2 comprises an acceleration conveyor 84, which may also be referred to as a feed means 84 for feeding the paper 12 at a predetermined speed to the sensor means 22, 23. The acceleration conveyor 84 is positioned downstream of the inclined conveyors 50 and 52. Fig. 10 shows an enlarged elevated side view of the feed means 84. In one embodiment the second conveyor 52 operates at an inclined conveyor speed which is slower than the predetermined speed at which the paper 12 is fed to the sensor 22, 23.

Fig. 11 shows an embodiment in which the acceleration conveyor 84 comprises an acceleration belt 86. Referring to Fig. 12, the acceleration belt 86 accelerates the paper 88 to a predetermined speed at which it passes through the sensor 23. The sensor 23 shown in Fig. 12 comprises a light source 90 under which the paper 88 passes. Downstream of the sensor 23 is an ejector 92. Preferably the paper 88 passes through the sensor 23 at the predetermined speed so that the ejector 92 may be operated to eject the selected paper. The velocity at which the paper travels and the distance to the sensor determines when the ejector must emit a burst of air to remove the target paper from the waste stream. In one preferred embodiment the ejector 92 includes a plurality of high compression air jets. Any paper which adheres to the acceleration belt 86 and carries over the discharge end thereof will be directed to a canvas chute 89 which transfers that material to a waste container (not shown).

The system 10 includes a mechanical pinning means 94 for pinning the paper 88 to the acceleration belt 86. The pinning means 94 is a rotary feeder 96 positioned above and contacting the acceleration belt 86. In some preferred embodiments, the acceleration belt 86 comprises standard PVC material. In some preferred embodiments the rotary feeder 96 is flexible and in contact with the acceleration belt 86. In one embodiment the rotary feeder 96 includes a plurality of flexible bristles 98 extending radially.

Fig. 2 shows a product removal apparatus 100 downstream of the sensor 23. The ejector 92, shown more clearly in Fig. 12, is positioned between the sensor 23 and the product removal apparatus 100. The product removal apparatus 100 shown in Fig. 12 comprises a product conveyor 102 below and downstream of the acceleration belt 86. Product 104 is carried downstream by the product conveyor 102. The product conveyor 102 will take non- targeted paper (also referred to as product 104) away from the sensing area 118. In some embodiments it will operate at a fixed speed of approximately 600 feet per minute. The conveyor belting may be vulcanized seamless rubber.

Ejected paper 106 (also referred to as targeted paper 106) is ejected by the ejector 92. Preferably the amount of material selected for ejection is smaller than the amount of product going to product conveyor 102. The precision air -jet ejection system may be mounted on the infeed of the product take-away conveyor (also referred to as product conveyor 102). The ejector 92 uses signals received from the sensor 23 to selectively eject targeted materials using an array of high-pressure compressed air nozzles.

Any paper adheres to product conveyor 102 and carries over the discharge end thereof is directed through a drop-out opening to a canvas chute 105 to transfer the waste paper material to a container on the floor.

Fig. 13 shows an enlarged view of the product removal apparatus 100 shown in Fig. 2. The product removal apparatus 100 shown in Fig. 13 includes a sort conveyor 108 and an airlock 110. The sort conveyor 108 will take the paper fraction that passes through the system without being ejected and deliver it to a baler (not shown). The sort conveyor 108 will be operated in some embodiments at a fixed speed of 100 feet per minute. The sort conveyor 108 includes the product output 16 and the airlock 110. The airlock 110 is proximate the product output 16. The airlock 110 is used to de- entrain paper, or product, 104. The airlock 110 acts as an air seal on the sort conveyor 108 to allow paper 104 to exit while restricting the discharge of air. Rotating tips 122 have a tip speed 123. The tip speed 123 may be fixed, in some embodiments, to match the speed of the sort conveyor 108. In some embodiments the tip speed 123 is 100 ft./min.; and the sort conveyor 108 operates at 100 ft./min. In some applications the airlock 110 may be replaced by a system of rubber flaps.

The acceleration conveyor 84 may also be described as a paper handler 130 (an embodiment of which is shown in Fig. 12) adapted for use with a sorting machine including a sensor 23 for sorting paper. In the embodiment shown in Fig. 12 the handler 130 comprises a paper input 132 for receiving the paper 12. A product output (not shown in Fig. 12) is downstream of the paper input 132. The paper handler 130 also includes a feed accelerator 134 including an acceleration conveyor 136 operably positioned to feed paper 12 (also shown as paper 88) through the sensor 23.

The paper handler 130 may further comprise the plurality of inclined conveyors 50 and 52 positioned upstream of the acceleration conveyor 136, as shown in Fig. 2. In one embodiment of the paper handler 130, the first inclined conveyor 50 includes a belt substantially similar to the belt 70 shown in Fig. 9, operating at a first inclined conveyor speed 54. The paper handler 130 also includes a second inclined conveyor 52 including a belt 55 operating at a second inclined conveyor speed 56. In one preferred embodiment the second inclined conveyor speed 56 is greater than the first inclined conveyor speed 54. The accelerator conveyor 136 operates at an accelerator conveyor speed 124 (also referred to herein as acceleration belt speed) greater than the second inclined conveyor speed 56.

In one preferred embodiment the first inclined conveyor speed is approximately four hundred fifty feet per minute (450 ft./min.); the second inclined conveyor speed is approximately seven hundred fifty feet per minute (750 ft./min.); and the accelerator conveyor speed is approximately twelve hundred feet per minute (1200 ft./min.).

In the embodiment of the paper handler 130 shown in Fig. 2 the first inclined conveyor 50 is operably positioned to receive paper 12 from the spreader 26 which in turn is operably positioned to receive paper 12 from the paper input 14.

Referring to Figs. 2 and 6, one embodiment of the paper handler 130 comprises rotatable shafts 28 positioned transversely relative to a stream of paper in the spreader 26. The rotatable shafts 42 closer to the first inclined conveyor 50 rotate faster than the rotatable shafts 34 closer to the paper input 14. In Figs. 3 and 6, the paper input 14 and the first inclined conveyor 50 are not shown. However, the product input 14 would be nearer to the first set of shafts 34, and the first inclined conveyor 50 would be located closer to the third set of rotatable shafts 42.

In some embodiments the acceleration conveyor 136 will include a high-speed belt (operating at approximately 1200 ft./min.) to deliver a thin layer of mixed paper beneath the paper-sort sensor (also referred to herein simply as sensor). The conveyor will have a variable frequency drive and preferably vulcanized seamless belting. Provisions may be incorporated into the design of the belt to minimize carry-over of paper, and ease access for removal of materials which become entrapped. A drop-out chute may be incorporated into the under pan beneath the acceleration conveyor 136 to allow materials which enter beneath the belting to drop free without being moved to the tail section of the conveyor. A small rotary brush may be positioned at the discharge end of the conveyor (proximate air sensor end 138) to assist with discharge of paper. It may be driven from a head-pulley of the acceleration conveyor. A large rotary brush 98 may be mounted on the acceleration conveyor to "pin" paper to the belt prior to entering the sensor area (118). The rotary brush 98 may have a fixed tip speed of approximately 800 feet per minute.

It is desirable to avoid unwanted disturbances to the paper flow by avoiding large speed differentials between the acceleration belt 86, 136 and rotating pinning device 96. This can be accomplished by rotating the pinning device so that the tips of its flexible bristles 98 have a tip speed approximately two-thirds of the speed at which the acceleration belt 86, 136 operates. The flexible bristles 98 further reduce damage to the rotatable pinning apparatus 96 if bulky materials are carried through by the acceleration belt 86, 136. The flexible bristles 98 can flex to allow the bulky materials to pass.

As previously noted, the speed of the acceleration belt 86 adjacent the sensor 22 may be as high as approximately twelve hundred feet per minute. Such a high speed of the acceleration belt 86 is sufficient to create a suction phenomena such that once paper such as 88 is pinned to the belt 86, such as by means of the rotary pinning device 96, the suction phenomena serves to further pin the paper to the belt so that the paper moves at substantially the same speed as the acceleration belt 86.

As best seen in Fig. 10, at the input end 132 of the paper handler 130 there is located a catching structure 150 including a downwardly inclined catching plate 152 to facilitate delivery of paper to the acceleration belt 86, 136. Paper slides off of catching plate 152 onto acceleration belt 86, 136. The catching structure 150 further includes a plurality of rods such as 154 projecting downwardly in a general direction toward the catching plate 152 and the acceleration belt 86, 136. Thus, as seen in Fig. 10, paper which is cascading off the end of the second inclined conveyor 52 is directed by rods 154 and catching plate 152 onto the upper surface of the acceleration conveyor 86, 136.

The paper impacts the plurality of rods 154 thus allowing the paper to separate as it falls onto the catching plate 152 and the conveyor belt 86, 136.

As best seen in Fig. 12, when the paper 88 reaches the left hand end or output end of acceleration conveyor 86 after it has passed under the sensor 23, it passes through a transition zone 156. As the paper passes through the transition zone 156 it is still moving at substantially the same speed at which it was travelling on the acceleration conveyor 86, 136. This continued motion is in part assisted by the air flow through the system.

As the paper passes through the transition zone 156, if it has been targeted by the sensor for ejection, a rapid burst of air from ejector 92 will blow the paper downward causing it to become targeted or ejected paper 106. If the paper crossing through transition zone 156 is not impacted by air jets from ejector 92, it will continue to flow generally horizontally and fall downward upon the product conveyor 102.

The transition zone 156 which communicates the acceleration conveyor 86, 136 with the product conveyor 132 can be described as including a separation region adjacent the acceleration conveyor 86, 136 at which the paper separates from the acceleration conveyor 86, 136. The transition zone 156 may also be described as including a reception region adjacent and immediately above the transition plate 158 of product conveyor 102 wherein the product conveyor 102 receives a majority of the paper crossing through the transition zone 156. The transition zone 156 may also be described with reference to an imaginary transition plane 160 seen in Fig. 12 which extends from the top of the acceleration conveyor 86, 136 and extends to that portion of the product conveyor 102 wherein the top surface thereof becomes generally horizontal and upon which the product paper will fall downstream of the transition plate 158.

The transition plane 160 may be described as lying at an angle 162 relative to the horizontal, where the angle 162 lies in the range of from 15° to 60°. The transition angle 162 is preferably approximately 30°.

THE SENSOR AND EJECTOR SYSTEM

The sensor 23 is preferably a linear array of sensors spread across the width of the acceleration belt 86 in a direction normal to the plane of Fig. 12. For example, for a forty-eight inch wide acceleration belt 86, an array of approximately thirty- two sensors spaced across the width of the acceleration belt would be utilized.

The ejector 92 also comprises a linear array of ejectors spaced across the width of the transition zone 156 between acceleration belt 86 and product conveyor 102. In general the sensors 23 operate to identify bright white paper by searching for fluorescing additives in the individual sheets of paper. This type of paper has a higher value of fluorescence than paper without the additives.

The sensors illuminate the paper with a constant light source having a wave length of 360 nanometers. An elliptical mirror is used to focus light onto a region above the conveyor belt at approximately ten inches from the optic system. When paper with the fluorescing additives is illuminated with the light source, light is re-radiated in the 400 to 550 nanometer range. The sensor has a second light source that emits light in the 480 nanometer range. This light source is used to determine if any type of paper is present on the conveyor belt. It is turned on momentarily every three milliseconds and a reflected light measurement is made to determine if paper is present on the conveyor belt. The details of construction of the sensor 23 are set forth in U.

S. Patent Application, Serial No. , of Bruner et al. filed concurrently herewith, entitled "SYSTEM AND METHOD FOR SENSING WHITE PAPER", and assigned to the Assignee of the present invention, the details of which are incorporated herein by reference.

The sensor system 23 will sense whether there is a piece of white paper on the belt 86, and it will sense the location of that paper upon the belt. Since the paper is moving at a predetermined fixed speed, the time at which the paper passes through the transition zone 156 can be calculated by the computer associated with sensor 23. This computerized control system will in turn actuate the appropriate number of the array of jets 92 at the appropriate time so as to blow any reject paper downward through the transition zone 156.

THE AIR CIRCULATION SYSTEM

Fig. 15 shows an overall schematic view of an air circulation system 200 of the paper handling system 10. Details of the air circulation system 200 are seen in Figs. 13, 15, 2 and 9. With reference to Fig. 15, it can be seen that air is circulated through the system 200 by a blower 202. Pressurized air from blower 202 enters a discharge duct 204 which splits into a supply duct 206 and a filter duct 208. The supply duct 206 spirts into first and second supply duct arms 210 and 212 which are directed to the housings immediately above the first and second inclined conveyor belts 50 and 52.

Air knives 82 and 214 are disposed in the first and second supply duct arms 210 and 212, respectively, adjacent their inlets to the housings surrounding the first and second inclined conveyors 50 and 52, in order to control the flow of air into the housings adjacent the conveyors, and particularly to their louvers such as the louvers 78 associated with first inclined conveyor 50. The first and second supply duct arms 210 and 212 may also include iris-type flow controls adjacent the air knives 82 and 214.

It will be appreciated from the views previously described of the several components, that the inclined conveyors 50 and 52, the acceleration conveyor 84, and the product conveyor 102 all have associated therewith substantially enclosed housings so that the air which is provided through air supply duct arms 210 and 212 to the housings adjacent inclined conveyors 50 and 52 is directed through the housings of conveyors 50 and 52, then through the housings surrounding acceleration conveyor 84 then through the sensing area 118 across the product conveyor 102.

A portion of this air circulation system can be described as an air assist means 112 which is part of the product removal apparatus 100 and which assists in maintaining the predetermined speed of the paper 88 through the sensor 23. In one preferred embodiment the air assist means 112 includes a vacuum 114, which may also be described as a low pressure area 114, downstream of the sensor 23 as is illustrated in Fig. 13.

The vacuum or low pressure area 114 forms within a plenum chamber 116 defined adjacent the left hand end of product conveyor 102 in Fig. 13. An air recycle duct 216 is connected to the suction inlet 218 of blower 202 in order to pull air from the plenum chamber 116 thus creating the low pressure zone 114 therein. A screen may be utilized adjacent return duct 216 to prevent carry over of paper to the blower 202.

The filter duct 208 leads to a plenum 220 and air flow thereto can be controlled by a motorized damper 222. Plenum 220 is connected to a plurality of filter bags 224. The filter bags 224 are used to remove dust from the air system prior to releasing it to the atmosphere.

In one embodiment, the blower 202 is a 6000 CFM blower, which is a variable speed blower for controlling the speed of the air drawn through the sensor area 118. In a typical system, 2000 CFM would be directed to the filter duct 208, with 4000 CFM flowing through supply duct 206 which in turn splits into two streams of 2000 CFM each in supply duct arms 210 and 212 which are directed to the inclined conveyors 50 and 52.

It is noted that in Fig. 12 the area between the product conveyor 102 and the acceleration belt 86 is shown open at the bottom for clarity. In practice this area will be closed in order to facilitate control of air flow through the system.

The air circulating through the system illustrated in Fig. 15 provides several functions.

When the air first flows in through the louvers such as 78 of the first and second inclined conveyors 50 and 52, that air flow functions to help pin the paper onto the inclined conveyors so as to help accelerate the paper speed up to the conveyor speed.

The air also aids in fluffing the paper as it cascades off the ends of the inclined conveyors. The air also assists in the downstream movement of the paper through the system.

Particularly, the air assists in the movement of the paper through the sensing area 118 across the gap between acceleration belt 86 and product belt 102.

The plenum chamber 116 adjacent the downstream end of the product conveyor 102 may be utilized to reduce the air flow to a speed below two hundred feet per minute in order to allow the paper to settle out on the product conveyor 102. The housing which defines the plenum 116 has a much larger area at plenum 116 than it does upstream near the transition zone 156, so that the air speed is much higher near the transition zone 156 than it is downstream adjacent the plenum 116.

The right hand end of the product conveyor 102 may generally be described as a transition end thereof. A transition plate 158 is located immediately above the transition end of the product conveyor 102. The transition plate 158 is curved to conform to the general shape of the curved end of the product conveyor 102, and functions to prevent paper from falling back off the transition end of the product conveyor.

METHODS

The present invention also includes various methods for handling paper. One method comprises the steps of distributing clumps of paper 140 (see Fig. 2) into operably thin layers of paper 142 (see Fig. 12). Operably thin is defined to be thin enough to accomplish the goal for which the paper is being handled. In one preferred embodiment the goal is to sense the paper by passing it through a sensor. To accomplish this goal the paper should be thin enough that the sensor may adequately sense and distinguish pieces of paper. The paper may then be sorted by an ejector. The method of handling paper also comprises accelerating the paper. The step of accelerating the paper includes progressively increasing the speed at which the paper is transported downstream. One embodiment of this method comprises the steps of breaking up clumps of paper 42 in a spreader 26. An apparatus for accomplishing this is shown in Fig. 6. The method may also comprise rotating rotatable shafts 28 in the spreader 26 to progressively increase the speed at which the paper travels. The paper is also generally referred to herein by designation 12. Another method of the invention comprises the step of feeding the paper 12 into a plurality of inclined conveyors 50 and 52. This is shown in Figs. 2 and 9. The respective plurality of inclined conveyor belts catch underlying layers of paper 68. The underlying layers of paper 68 are also referred to as bottom layers of paper 68. The method includes accelerating the underlying layers of paper 68 up to speeds approximating speeds at which the respective plurality of inclined conveyor belts operate.

One preferred embodiment of the invention comprises the step of inclining the inclined conveyors between fifteen degrees and thirty - five degrees (15°-35°). This is the optimal range for paper to adhere to and travel up the conveyor while paper on the top slides off the bottom paper due to gravity. Generally, layers of paper will begin to slide over lower layers of paper due to gravity at an incline of 15°. Beyond 35° the paper will not adhere to the belt as easily. This takes advantage of paper's friction co-efficient. The method includes allowing paper 66 above the underlying layers 68 to slide down the incline and become new underlying layers. A new underlying layer 144 is shown in Fig. 9. The method then includes catching the new underlying layers 144 with the respective plurality of inclined conveyor belts and accelerating the new underlying layers 144 of paper 12 up to speeds approximating the speeds at which the respective plurality of inclined conveyor belts operate.

In some embodiments the method comprises the step of pinning the underlying layers of paper 68 to the respective plurality of inclined belts with air 76 and 126. This is shown in Fig. 9 in which air-assist means 74 pins and fluffs the paper 12. Accordingly, one method comprises the step of fluffing the paper 12 as it cascades off respective ends of the respective plurality of inclined conveyors. In Fig. 9 one respective end is designated 146 on inclined conveyor 50. It is desirable to adjust volumes of air flow 76 with air knives

82 and direct air 76 (also shown as direction of air 126) with respective sets of louvers 78 in the inclined conveyors 50 and 52.

Preferably inclined conveyors downstream are operated at higher speeds than inclined conveyors upstream. Referring to Figs. 2 and 12, it will be apparent that the present invention also includes the method of catching underlying layers of paper 68 on an acceleration belt 86. The underlying paper 68 is accelerated to a predetermined speed. The paper (referred to in Fig. 12 by designation number 88) is allowed to pass through a sensor 23 at the predetermined speed.

In one preferred embodiment a rotary feeder 96 is rotated above the acceleration belt 86 to pin the paper 88 to the acceleration belt 86. The method also includes contacting the paper 88 and pinning the paper 88 to the acceleration belt 86 as the paper 88 passes between the acceleration belt 86 and the rotary feeder 96. Preferably damage to the rotary feeder 96 is prevented by allowing the rotary feeder 96 to flex. In some embodiments the rotary feeder operates at a speed less than the acceleration belt 86. In one embodiment the rotary feeder rotates at speeds of eight hundred feet per minute (800 ft./min.) and the acceleration belt operates at speeds approximating twelve hundred feet per minute (1200 ft./min.). More generally, a preferred embodiment in the present invention includes the step of rotating the rotary feeder 96 at approximately two-thirds of the speed at which the acceleration belt 86 operates. This prevents the pinning device from being bent up by a large speed differential when the pinning device contacts the high velocity acceleration belt 86. This also reduces the likelihood that the paper 88 will be turned up at its end as it is caught between a stationary pinning device and a high velocity belt. Another method of the present invention comprises the steps of allowing the paper 88 to pass through a sensor 23 and ejecting paper 106 (also referred to as targeted paper) selected for ejection (See Fig. 12). The method also includes allowing non-selected paper, also referred to herein as product, 104 to continue downstream to a product conveyor 102. Preferably the predetermined speed of the paper 88 is maintained through the sensor 23 with air-assistance 112 (not shown in Fig. 12).

Another embodiment of handling paper comprises drawing the paper 88 with a vacuum 114 downstream of the ejector 92, and matching a vacuum speed at which the vacuum 112 draws to a belt speed at which the acceleration belt 86 operates. The acceleration belt 86 accelerates paper 88 through the sensor 23 at a sensor speed (not shown) substantially equal to the acceleration belt speed 124 at which the acceleration belt 86 operates. Sensor speed as used here refers to the rate at which the sensor may sense material passing through it.

In some embodiments the method comprises the steps of adhering the paper 104 to the product conveyor belt 102 with the vacuum 114. Other methods of the invention comprise spreading and accelerating the paper in a spreader 26, and transporting and accelerating the paper 12 up a first inclined conveyor 50. The paper 12 is accelerated with the first inclined conveyor. The method also includes transporting and accelerating the paper 12 up a second inclined conveyor 52 and then accelerating the paper through a sensor 23 at a predetermined feed. In some embodiments the paper is pinned with a rotary feeder 96 proximate the sensor 23. It is desirable in some embodiments to maintain paper flow through the sensor 23 with a vacuum 114. The method also comprises ejecting selected paper 106.

Thus, although there have been described particular embodiments of the present invention of a new and useful PAPER SORTING SYSTEM, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.

Claims

What is claimed is:

1. A paper handling system for handling paper fed to the system, the system comprising: a paper input adapted to receive the paper; a product output; and acceleration means operably positioned between the paper input and the product output for accelerating the paper.

2. The system of claim 1, comprising: an ejection output between the paper input and the product output; sensor means for determining whether paper should be routed to the ejection output or the product output; and wherein the acceleration means includes a means for accelerating the paper from a first speed proximate the paper input to a second higher speed proximate the sensor means.

3. The system of claim 2, wherein the second higher speed is a predetermined speed.

4. The system of claim 3, wherein the paper passes through the sensor means at the predetermined speed.

5. The system of claim 1, wherein the acceleration means comprises spreading means for spreading clumps of paper.

6. The system of claim 5, wherein the spreading means comprises a plurality of rotatable shafts, wherein each rotatable shaft includes a plurality of discs.

7. The system of claim 6, wherein the paper flows downstream from the paper input to the product output, and wherein the plurality of rotatable shafts are transverse to the flow of paper.

8. The system of claim 6, wherein the plurality of shafts comprises a first set of shafts operating at a first speed and a second set of shafts operating at a second speed higher than the first speed.

9. The system of claim 6, wherein the discs are rubber tipped.

10. The system of claim 5, wherein the acceleration means comprises a feed section downstream of the spreading means, the feed section including a first inclined conveyor.

11. The system of claim 10, wherein: the feed section comprises a second inclined conveyor downstream of the first inclined conveyor.

12. The system of claim 11, wherein: the first inclined conveyor operates at a first inclined conveyor speed; and the second inclined conveyor operates at a second inclined conveyor speed higher than the first inclined conveyor speed.

13. The system of claim 12, wherein the spreading means comprises a spreader output, the spreading means operates at an output speed proximate the spreader output, and the first inclined conveyor speed is higher than the spreader output speed.

14. The system of claim 12, wherein the first and second inclined conveyors are inclined, relative to a horizontal floor, in the range of 10° to 35°.

15. The system of claim 14, wherein the first and the second inclined conveyors are inclined 25°.

16. The system of claim 10, wherein the inclined conveyor comprises a belt including rough-top material.

17. The system of claim 10, wherein the inclined conveyor comprises: a belt; and assist means for pinning the paper to the belt.

18. The system of claim 17, wherein the assist means comprises a set of louvers above the belt, and the paper is fluffed as it cascades off of the belt.

19. The system of claim 10, comprising feed means for feeding the paper at a predetermined speed, wherein the feed means is downstream of the inclined conveyor.

20. The system of claim 19, wherein the inclined conveyor operates at an inclined conveyor speed and wherein the inclined conveyor speed is slower than the predetermined speed.

21. The system of claim 19, wherein the feed means comprises an acceleration belt.

22. The system of claim 21, wherein the acceleration belt accelerates the paper to the predetermined speed.

23. The system of claim 22, comprising a sensor, wherein the paper is fed at the predetermined speed through the sensor.

24. The system of claim 23, comprising pinning means for pinning the paper to the acceleration belt.

25. The system of claim 21, comprising pinning means for pinning the paper to the acceleration belt.

26. The system of claim 25, wherein the pinning means is a rotary feeder positioned above and contacting the acceleration belt.

27. The system of claim 19, comprising: a sensor downstream of the inclined conveyor; and a product removal apparatus downstream of the sensor, wherein the feed means feeds paper at the predetermined speed through the sensor.

28. The system of claim 27, comprising an ejector between the sensor and the product removal apparatus.

29. The system of claim 28, wherein: the feed means comprises an acceleration belt; and the product removal apparatus comprises a product conveyor below and downstream of the acceleration belt.

30. The system of claim 29, wherein the product removal apparatus comprises air assist means for maintaining the predetermined speed of the paper through the sensor.

31. The system of claim 30, wherein the air-assist means comprises a vacuum downstream of the sensor.

32. The system of claim 30, wherein the product removal apparatus comprises: a sort conveyor including the product output; and an air-lock proximate the product output to de-entrain paper.

33. The system of claim 1, comprising: a sensor downstream of the paper input; and an ejector downstream of the sensor.

34. The system of claim 33, wherein the acceleration means comprises feed means for feeding the paper through the sensor.

35. The system of claim 34, wherein the acceleration means comprises air-assist means for assisting the paper through the sensor.

36. The system of claim 35, wherein the air-assist means includes a vacuum.

37. The system of claim 34, wherein the feed means comprises an acceleration belt operably positioned relative to the sensor to feed paper through the sensor, wherein the belt operates at an acceleration belt speed.

38. The system of claim 37, wherein the feed means comprises pinning means for pinning the paper to the belt and accelerating the paper to a speed substantially equal to the acceleration belt speed.

39. The system of claim 38, wherein the pinning means comprises a rotary feeder positioned proximate to and upstream of the sensor and positioned above the acceleration belt.

40. The system of claim 39, wherein the rotary feed is flexible and is in contact with the acceleration belt.

41. The system of claim 40, wherein the rotary feed includes a plurality of flexible bristles extending radially.

42. The system of claim 1, wherein the acceleration means comprises a plurality of inclined conveyors including a first conveyor positioned downstream of the paper input and a second inclined conveyor positioned downstream of the first inclined conveyor.

43. The system of claim 42, wherein the first inclined conveyor is operably positioned to feed into the second inclined conveyor.

44. The system of claim 43, wherein: the first inclined conveyor operates at a first inclined conveyor speed; the second inclined conveyor operates at a second inclined conveyor speed; and the second inclined conveyor speed is greater than the first inclined conveyor speed.

45. The system of claim 43, wherein each of the inclined conveyors comprises: a belt; and air-assist means for pinning the paper to the belt and for fluffing the paper as it cascades off the belt.

46. The system of claim 45, wherein the air-assist means of each inclined conveyor comprises: a set of louvers above the belt for adjusting a direction of air; and an air gate for adjusting a volume of air.

47. The system 42, wherein the inclined conveyors are inclined relative to a horizontal floor in the range of 10° to 35°.

48. The system of claim 47, wherein the inclined conveyors are inclined 25° relative to the horizontal floor.

49. The system of claim 1, comprising a product removal apparatus including a product conveyor and a sort conveyor downstream of the product conveyor, wherein the sort conveyor includes the product output.

50. The system of claim 49, comprising air-assist means for assisting the paper downstream, including pinning the paper to the product conveyor.

51. The system of claim 50, wherein the product removal apparatus comprises an air lock proximate the product output.

52. The system of claim 50, wherein the air-assist means comprises a vacuum.

53. A paper handler adapted for use with a sorting machine including a sensor for sorting paper, the handler comprising: a paper input for receiving paper; a product output downstream of the paper input; and a feed accelerator including an acceleration conveyor located downstream of the paper input operably positioned to feed the paper through the sensor.

54. The paper handler of claim 53, wherein the feed accelerator comprises a pinning feed above the acceleration conveyor.

55. The paper handler of claim 54, wherein the pinning feed is a rotary feed, and the rotary feed is flexible and contacts the acceleration conveyor.

56. The paper handler of claim 53, comprising a plurality of inclined conveyors positioned upstream of the acceleration conveyor, wherein the plurality of inclined conveyors includes a first inclined conveyor and a second inclined conveyor, the second inclined conveyor positioned downstream of the first inclined conveyor.

57. The paper handler of claim 56, wherein the first inclined conveyor and the second inclined conveyor are inclined between 10° and 35° relative to a horizontal orientation.

58. The paper handler of claim 57, wherein: the first inclined conveyor includes a belt operating at a first inclined-conveyor speed; the second inclined conveyor includes a belt operating at a second inclined-conveyor speed, wherein the the second- inclined conveyor speed is greater than the first inclined- conveyor speed; and the accelerator conveyor operates at an accelerator conveyor speed greater than the second inclined-conveyor speed.

59. The paper handler of claim 58, wherein: the first inclined-conveyor speed is approximately 450 feet per minute; the second inclined-conveyor speed is approximately 750 feet per minute; and the accelerator conveyor speed is approximately 1200 feet per minute.

60. The paper handler of claim 58, wherein each inclined conveyor includes a set of louvers above the belt.

61. The paper handler of claim 58, wherein each belt comprises rough-top material.

62. The paper handler of claim 58, wherein each inclined conveyor comprises an air gate for adjusting a volume of air.

63. The paper handler of claim 56, comprising a spreader positioned upstream of the first inclined conveyor and operably positioned to receive paper from the paper input, wherein the spreader includes: a plurality of rotatable shafts positioned transversely relative to a stream of paper; and a plurality of discs positioned on each shaft.

64. The paper handler of claim 63, wherein the rotatable shafts closer to the first inclined conveyor rotate faster than the rotatable shafts closer to the paper input.

65. The paper handler of claim 63, wherein the plurality of rotatable shafts includes a first, a second, and a third set of rotatable shafts, and wherein the first, the second, and the third set of shafts rotate at progressively increasing speeds.

66. The paper handler of claim 65, wherein: the first set of rotatable shafts rotates at approximately 155 feet per minute; the second set of rotatable shafts rotate at approximately 280 feet per minute; and the third set of rotatable shafts rotates at approximately 386 feet per minute.

67. The paper handler of claim 53, comprising: a product removal apparatus positioned downstream of the sensor; and an ejector positioned between the sensor and the product removal apparatus.

68. The paper handler of claim 67, wherein the ejector is an air ejector.

69. The paper handler of claim 67, wherein the feed accelerator sends paper through the sensor at a predetermined speed; and wherein the product removal apparatus comprises an air-assist apparatus.

70. The paper handler of claim 69, wherein the air-assist apparatus is a vacuum downstream of the ejector.

71. The paper handler of claim 69, wherein the product removal apparatus comprises: a product conveyor downstream of the ejector; a sort conveyor downstream of the product conveyor; and an air-lock in operable communication with the sort conveyor and proximate the product output.

72. A paper sorting machine comprising: a paper input; a spreader positioned to receive paper from the paper input; an inclined feed section downstream of the spreader, wherein the inclined feed section includes a first and a second inclined conveyor, and wherein the second inclined conveyor is downstream of the first inclined conveyor; a feed accelerator operably positioned to receive paper from the second inclined conveyor, wherein the feed accelerator includes an accelerator conveyor having a sensor end; a sensor operably positioned to sense paper passing over the accelerator conveyor sensor end; an ejector downstream of the sensor; a product conveyor downstream of the ejector; and a product output downstream of the product conveyor.

73. The sorting machine of claim 72, wherein: the paper input receives paper at a first speed; the spreader accelerates the paper to a second speed, wherein the second speed is greater than the first speed; the inclined feed section accelerates the paper to a third speed, wherein the third speed is greater than the second speed; and the feed accelerator accelerates the paper to a fourth speed, wherein the fourth speed is greater than the third speed.

74. The sorting machine of claim 73, wherein the fourth speed is a predetermined speed and the paper passes through the sensor at the predetermined speed.

75. The sorter of claim 72, wherein the feed accelerator comprises a rotary feeder proximate to and upstream of the sensor and above the accelerator conveyor.

76. The sorter of claim 75, wherein the rotary feeder is flexible and contacting the accelerator conveyor.

77. The sorter of claim 72, comprising an air-assist device for maintaining the paper at a predetermined speed through the sensor.

78. The sorter of claim 72, comprising a sort conveyor downstream of the product conveyor, wherein the sort conveyor comprises an air-lock proximate the product output.

79. The sorting machine of claim 72, wherein the spreader comprises three sets of rotatable shafts, each shaft including a plurality of bulged triangular discs, wherein the rotatable shafts closer to the inclined feed section rotate faster than the rotatable shafts closer to the paper input.

80. The sorting machine of claim 79, wherein a portion of the bulged triangular discs are rotated 45° relative to a remainder of the bulged triangular discs.

81. A method of handling paper comprising the steps of: distributing clumps of paper into operably thin layers of paper; and accelerating the paper, wherein the step of accelerating the paper includes progressively increasing the speed at which the paper is transported downstream.

82. The method of claim 81, comprising the steps of: breaking up clumps of paper in a spreader; and rotating rotatable shafts in the spreader to progressively increase the speed at which the paper travels.

83. The method of claim 81, comprising the steps of: feeding the paper into a plurality of inclined conveyors; catching underlying layers of the paper with a respective plurality of inclined conveyor belts; and accelerating the underlying layers of paper up to speeds approximating speeds at which the respective plurality of inclined conveyor belts operate.

84. The method of claim 83, comprising the steps of: inclining the inclined conveyors between 15° and 35°; allowing paper above the underlying layers to slide down the incline and become new underlying layers; catching the new underlying layers with the respective plurality of inclined conveyor belts; and accelerating the new underlying layers of paper up to speeds approximating the speeds at which the respective plurality of inclined conveyor belts operate.

85. The method of claim 83, comprising the step of pinning the underlying layers of paper to the respective plurality of inclined belts with air.

86. The method of claim 83, comprising the step of fluffing the paper as it cascades off respective ends of the respective plurality of inclined conveyor belts.

87. The method of claim 86, comprising the steps of: adjusting volumes of air flow with air knives; directing air with respective sets of louvers in the inclined conveyors; and pinning the underlying layers of paper to the respective plurality of inclined conveyor belts.

88. The method of claim 83, comprising the step of operating inclined conveyors downstream at higher speeds than inclined conveyors upstream.

89. The method of claim 81, comprising the steps of: catching underlying papers on an acceleration belt; accelerating the underlying paper to a predetermined speed; and allowing the paper to pass through a sensor at the predetermined speed.

90. The method of claim 89, comprising the step of pinning the paper to the acceleration belt.

91. The method of claim 90, comprising the steps of: rotating a rotary feeder above the acceleration belt; and contacting the paper and pinning the paper to the acceleration belt as the paper passes between the acceleration belt and the rotary feeder.

92. The method of claim 91, comprising the step of preventing damage to the rotary feeder by allowing the rotary feeder to flex.

93. The method of claim 91, comprising the step of rotating the rotary feeder at a speed less than the acceleration belt.

94. The method of claim 93, comprising the step of rotating the rotary feeder at approximately two-thirds of a speed at which the acceleration belt operates.

95. The method of claim 81, comprising the steps of: allowing paper to pass through a sensor; ejecting paper selected for ejection; allowing non-selected paper to continue downstream to a product conveyor; and maintaining a predetermined speed of the paper through the sensor with air-assistance.

96. The method of claim 95, comprising the steps of: drawing the paper with a vacuum downstream of the ejector; and matching a vacuum speed at which the vacuum draws to a belt speed at which an acceleration belt operates, wherein the acceleration belt accelerates the paper through the sensor at a sensor speed substantially equal to the belt speed at which the acceleration belt operates.

97. The method of claim 96, comprising the step of de-entraining the paper.

98. The method of claim 96, comprising the step of adhering the paper to the product conveyor with the vacuum.

99. The method of claim 81, comprising the steps of: spreading and accelerating the paper in a spreader; transporting and accelerating the paper up a first inclined conveyor; accelerating the paper with the first inclined conveyor; transporting and accelerating the paper up a second inclined conveyor; accelerating the paper through a sensor at a predetermined speed, including pinning the paper with a rotary feeder proximate the sensor; maintaining paper flow through the sensor with a vacuum; and ejecting selected paper.

100. A paper handler comprising: a first inclined conveyor operating at a first speed and having an output end; and a second inclined conveyor operating at a second speed and operably positioned to receive paper output from the first inclined conveyor.

101. The paper handler of claim 100, wherein the first and second inclined conveyors are inclined between 15° and 35° relative a floor.

102. The paper handler of claim 101, wherein the first and the second inclined conveyors are inclined 25° relative to the floor.

103. The paper handler of claim 100, wherein the second speed is greater than the first speed.

104. The paper handler of claim 103, wherein: the first speed is greater than 400 ft./min.; and the second speed is greater than 600 ft./min.

105. The paper handler of claim 104, wherein: the first speed is approximately 450 ft./min.; and the second speed is approximately 750 ft./min.

106. The paper handler of claim 104, wherein the first and the second inclined conveyors are inclined between 15° and 35°.

107. The paper handler of claim 100, comprising air assist means for pinning paper to the first inclined conveyor.

108. The paper handler of claim 107, wherein the air assist means is adapted for fluffing the paper.

109. The paper handler of claim 100, comprising: a first belt operatively positioned in the first inclined conveyor; and a blower supplying air to the first inclined conveyor and structure directing the air such that the paper is pinned to the first belt.

110. The paper handler of claim 109, wherein the structure directing air comprises a set of louvers above the first belt.

111. The paper handler of claim 110, wherein the first belt has an end and wherein the louvers are positioned to direct air such that paper cascading off of the end of the first belt is fluffed.

112. The paper handler of claim 109, wherein the structure directing air comprises adjustment means for adjusting a volume of air blowing toward the first belt.

113. The paper handler of claim 100, wherein each inclined conveyor comprises a respective belt including tacky material, and wherein each inclined conveyor is inclined 25° relative to a floor.

114. The paper handler of claim 113, wherein the tacky material is rough-top-rubber material.

115. The paper handler of claim 100, wherein the second inclined conveyor is downstream of and adjacent to the first inclined conveyor.

116. The paper handler of claim 100, wherein the second inclined conveyor is linearly aligned with the first inclined conveyor and wherein the second inclined conveyor is downstream of the first inclined conveyor.

117. A method of handling paper comprising the steps of: supplying paper to a first inclined conveyor; carrying the paper up the first inclined conveyor; feeding the paper output from the first inclined conveyor to a second inclined conveyor; and carrying the paper up the second inclined conveyor.

118. The method of claim 117, comprising the step of allowing upper layers of paper to slide down lower layers of paper thereby forming new lower layers of paper.

119. The method of claim 118, comprising the step of inclining the first and second inclined conveyors between 15° and 35°.

120. The method of claim 119, wherein the step of carrying the paper comprises the steps of: operating a first belt at a first speed in the first inclined conveyor; accelerating lower layers of paper on the first belt up to speeds approximating the first speed; operating a second belt at a second speed in the second inclined conveyor; and accelerating lower layers of paper on the second belt up to speeds approximating the second speed.

121. The method of claim 120, wherein the second speed is greater than the first speed.

122. The method of claim 121, comprising the step of pinning lower layers of paper to the first and second belts with air.

123. The method of claim 121, wherein the step of accelerating the lower layers of paper comprises gripping the lower layers of paper with tacky material.

124. The method of claim 123, wherein the tacky material comprises rough-top rubber and wherein each belt comprises the rough-top rubber.

125. The method of claim 117, comprising the step of inclining the first and second inclined conveyors between 15° and 35°.

126. The method of claim 117, comprising the steps of: operating the first inclined conveyor at a first speed; and operating the second inclined conveyor at a second speed, wherein the second speed is greater than the first speed.

127. The method of claim 126, wherein the step of supplying paper to the first inclined conveyor comprises the step of supplying the paper at a supply speed, and wherein the first speed is greater than the supply speed.

128. The method of claim 127, wherein the second speed is approximately twice the supply speed.

129. The method of claim 126, wherein the first speed is approximately 450 ft./min.; and the second speed is approximately 750 ft./min.

130. The method of claim 117, wherein the step of carrying paper up the inclined conveyors comprises the step of spreading the paper into thinner layers of paper.

131. The method of claim 130, wherein the step of spreading the paper comprises the step of accelerating underlying layers of paper up the inclined conveyors while allowing overlying layers of paper to slide down the underlying layers of paper.

132. The method of claim 131, wherein the step of spreading comprises the step of allowing the overlying layers of paper to become new underlying layers of paper and accelerating the new underlying layers of paper up the incline conveyors.

133. The method of claim 117, wherein the steps of carrying the paper comprise pinning the paper with air.

134. The method of claim 117, wherein the step of feeding the paper output to the second inclined conveyor comprises the step of fluffing the paper.

135. The method of claim 117, comprising the step of positioning the second inclined conveyor downstream of and adjacent to the first inclined conveyor such that paper cascading off of an end of the first inclined conveyor is fed into the second inclined conveyor.

136. The method of claim 135, comprising the step of fluffing the paper as it cascades from the end of the first inclined conveyor.

137. The method of claim 117, comprising the steps of: spreading the paper; and adjusting volumes of air flow to facilitate spreading of the paper.

138. A paper handler comprising: an acceleration conveyor including an acceleration belt operating at an acceleration speed; and a pinning structure operably positioned to pin paper to the acceleration belt.

139. The paper handler of claim 138, wherein the pinning structure is a rotary feeder positioned above the acceleration belt.

140. The paper handler of claim 139, wherein the rotary feeder is contacting the acceleration belt.

141. The paper handler of claim 139, wherein the rotary feeder comprises a plurality of flexible bristles extending radially from a roller.

142. The paper handler of claim 139, wherein the rotary feeder has an outer surface rotating at a rotary surface speed, and wherein the rotary surface speed is less than the acceleration speed.

143. The paper handler of claim 142, wherein the rotary surface speed is approximately two-thirds of the acceleration speed.

144. The paper handler of claim 143, wherein the acceleration speed is approximately 1200 ft./min.

145. The paper handler of claim 138, wherein the acceleration speed is sufficiently high to create a suction phenomena such that when paper is pinned to the acceleration belt the paper will be accelerated to a paper speed substantially equal to the acceleration speed.

146. The paper handler of claim 145, wherein the acceleration speed is at least 800 ft./min.

147. The paper handler of claim 146, wherein the acceleration speed is approximately 1200 ft./min.

148. The paper handler of claim 138, wherein the acceleration speed is at least 1000 ft./min.

149. A paper handler comprising: an acceleration conveyor adapted to receive paper and accelerate the paper to a predetermined speed, wherein the acceleration conveyor includes an input end, an output end, and an acceleration belt; and a catching structure proximate the input end, wherein the catching structure includes a downwardly inclined catching plate to facilitate delivery of paper to the acceleration belt.

150. The paper handler of claim 149, wherein the catching structure comprises a plurality of rods projecting downwardly in a general direction toward the catching plate and the acceleration belt.

151. The paper handler of claim 149, wherein the predetermined speed is higher than a feed rate at which the acceleration conveyor receives paper.

152. The paper handler of claim 149, wherein the acceleration belt operates at a speed of at least 1000 ft./min.

153. A paper handler adapted for use with a device, the paper handler comprising: an acceleration conveyor adapted to feed paper to the device at a predetermined speed; a product conveyor downstream of the acceleration conveyor; a transition between the acceleration conveyor and the product conveyor; and a blowing system operatively positioned to facilitate carrying the paper across the transition at a speed substantially equal to the predetermined speed.

154. The paper handler of claim 153, wherein the device is a sorter comprising a sensor and an ejector, wherein the ejector is downstream of the sensor and operably positioned to eject targeted paper crossing the transition.

155. The paper handler of claim 153, wherein the blowing system comprises a blower and a plenum chamber operably connected to the blower to create a vacuum downstream of the transition.

156. The paper handler of claim 155, comprising a housing for the product conveyor and through which the vacuum creates an air flow flowing at air speed, wherein the housing has an interior cross section such that the air speed is higher near the transition than further downstream of the transition.

157. The paper handler of claim 153, wherein the product conveyor comprises: a transition end proximate the transition; and a transition plate above the transition end.

158. The paper handler of claim 157, wherein the transition plate is curved to conform to the product conveyor transition end.

159. The paper handler of claim 153, wherein the product conveyor comprises a transition end below the acceleration conveyor.

160. The paper handler of claim 159, wherein the acceleration conveyor comprises a device end and the product conveyor transition end is downstream of the device end.

161. The paper handler of claim 153, wherein the blowing system creates a vacuum drawing air across the transition.

162. The paper handler of claim 153, wherein the vacuum draws air through the transition.

163. The paper handler of claim 153, wherein the acceleration conveyor operates at a speed of at least 1000 ft./min. and the predetermined speed is at least 1000 ft./min.

164. The paper handler of claim 153, wherein the acceleration conveyor comprises a pinning structure upstream of the device.

165. The paper handler of claim 164, wherein the acceleration conveyor comprises a belt, and the pinning structure comprises a rotary feeder contacting the belt.

166. The paper handler of claim 165, wherein the blowing system creates a vacuum drawing air across the transition.

167. The paper handler of claim 153, wherein: the acceleration conveyor comprises a separation region at which the paper separates from the acceleration conveyor; the product conveyor comprises a reception region downstream of the transition wherein the product conveyor receives a majority of the paper crossing the transition; and the transition comprises a transition plane intersecting the separation region and the reception region, wherein the transition plane is at a transition angle measured relative to the acceleration conveyor, and wherein the transition angle is between 15° and 60°.

168. The paper hander of claim 167, wherein the transition angle is approximately 30°.

169. The paper handler of claim 153, wherein the acceleration conveyor is horizontal.

170. A method of handling paper comprising the steps of: receiving paper at an input end of an acceleration conveyor; accelerating the paper to a predetermined speed; and operating a belt of the acceleration conveyor at a sufficiently high speed to create a suction phenomena, wherein the paper is accelerated to a paper speed substantially equal to the belt high speed.

171. The method of claim 170, wherein the step of operating a belt comprises operating the belt at at least 1000 ft./min.

172. The method of claim 170, wherein the belt high speed is substantially equal to the predetermined speed.

173. The method of claim 170, wherein the step of accelerating the paper comprises the step of pinning the paper to the belt.

174. The method of claim 173, wherein the step of pinning the paper comprises the step of reducing unwanted interference to the paper stream due to a speed discontinuity between a pinning device and the belt.

175. The method of claim 174, wherein the step of reducing unwanted interferences with the paper stream comprises the step of rotating a rotary feeder.

176. The method of claim 175, wherein the step of rotating the rotary feeder comprises the step of rotating a surface of the rotary feeder at approximately two-thirds of the belt high speed.

177. The method of claim 170, comprising the steps of: providing a product conveyor downstream of the acceleration conveyor; and maintaining the predetermined speed across a transition between the product conveyor and the acceleration conveyor.

178. The method of claim 177, wherein the step of maintaining the predetermined speed across the transition comprises the step of creating a vacuum downstream of the transition and drawing the paper across the transition.

179. A method of supplying paper comprising the steps of: receiving paper at an input end of an acceleration conveyor at an input rate; accelerating the paper to a predetermined speed; and feeding the paper at the predetermined speed to a sensor.

180. The method of claim 179, wherein the predetermined speed is higher than the input rate.

181. The method of claim 179, wherein the predetermined speed is at least 1000 ft./min.

182. The method of claim 179, wherein the step of receiving paper at the input end comprises catching the paper on a catching plate and allowing the paper to slide onto an acceleration belt.

183. The method of claim 182, wherein the step of receiving paper comprises allowing the paper to impact a plurality of rods and allowing the paper to separate.

184. The method of claim 179, comprising the step of maintaining the paper at the predetermined speed across a transition between the acceleration conveyor and a product conveyor.

85. The method of claim 184, comprising the steps of: ejecting targeted paper through the transition; and allowing non-targeted paper to continue downstream.

186. The method of claim 184, wherein the step of maintaining the paper at the predetermined speed across the transition comprises the step of drawing the paper across the transition with a vacuum.

187. The method of claim 186, wherein the predetermined speed is at least 1000 ft./min.

188. The method of claim 186, wherein the step of accelerating the paper comprises the step of pinning the paper to the belt on the acceleration conveyor.

189. The method of claim 184, comprising the step of reducing back feed from the product conveyor.

190. The method of claim 189, wherein the step of reducing back feed comprises the step of operably positioning a transition plate proximate the product conveyor so that the product conveyor will not back feed short falling paper.

191. The method of claim 179, wherein the step of accelerating the paper comprises the step of pinning the paper to a belt on the acceleration conveyor.

192. The method of claim 191, wherein the step of pinning the paper comprises the step reducing unwanted disturbances to the paper flow by avoiding large speed differentials between the belt and a pinning device.

193. The method of claim 192, comprising the step of operating the pinning device at approximately two-thirds of a speed at which the belt operates.

194. The method of claim 191, wherein the step of pinning the paper comprises the step of reducing damage to a pinning device due to bulky material.

195. The method of claim 194, wherein the step of reducing damage to the pinning device comprises the step of allowing the pinning device to flex.

196. A method of handling paper comprising the steps of: feeding paper to an acceleration conveyor; and aiding transport of the paper across a transition between the acceleration conveyor and a product conveyor.

197. The method of claim 196, wherein the step of aiding transport of the paper comprises the steps of: creating a vacuum; and drawing the paper across the transition.

198. The method of claim 196, comprising the step of accelerating the paper to a predetermined speed.

199. The method of claim 198, comprising the step of maintaining the paper at the predetermined speed across the transition.

200. The method of claim 199, wherein the predetermined speed is at least 1000 ft./min.

201. The method of claim 198, wherein the predetermined speed is greater than a speed at which the paper is fed to the acceleration conveyor.

202. A paper spreader comprising: a bulk spreader having an input end, an output end, and a plurality of rotatable shafts disposed therebetween, the plurality of rotatable shafts including a shaft proximate the output end rotating at an output speed; and an inclined conveyor operably positioned to receive paper from the bulk spreader output end, wherein the inclined conveyor includes a belt operating at a belt speed.

203. The paper spreader of claim 202, wherein the belt speed is greater than the output speed of the bulk spreader.

204. The paper spreader of claim 202, wherein the rotatable shafts include gripping means for gripping paper and propelling paper forward.

205. The paper spreader of claim 204, wherein the gripping means comprises a plurality of discs spaced along the shafts.

206. The paper spreader of claim 205, wherein each disc comprises rubber tipped edges.

207. The paper spreader of claim 205, wherein the discs are non- circular.

208. The paper spreader of claim 207, wherein: the plurality of shafts includes a subset of shafts; and the discs on the subset of shafts are rotated about respective shafts at an angle greater than zero relative to the discs not on the subset of shafts.

209. The paper spreader of claim 208, wherein the angle is 45°.

210. The paper spreader of claim 202, wherein the inclined conveyor is inclined between 15° and 35°.

211. The paper spreader of claim 210, wherein the belt comprises rough-top-rubber material.

212. The paper spreader of claim 210, comprising air assist means for pinning paper to the belt.

213. The paper spreader of claim 212, wherein the air assist means is adapted to fluff paper as the paper cascades off of the belt.

214. The paper spreader of claim 202, wherein:

the bulk spreader is upwardly inclined.

215. A paper spreader comprising: a bulk spreader having an input end, an output end, an input shaft proximate the input end rotating at an input speed, and an output shaft proximate the output end rotating at an output speed, wherein the output speed is greater than the input speed; and an inclined conveyor, inclined between 15° and 35°, operably positioned to receive paper from the bulk spreader, wherein the inclined conveyor includes a belt operating at a belt speed.

216. The paper spreader of claim 215, wherein the belt speed is greater than the bulk spreader output speed.

217. The paper spreader of claim 215, wherein the bulk spreader comprises: an input set of shafts, including the input shaft, rotating at the input speed; and an output set of shafts, including the output shaft, rotating at the output speed.

218. The paper spreader of claim 217, wherein the bulk spreader includes a third set of shafts and the shafts in the third set rotate at an intermediate speed between the input speed and the output speed.

219. The paper spreader of claim 215, wherein the inclined conveyor comprises air assist structure including a blower blowing air toward the belt.

220. The paper spreader of claim 219, wherein the air assist structure comprises air adjustment means for adjusting a volume of air blowing toward the belt.

221. The paper spreader of claim 219, wherein the air assist structure comprises a set of louvers above the belt.

222. The paper spreader of claim 221, wherein the set of louvers are operably positioned to fluff paper as the paper cascades off of the belt.

223. The paper spreader of claim 219, wherein each shaft comprises a plurality of discs.

224. The paper spreader of claim 215, wherein: the bulk spreader comprises three sets of rotatable shafts, the first set including the input shaft and the third set including the output shaft, all shafts in the first set rotate at a first speed equal to the input speed, all shafts in the second set rotate at a second speed greater than the first speed and less than the output speed, all shafts in the third set rotate at a third speed equal to the output speed; each shaft comprises a plurality of discs; the inclined conveyor comprises air assist structure including a blower blowing air on the belt, and a set of louvers directing air; and the belt comprises tacky material.

225. The paper spreader of claim 224, wherein the tacky material is rough-top rubber.

226. The paper spreader of claim 215, wherein the bulk spreader is upwardly inclined at an angle in the range of 10° to 20°.

227. A method of spreading paper comprising the steps of: feeding clumps of paper to a bulk spreader; breaking up the clumps of paper by progressively accelerating the paper; feeding output from the bulk spreader to an inclined conveyor; allowing layers of paper to slide down underlying layers of paper and thereby form new underlying layers; and propelling the underlying layers, including the new underlying layers, up the inclined conveyor.

228. The method of claim 227 wherein the step of breaking up the clumps of paper comprises the step of spreading the paper transversely relative to the paper stream.

229. The method of claim 227, wherein the step of breaking up the clumps of papers comprises undulating the paper stream.

230. The method of claim 229, wherein the step of undulating the paper stream comprises the step of rotating non-circular discs in the bulk spreader.

231. The method of claim 227, comprising the step of operating the inclined conveyor at a speed greater than the speed at which paper is fed from the bulk spreader.

232. The method of claim 231, comprising the step of gripping the underlying layers of paper with a belt having a tacky surface.

233. The method of claim 231, comprising the step of pinning the paper to the belt with air.

234. The method of claim 231, comprising the steps of: propelling the underlying layers of paper downstream at a speed greater than a speed at which paper is being output from the bulk spreader; and spreading the paper into thinner layers.

235. The method of claim 231, comprising the step of fluffing the paper as it cascades off of the end of the inclined conveyor.

236. The method of claim 235, wherein the step of fluffing comprises directing air flow.

237. A method of handling paper comprising the steps of: receiving paper in a bulk spreader; spreading the paper in the bulk spreader; positioning an incline conveyor to receive output from the bulk spreader; transporting paper contacting a belt in the incline conveyor up an incline; and allowing upper layers of paper to slide over lower layers of paper.

238. The method of claim 237, wherein the step of transporting comprises operating the incline conveyor belt at a higher speed than an output of the bulk spreader.

239. The method of claim 238, wherein the step of spreading the paper in the bulk spreader comprises the step of progressively increasing a speed at which the paper in the bulk spreader travels as the paper travels downstream.

240. The method of claim 238, wherein the step of spreading the paper in the bulk spreader comprises the step of thinning layers of paper.

241. The method of claim 240, wherein the step of thinning layers of paper comprises the step of accelerating underlying layers of paper relative to overlying layers of paper.

242. The method of claim 238, wherein the step of transporting comprises the step of inclining the incline conveyor between

15° and 35°.

243. The method of claim 242, wherein the step of allowing upper layers of paper to slide comprises the step of accelerating underlying layers of paper contacting the incline conveyor belt relative to overlying layers of paper above the underlying layers of paper.

244. The method of claim 242, comprising the step of pinning the lower layers of paper to the incline conveyor belt with air.

245. The method of claim 242, comprising the step of fluffing the paper with air.

246. The method of claim 245, wherein the step of fluffing the paper comprises the step of directing air proximate an end of the incline conveyor belt to fluff paper as it cascades off of the end of the incline conveyor belt.

247. A method of supplying paper comprising the steps of: receiving paper into an input end of a bulk spreader; feeding paper output from the bulk spreader to an incline conveyor; and spreading the paper into thinner layers of paper, relative to paper layer thicknesses near the bulk spreader input end, as the paper travels downstream from the bulk spreader input end.

248. The method of claim 247, comprising the step of positioning the incline conveyor adjacent to and downstream of the bulk spreader.

249. A paper spreader comprising: a frame having a length, an input end and an output end; a plurality of rotatable shafts disposed in the frame, the shafts being transverse to and spaced along the length of the frame, wherein the plurality of shafts includes a first shaft proximate the input end rotating at a first speed and a second shaft closer to the output end rotating at a second speed, and wherein the second speed is greater than the first speed; and a plurality of discs spaced along each shaft.

250. The paper spreader of claim 249, wherein the plurality of shafts lie in a common plane.

251. The paper spreader of claim 250, wherein the common plane is horizontal relative to a floor.

252. The paper spreader of claim 250, wherein the common plane lies at an angle in the range of 10° to 20° relative to a floor.

253. The paper spreader of claim 249, wherein: the plurality of shafts comprises a first set of shafts, including the first shaft, a second set of shafts, including the second shaft, and a third set of shafts, the third set being closer to the output end than the second set; and the paper spreader includes a drive means for driving the plurality of shafts so that the first set of shafts rotate at the first speed, the second set of shafts rotate at the second speed, and the third set of shafts rotate at a third speed, wherein the third speed is greater than the second speed.

254. The paper spreader of claim 253, wherein the third speed is at least twice as great as the first speed.

255. The paper spreader of claim 254, wherein the first speed is at least twice as great as a speed at which paper is fed into the spreader.

256. The spreader of claim 253 wherein: the first speed is less than 200 ft./min.; and the third speed is greater than 300 ft./min.

257. The spreader of claim 253, wherein the discs are bulged triangular discs.

258. The spreader of claim 257, wherein the discs on the first set of shafts are rotated 45° about respective shafts relative to the discs on the second set of shafts.

259. The spreader of claim 253, wherein the discs are non-circular and the discs on the first set of shafts are rotated 45° about respective shafts relative to discs on the second set of shafts.

260. The spreader of claim 249, wherein the discs are bulged triangular discs.

261. The spreader of claim 260, wherein the plurality of discs include a subset of discs rotated 45° about respective shafts relative to a remainder of the plurality of discs.

262. The spreader of claim 261, wherein each of the discs of the subset are interspersed among the remainder of the discs.

263. The spreader of claim 262, wherein the discs on respective shafts are rotated equal amounts about the respective shafts.

264. The spreader of claim 263, wherein the shafts having the subset of discs are alternated with shafts having the remainder of the plurality of discs.

265. The spreader of claim 260, wherein the bulged triangular discs comprise rubber tipped edges.

266. The spreader of claim 249, wherein the discs comprise edges having means for propelling paper.

267. The spreader of claim 249, wherein the frame has an opening beneath the rotatable shafts and the shafts are spaced apart to allow material below a predetermined size to fall between shafts through the opening.

268. A method of spreading batches of paper comprising the steps of: feeding paper to a plurality of rotatable shafts; progressively accelerating the paper as the paper travels downstream by rotating shafts at downstream locations faster than shafts at upstream locations; and allowing the paper to spread.

269. The method of claim 268, wherein the step of progressively accelerating the paper comprises the step of gripping the paper with gripping means spaced along the shafts.

270. The method of claim 268, wherein the step of allowing the paper to spread includes the step of separating layers of paper into thinner layers of paper as the paper travels downstream.

271. The method of claim 268, further comprising the step of vibrating the paper.

272. The method of claim 271, wherein the step of vibrating the paper comprises the step of undulating the paper stream.

273. The method of claim 272, wherein the step of undulating the paper stream comprises the step of rotating non-circular discs disposed along the shafts.

274. The method of claim 273, wherein the plurality of shafts comprises at

least two sets of shafts, and the step of progressively accelerating the paper comprises the steps of: rotating the shafts in one of the at least two sets at a first speed; and rotating the shafts in another of the at least two sets at a second speed, wherein the second speed is greater than the first speed and wherein the other set is downstream of the one set of shafts.

275. The method of claim 268, wherein the acceleration step includes accelerating the paper up an inclined path with the rotatable shafts.

276. A method of handling paper comprising the steps of: receiving paper into a spreader; vibrating the paper; accelerating lower layers of paper relative to upper layers of paper; and allowing the paper to spread into thinner layers as the paper progresses downstream.

277. The method of claim 276, wherein the step of vibrating the paper comprises the step of impacting the paper stream at regular time intervals between impacts as the paper travels downstream.

278. The method of claim 276, wherein the step of impacting the stream of paper comprises rotating non-circular discs below the paper stream such that the discs interact with the paper stream, and rotating discs downstream at a greater speed than discs upstream.

279. The method of claim 276, wherein the step of accelerating lower layers of paper comprises the step of gripping the lower layers of paper, and allowing the upper layers of paper to slide relative to the lower layers of paper.

280. The method of claim 279, wherein the step of gripping the lower layers of paper comprise the step of rotating rubber strips on rotating shafts.

281. The method of claim 280, wherein the step of rotating the rubber strips comprises the steps of attaching the rubber strips to discs on the rotating shafts.

282. The method of claim 276, wherein the step of accelerating the paper comprises the steps of: rotating first, second, and third sets of rotatable shafts; rotating the first set of shafts at a first speed, wherein the first speed is greater than the speed at which the spreader receives paper; rotating the second set of shafts at a second speed, wherein the second speed is greater than the first speed; and rotating the third set of shafts at a third speed, wherein the third speed is greater than the second speed.

283. The method of claim 276, wherein the accelerating step includes accelerating the paper up an inclined path.