From Raw Material to Fiber: The Meticulous Preparatory Work

The entire washi-making process begins with preparing the plant-based raw materials. The primary materials are the bast fibers of plants like *kōzo* (paper mulberry), *mitsumata*, and *ganpi*. First, the harvested branches are steamed, and their outer bark is stripped away. This stripped bark is then carefully sorted by hand into three layers: the outermost black bark (*kurokawa*), the green layer beneath it (*amakawa*), and the innermost white fiber layer used for papermaking, known as *shirokawa*.

Next, the *shirokawa* is boiled in an alkaline solution, such as soda ash or caustic soda. This step, called *shajuku* (boiling), is done to soften the fibers and remove impurities that bind them together. Through this process, the raw material is refined into the pure fibers suitable for making paper.

The Test of Patience: *Chiritori*, the Step that Defines the Paper's Beauty

After the boiling process is complete, the fibers are rinsed and washed in clean water. This is where *chiritori*, a crucial step that greatly influences the quality of the washi, begins. This task involves painstakingly removing any remaining specks of bark, discolored areas, or other tiny impurities (*chiri*) from the fibers, one by one, by hand.

This is an extremely demanding task, with one artisan noting that it is the most time-consuming part of the entire manufacturing process. How meticulously the specks are removed at this stage directly impacts the whiteness and beauty of the finished paper. For example, *ganpi* fibers are known to contain particularly fine impurities, making their *chiritori* process incredibly time-consuming.

Depending on the client's request, the work at this stage can vary. Some papers are made to retain the natural, rustic texture of the raw material, while for others, specks are thoroughly removed to create a pristine white sheet. This patient, manual labor is the foundation for the elegant appearance of washi paper.

Unraveling the Fibers: The *Kōkai* Beating Process

Once the impurities have been removed, the clean fibers move on to a process called *kōkai* (beating). This involves beating the fibers in water to loosen and separate them. The goal is to break down the fiber bundles into individual strands, allowing them to intertwine evenly to form a sheet of paper. While traditionally done with mallets made from oak, machines are sometimes used today.

Beating by hand can take at least two to three hours, and the result is vastly different from machine beating. According to one artisan, while machines are efficient at breaking down fibers, their force can be too strong, sometimes stripping the fibers of their inherent texture and character.

In contrast, fibers that are carefully beaten by hand retain their natural length and suppleness. This imparts a unique softness and a warm, gentle feel to the finished paper. The choice made during this *kōkai* process is a critical factor in determining the final texture and feel of the washi.

The Heart of Washi Making: The Role of Nagashi-zuki and Neri

The beaten fibers are poured into a large vat called a sukibune, marking the start of the papermaking's core process: sheet forming. A vital ingredient here is "neri," a viscous liquid made from the root of the tororo-aoi plant, a type of hibiscus. When mixed with the raw materials in the vat, neri prevents the fibers from sinking or clumping together.

This neri allows artisans to employ nagashi-zuki, a uniquely Japanese technique. They rhythmically rock a tool called a sugeta to create a thin, uniform layer of intertwined fibers. This method involves repeatedly scooping the pulp mixture onto the screen and rocking it to drain excess water, building up the sheet layer by layer.

One artisan explained that preparing the neri is a critical task in itself. Its viscosity changes subtly with the temperature and humidity, requiring daily adjustments to achieve the perfect consistency. This fine-tuning relies entirely on the artisan's years of experience and intuition. Such delicate control is the secret to creating washi that is thin but durable, with a beautifully fine texture.

The Finishing Touches: Pressing and Drying

The freshly formed sheets of paper are still saturated with water. They are carefully stacked one on top of another to form a pile called a shito. This stack is placed in a press, where water is slowly squeezed out over a full day and night. Applying pressure too quickly would ruin the paper’s texture, so this step demands great care.

After pressing, the damp sheets are separated one by one for drying. The traditional method involves pasting each sheet onto a large wooden board, often made from ginkgo wood. A brush is used to smooth out any wrinkles before the boards are left to dry in the sun. The workshop we visited also employed this technique, known as itahoshi (board drying).

More recently, some workshops use steam-heated stainless steel dryers. Once all the steps are complete, each sheet of paper undergoes a strict inspection by a master's eye. Only the finest, hand-picked sheets are shipped out as finished products.