Abstract: A method for processing high bulk tissue webs is disclosed for forming a wet web, drying the web, winding the dried web to form a plurality of parent rolls, unwinding the parent rolls by transmitting torque through the roll center and/or ends, moving the partially unwound roll to effect splicing with a subsequent parent roll, and rewinding the thus united web. In particular embodiments, the torque transmitting means comprise side clamping mechanisms that engage only the end surfaces of the parent rolls. In other embodiments, an automated off-line method for splicing tissue webs from different parent rolls utilizes a finishing unit that substantially continuously impacts each web during unwinding to splice the webs together.

Abstract: A method of compressively modifying, such as by calendering, an uncreped throughdried tissue sheet is disclosed. The dried tissue sheet, initially supported by the throughdrying fabric, is removed from the throughdrying fabric and compressively modified. Thereafter, the compressively modified sheet is recombined with a papermaking fabric and carried to a reel section while supported by the fabric. The sheet is always, or substantially always, supported by a fabric or a roll surface to minimize opportunities for sheet breaks or otherwise adversely affecting sheet properties.

Abstract: The energy efficiency of a throughdrying papermaking process is improved by recycling exhaust air from one or more throughdryers to further heat the web at various places in the process.

Abstract: The energy efficiency of a throughdrying papermaking process is improved by recycling exhaust air from one or more throughdryers to further heat the web at various places in the process.

Abstract: A method of compressively modifying, such as by calendering, an uncreped throughdried tissue sheet is disclosed. The dried tissue sheet, initially supported by the throughdrying fabric, is removed from the throughdrying fabric and compressively modified. Thereafter, the compressively modified sheet is recombined with a papermaking fabric and carried to a reel section while supported by the fabric. The sheet is always, or substantially always, supported by a fabric or a roll surface to minimize opportunities for sheet breaks or otherwise adversely affecting sheet properties.

Abstract: A suction breast roll former has a support surface with a plurality of apertures formed therein that are operatively connected to a vacuum source. A headbox has a flexible roof extending downstream from a slice opening and disposed adjacent to a support surface of the suction breast roll. The headbox permits the flexible roof to bend over a range of movement relative to the support surface to match the shape of a drainage curve suiting current operating conditions. A method of forming a paper web includes the steps of supplying an aqueous suspension of papermaking fibers to a forming zone created between the suction breast roll and the headbox. The headbox includes a slice body and an apron that define a slice opening therebetween and also has a flexible roof extending from the slice opening and spaced from the support surface to define a forming zone therebetween. A forming fabric is passed through the forming zone to receive the aqueous suspension of papermaking fibers.

Abstract: A uniformly wound parent roll of soft, high bulk tissue has greater uniformity in sheet basis weight, machine direction stretch and bulk when compared to parent rolls wound by conventional winding methods. The method involves carrying the tissue sheet on a relatively air impermeable transfer belt which traverses an unsupported span between two winding drums. The sheet is transferred from the transfer belt to the parent roll as the parent roll is urged against the sheet/transfer belt at a point within the unsupported span. The resulting deflection of the transfer belt is detected and, in response, the reel spool position is controllably changed to maintain the deflection within predetermined limits. The tension of the sheet is controlled by the predetermined differential speed between the outer most surface of the parent roll and the transfer belt.

Abstract: An apparatus and method for winding tissue webs into a parent roll is disclosed which results in greater uniformity in sheet basis weight, machine direction stretch and bulk when comparing the corresponding sheet properties taken from representative locations throughout the roll. The apparatus and method includes engaging the tissue web against a reel spool with a flexible member such as a transfer belt which traverses an unsupported span between two support rolls. The web is transferred from the transfer belt to the parent roll as the parent roll is urged against the sheet/transfer belt at a point within the unsupported span. The resulting deflection of the transfer belt is detected and, in response, the reel spool position is changed to control the deflection at a desired level. Accordingly, a predetermined light nip pressure can be applied to the roll as the tissue web is wound thereon and large parent rolls of high bulk tissue can be manufactured with desired properties when unwound.