Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: An acoustical geopolymer panel element includes a layer including a fibre component and a geopolymer binder made from a mixture including ground mineral wool, and an additional layer including mineral wool. The layer including a fibre component and a geopolymer binder has a density in the range of 20-400 kg/m3, a porosity in the range of 0.75-0.99 and a thickness in the range of 5-75 mm. The ground mineral wool may be ground glass or stone wool and the fibre component may be a wood fibre component, a polymer fibre component and/or a mineral wool component. Further, a geopolymer mixture is provided upon recycling mineral wool which is ground to powder and mixed with an alkali activator component. Additionally, a method for producing acoustical geopolymer panel elements includes grinding elements including mineral wool for provision of a powder component.

Abstract: A method for producing a structured fibrous web, in particular a tissue web, includes bringing a fibrous suspension into contact with at least one structured forming belt and dewatering by using at least one dewatering element, in particular a suction element. The at least one structured forming belt includes a layer of polymer foam providing a paper-contacting side of the structured forming belt. The structure of the foam layer is at least partially transferred to the fibrous web. A structured forming belt and a machine for producing a fibrous web are also provided.

Abstract: A coater assembly includes an array of side-by-side selectively closable slot portions to control pressurized fluid flow onto a substrate during relative movement between the coater assembly and the substrate to form a coating pattern on the substrate. A control module produces the coating pattern via control over selective independent closure of the slot portions based on a mapping matrix of individually addressable coatable elements.

Abstract: Methods related to inductive heating in extruders. In some embodiments, a method for heating a feedstock or liquid material can include providing a heating body having inlet and outlet orifices connected via a passage or passages or mixing chamber to define a nozzle, and forming a magnetic loop with a coil of conductive wire wound through the center and around the outside of a core of magnetic but electrically non-conductive or low-conductivity material. The method can further include a high-frequency alternating current applied to the coil, producing a magnetic flux locally heating the nozzle. Some embodiments have passive regulation or limiting of nozzle temperature by selection of a core material with an appropriate Curie temperature.

Abstract: Paper product is made starting from aqueous furnish containing fibers and filler. Anionically charged nanofibrillar cellulose and cationic strength additive are added to the aqueous furnish, and the furnish is made to a paper product by dewatering the furnish. Filler content of the paper product can be increased above 40 wt-%.

Abstract: One embodiment of a heated nozzle for extruding meltable material consists of an electrically conductive nozzle, comprised of an inlet, an outlet, and a passage connecting inlet and outlet. The nozzle fits into a hole or gap cut or formed through a loop of high permeability soft magnetic material such as ferrite or pressed iron powder. Electrically conductive wire is coiled around and through this magnetic loop to form a coil. A high-frequency alternating current is supplied to the coil, inducing a magnetic field in the magnetic core. The magnetic field, when passing through the electrically conductive nozzle, induces eddy currents that heat the nozzle to melt the material entering the inlet.

Abstract: A method for individualizing a trichome from an epidermis of a non-seed portion of a trichome-bearing plant in the Stachys genus to form a fibrous structure is provided. The method comprises contacting the plant with a device to separate the trichome from the epidermis and incorporating the separated trichome into a fibrous structure.

Abstract: Processes for making fluff pulp sheets mechanically eliminate many unwanted fiber-to-fiber bonding (fiber bundles) in the sheet. Pulp slurry is deposited on a moving bottom forming wire to form a stock web. Pulp slurry is brought into contact with a moving top forming wire. The stock web is subjected to up and down dewatering creating separately formed layers to reduce fiber-to-fiber bonding. The stock web can be subjected to strong pulsating shear forces as it is being advanced along the bottom forming wire to break fiber bundles. The pulp slurry can be deposited on the bottom forming wire utilizing a headbox with dilution control to selectively adjust the concentration of the pulp slurry. Shoe presses can be used to dewater the web after it is subjected to the pulsating shear forces.

Abstract: Disclosed herein are cylinder forming apparatuses for making nonwoven webs. In one embodiment, a cylinder forming apparatus has a first source configured to dispense a first fluid flow stream, and a second source configured to dispense a second fluid flow stream, wherein at least the first fluid flow stream comprises a fiber; an arcuate mixing partition downstream from the one or more sources, the arcuate mixing partition positioned between the first and second flow streams, the apparatus defining one or more openings that permit fluid communication between the two flow streams; and a cylindrical receiving region situated downstream from the sources and proximal to the first flow stream and designed to receive at least a combined flow stream and form a nonwoven web by collecting fiber from the combined flow stream. Methods of using the apparatuses are also disclosed.

Abstract: A forming section for a gap blade former type papermaking machine having a headbox which delivers a jet of papermaking stock between a conveying forming fabric and a backing forming fabric is provided. The conveying fabric moves in sliding contact over an impingement shoe on which the jet of papermaking stock is delivered at a point of impingement. A forming shoe located immediately downstream of the impingement shoe over which the backing forming fabric slides. The impingement shoe is mounted for at least one of pivoting and transverse movement so that a position of the point of impingement of the jet of papermaking stock can be adjusted by at least one of rotating the impingement shoe about a first pivot point and transversely shifting the impingement shoe. The forming shoe can also be mounted for movement.

Abstract: A multiple mode headbox is provided including a support surface, two or more chambers, and an adjustable roof. Each chamber includes a plurality of nozzles adapted to optionally supply papermaking fibers to the support surface. The adjustable roof is operably configured to adjust over a range of movement such that it defines a forming zone between the support surface and at least one chamber in a first mode, and between said support surface and at least one different said chamber in a second mode.

Abstract: Methods for achieving even transverse distribution and propagation of a flowing medium are disclosed in which the flowing medium is supplied through a conduit and is deflected during diverging propagation in at least one distribution gap. The method includes deflecting the flowing medium during diverging propagation along the distribution gap in which the medium is conveyed through a passage to an outlet gap having a larger depth than the depth of the distribution gap. The medium is conveyed over an edge of the passage extending transverse to the direction of the flow, and the edge is designed to obtain a propagation along the flowing path of the diverging medium that provides a substantially even and parallel flow of the medium along the outlet gap. Apparatus for achieving this method is also disclosed.

Abstract: The present invention relates to a method for machining of a surface (31) of a roll in a twin-wire press (2), comprising lower rolls (4, 6, 8, 25?), an endless lower wire (10), upper rolls (14, 16, 18, 25?), and an endless upper wire (12). The rolls comprise a coating (32). An apparatus (50) having a movable machining tool (54) for machining of the coating (32) is arranged in connection to a space between a wire (10, 12) and a roll (4, 6, 8, 14, 16, 18, 25?, 25?). The machining tool (54) of the apparatus is moved, in contact against the surface of the roll (31) for cutting of the coating (32) to a desired level during rotation of the roll. The present invention also relates to an apparatus (50) for machining of a surface (31) of a roll in a twin-wire press for dewatering of a fiber suspension comprising said apparatus.

Abstract: The invention relates to a process for blending liquid flows, particularly in the approach system to a paper machine. It is characterized by the individual liquid flows being merged, blended with one another, and degassed, all at the same time. In addition, the invention relates to a device for implementing the process, where a degassing device 5, particularly a rotor with degassing holes, is provided in a mixing pipe 1.

Abstract: This invention relates to a method for producing a fibrous web from at least one fibrous suspension in a twin mesh former with a twin mesh zone which has a wedge-shaped intake nip and is formed at least in some sections by two rotating endless meshes, of which the first mesh, which is passed over a preferably positionable inlet roller, is passed in the double mesh zone over several rails rigidly arranged a distance from each other on a preferably movable dewatering box, and of which the second mesh is passed in the twin mesh zone over several rails which are arranged opposite the rails of the preferably movable dewatering box, are supported by way of compliant elements and are pressed with a selectable force against the second mesh.

Abstract: A multiple mode headbox is provided including a support surface, two or more chambers, and an adjustable roof. Each chamber includes a plurality of nozzles adapted to optionally supply papermaking fibers to the support surface. The adjustable roof is operably configured to adjust over a range of movement such that it defines a forming zone between the support surface and at least one chamber in a first mode, and between said support surface and at least one different said chamber in a second mode.

Abstract: Twin-wire former for producing a fibrous web. The former includes two endless wire belts arranged to form a twin-wire zone, a dewatering element, and a headbox positioned at an angle relative to an imaginary first horizontal plane. The twin-wire zone includes a first section in which the two wire belts are arranged to run over the dewatering element. The two wire belts are further positioned to form a wedge-like inlet gap that is structured and arranged to receive a fibrous stock suspension directly from the headbox. Additional dewatering elements are utilized. The twin-wire zone includes a second section in which the two wire belts along with the fibrous web formed between the two wire belts are arranged to run downward over the additional dewatering elements. This Abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way.

Abstract: In a process and an arrangement for directing a papermaking pulp towards a regulated outlet (9), accept from successive cleaning stages (6, 14, 20) is totally or partly led towards the outlet (9) while excess accept is led in the opposite direction to the inlet (5) of the preceding cleaning stage (6). For feeding of a forming wire, a common base pipe (8) for collecting accept extends between the outlet (9) and a feeding (3) for fresh pulp, while reject pipes (11, 18) lead to the next cleaning stage (14, 20).

Abstract: Apparatus and process for controlling the basis weight cross-profile, the formation, the fiber direction and other quality parameters of a pulp sheet after the headbox in a dewatering plant. The apparatus including at least one suspension feed, at least one distribution device and at least one drainage device for excess suspension from the distribution device, where the distribution device has a distribution chamber and a turbulence-generating chamber made up of a number of pipes adjacent to one another. It is mainly characterized by the two peripheral zones of the headbox, comprising distribution chamber and turbulence-generating chamber, each having a discharge device in the sheet running direction for a partial suspension stream.

Abstract: A paper/board machine headbox (10) has a stock inlet header (J), a tube bank (11), a turbulence generator (13) and a slice opening (14) which is provided with a profile bar. The headbox (10) is provided with cross direction measuring sensors (D1, D2; Dmn), by means of which the flow rate profile of the headbox (10) is determined, and the profile bar of the slice opening (14) of the headbox (10) is adjusted in the cross direction on the basis of the thus determined flow rate profile. The headbox (10) is provided with measuring sensors (D1, D2; Dmn) for determining the cross direction flow rate profile of the headbox (10) and with means for adjusting the profile bar on the basis of the flow rate profile.

Abstract: A method for manufacturing paper having a variable characteristic in a crossmachine direction including the steps of feeding a slurry to a distributor and delivering the slurry from the distributor to a headbox through a plurality of delivery lines. The delivery lines are coupled to the headhox at a plurality of locations spaced across the headbox in a crossmachine direction. The method includes selectively introducing a property altering agent in at least two of the delivery lines at the distributor to selectively alter the properties of the slurry passing through the at least two delivery lines. The method also includes the step of depositing the slurry received by the headbox on a papermaking wire to form paper.

Abstract: A pulp moulding process including the steps of pulp stock, forming wet products by means of forming die (7), transferring the wet products from the forming die by means of a heated transferring die-and-heated pressing tool arrangement (13)(14) for in-mould pressing and drying of the wet product, and delivering the dried products to a down line facility (18). The invention encompasses a pulp moulding system, a pulp moulding apparatus, and a pulp moulded product made by such a process, system and/or apparatus.

Abstract: In a paper machine headbox, a stock suspension flow passes through turbulence pipes (14an) and is distributed into superimposed layers. Stepped expansion spots (16) of the flow cross-section area of the turbulence pipes (14) or the positions of trailing elements starting from between the pipe rows (Rn) and extending to the slice duct (12) of the headbox control the onset and level of turbulence in each layer. Turbulence is generated in different phases of the flow in different layers by arranging the expansion spots (16) and/or the trailing elements in superimposed layers to be located at different distances from the slice opening (13) of the headbox, whereby a different turbulence prevails at the slice opening (13) in different layers of the stock suspension flow.

Abstract: This invention, in one aspect, relates to a multi-ply paperboard having at least three inner plies and, in some aspects, a top liner and a back liner, wherein the multi-ply paperboard is derived from fiber sources comprising at least about 80% by weight recycled fiber. The multi-ply paperboard of the present invention exhibits strength characteristics comparable those of paperboard prepared from virgin board. In further aspects, the invention relates to methods of making the multi-ply paperboard of the present invention.

Abstract: The invention provides tube bank structure and a method of manufacturing a flow tube, which can improve the stabilization of the flow of stock in the tube bank of the headbox of a papermaking machine and prevent the development of turbulence and uneven concentration of stock flow by a simple and inexpensive means, resulting in speedup of papermaking process. Said flow tubes has a smaller diameter pipe portion of a circular cross-section in the inlet side, a larger diameter pipe portion connected to said smaller diameter pipe portion, a tapered pipe portion, and a rectangular pipe portion, the cross-sectional configuration of said tapered pipe portion being changed smoothly from circular to rectangular configuration.

Abstract: This invention, in one aspect, relates to a multi-ply paperboard having at least three inner plies and, in some aspects, a top liner and a back liner, wherein the multi-ply paperboard is derived from fiber sources comprising at least about 80% by weight recycled fiber. The multi-ply paperboard of the present invention exhibits strength characteristics comparable those of paperboard prepared from virgin board. In further aspects, the invention relates to methods of making the multi-ply paperboard of the present invention.

Abstract: Process for forming and a headbox for producing a fibrous material web from a pulp suspension to form one of a paper or cardboard web. The headbox includes a headbox nozzle and at least one lamella, and the process includes providing a structured surface with at least one structure one of in and on a surface of the at least one lamella, such that the structured surface is arranged to generate cross flows inside the pulp suspension, whereby the cross flows lead to shear flows in the suspension stream.

Abstract: In the short circulation of a paper machine, a chemicals flow (F1) is fed into a fibre suspension flow in connection with a pipe expansion comprising a first pipe (1) and a second pipe (2) having a larger diameter than the first pipe, which pipes are connected to each other by means of an expansion step (3) perpendicular to the direction of flow. The chemicals flow (F1) can be passed so as to be mixed with the fibre suspension flow either in the second pipe (2) in an ideal mixing zone situated after the expansion step (3) or in the first pipe (1) so close to the expansion step (3) that the chemicals which are added have no time to react with the fibre suspension before the flow enters the expansion step (3).

Abstract: The present invention relates to a method of and an apparatus for controlling the operation of the short circulation of a paper, paper board or the like production machine. The method and apparatus according to the invention are especially preferably suitable for use in the approach system, i.e. so-called short circulation, of said production machines for regulating the headbox feed pressure. A characteristic feature of the method and apparatus according to the invention is that at a suitable location in the approach system of said production machine there is arranged a controllable parallel flow, by means of which at least one flow in the approach system is regulated so that the pressure in the headbox remains essentially constant.

Abstract: Dispersed powders are disclosed that comprise fine nanoscale powders dispersed on coarser carrier powders. The composition of the dispersed fine powders may be oxides, carbides, nitrides, borides, chalcogenides, metals, and alloys. Fine powders discussed are of sizes less than 100 microns, preferably less than 10 micron, more preferably less than 1 micron, and most preferably less than 100 nanometers. Methods for producing such powders in high volume, low-cost, and reproducible quality are also outlined. Such powders are useful in various applications such as catalysts, sensor, electronic, electrical, photonic, thermal, biomedical, piezo, magnetic, catalytic and electrochemical products.

Abstract: A process, and an apparatus, for improving sheet properties in the initial impingement zone of a paper making machine including a forming section, a forming fabric moving in the machine direction and a head box having a head box slice which delivers a stock jet onto the moving forming fabric. The scale and intensity of agitation within the stock is adjusted by adjusting some of the support elements beneath the forming fabric adjacent the head box slice so that they either contact, or do not contact, the machine side surface of the forming fabric and observing the effect, if any, that the adjustment has on the quality of the sheet product being made on the paper making machine. This technique is of use in a papermaking machine forming section having a single open surface forming fabric, in the initial open surface section of a so-called hybrid gap former having two superposed forming fabrics, and in the forming section of a two fabric papermaking machine.

Abstract: This invention relates to an improved structure of a head box for a paper making machine. The sidewalls of a nozzle of a head box shall be movable with the rotation of a roll transporting a forming wire of the paper making machine. Thus, the homogeneity of produced paper can be improved and the production rate of paper increased.

Abstract: A cylinder former having a variable hydraulic pulse whilst drainage, for use in papermaking comprising a drainage means comprising a cylinder mould and a contoured member adjacent the cylinder mould having a plurality of hills and valleys which force entrained liquid through the fiber suspension forming on the cylinder mould so as to improve sheet formation. A baffle is provided in the discharge portion of the former to prevent stock build-up therein.

Abstract: This invention relates to an improvement in coatings particularly suited for the preparation of paper products having an ink jet coating applied thereto and to the resulting paper products. The improvement in ink jet coatings resides in the incorporation of a primary amine functional polyvinyl alcohol (PVOH/PVNH2) as a polymeric binder. One form of an amine functional polyvinyl alcohol is produced by the hydrolysis of a copolymer of vinyl acetate and N-vinylformamide or vinyl acetate and allyl amine. Another is the polyvinyl butyral derivative of polyvinyl alcohol which typically is formed by the reaction of a 4-amino alkyl aldehyde dialkyl acetal, such as 4-aminobutyraldehyde dimethyl acetal with polyvinyl alcohol.

Abstract: Method and apparatus for controlling the mixing proportions of feed streams being supplied to a headbox, using devices for sampling two or more of the feed streams upstream of the headbox and devices for measuring concentration of constituents in or other properties of those samples. A method of regulating one or more properties of a moving web, and especially a paper web during manufacture, employing the aforesaid method and apparatus are also disclosed.

Abstract: Apparatus and process for controlling the basis weight cross-profile, the formation, the fiber direction and other quality parameters of a pulp sheet after the headbox in a dewatering plant. The apparatus including at least one suspension feed, at least one distribution device and at least one drainage device for excess suspension from the distribution device, where the distribution device has a distribution chamber and a turbulence-generating chamber made up of a number of pipes adjacent to one another. It is mainly characterized by the two peripheral zones of the headbox, comprising distribution chamber and turbulence-generating chamber, each having a discharge device in the sheet running direction for a partial suspension stream.

Abstract: The invention relates to a process for distributing an especially medium-consistent fibrous suspension in front of a dewatering device. It is distinguished in that the fibrous suspension is taken to the dewatering device in fluidized form and evenly distributed. The invention also relates to a device for implementing the process in which there is a closed device with a fluidizing rotor in front of the dewatering device.

Abstract: A mat containing highly machine direction oriented (90% or greater), discontinuous reinforcement fibers, is produced on inclined wire or rotary paper making machinery. Fibers are first uniformly dispersed in an aqueous medium containing thickeners and wetting agents. In one embodiment, antifoaming agents are also added to prevent floating fibers which entangle and reduce orientation. Thermoplastic fibers or particles may also be included. Stock is brought into an open headbox in a flow pattern which allows the fibers to decelerate before approaching the porous suction belt (wire). As the fibers approach the suction belt, the fibers begin to turn and align in the streamline so as to present one end toward the suction wire. The leading ends of the fibers are gripped by the moving belt which drags the fibers out of the dispersion stock in a straight line. The porous mat produced may be dried and bonded through hot air, heat and/or pressure, or chemical binders.

Abstract: Methods and apparatus to condition the paper fiber stock of a wet paper web for enhanced dewatering and formation with an acoustic foil assembly used for removing water and redistributing fibers. A plane ultrasonic wave field is employed for interacting with water suspended pulp and paper fiber stock using acoustic techniques to subject particulate suspensions. The continuous process employees a piezoelectric ceramic transducer to selectively deflect flowing paper fiber stock as they penetrate the ultrasonic field. Depending upon the amount of dissolved gas in water, conditioning is obtained using a traveling wave field to improve paper properties for increased productivity and formation quality with headbox components having hydrodynamic optimization for paper and board forming.

Abstract: Method for forming a continuous web on a forming fabric includes providing a pressurized chamber, processing the forming fabric through the pressurized chamber, and distributing a pressurized flow of a slurry having a first composition in the pressurized chamber across the width of the forming fabric to form the continuous web.

Abstract: Methods and apparatus to enhance paper and board forming qualities with insert tubes and/or a diffuser block in the paper forming machine headbox component which generates vorticity in the machine direction (MD) which is superimposed on the streamwise flow to generate a swirling or helical flow through the tubes of the diffuser block. Tubes of the diffuser block are designed such that the direction of the swirl or fluid rotation of the paper fiber stock may be controlled and the direction thereof is controlled in such a way to provide effective mixing, coalescence and merging of the jets of fluid emanating from the tubes into the converging section, i.e., nozzle chamber of the headbox. Also disclosed is the effective mixing of the jets generating cross-machine direction (CD) shear between the rows of jets that form at the outlet of the tubes inside the nozzle chamber of the headbox to align paper fibers in the cross-machine direction.

Abstract: A multi-ply web forming method and apparatus are disclosed for forming a top ply onto a base ply. A fiber suspension jet is by means of a secondary headbox (21; 21′, 26) delivered into a twin-wire roll nip created by two tensioned wires (16, 22; 16′, 22′; 22, 27) one of which (16; 16′, 22) carries the moist base ply.

Abstract: A sheet forming system of a paper or cardboard machine. A headbox includes a headbox nozzle with to laterally extending side panels and first and second nozzle walls extending along a width of the machine. First and second screens converge in a region adjacent the headbox nozzle. At least two guide mechanisms, each having a guide surface, guide the first and second screens in the region. At least one support mechanism supports at least a portion of one of the first and second nozzle walls against said guide surface of at least one of said at least two guide mechanisms.

Abstract: An apparatus and method for forming a thin fibrous mat, such as a tissue sheet, with improved edge strength is disclosed. The apparatus includes a headbox having a top, a bottom, a pair of lateral sides, a back with an inlet formed therein and a front with an outlet formed therein. A first conduit is connected to the inlet of the headbox and flow therethrough is regulated to convey a first aqueous slurry at a desired flow rate into the headbox. The first aqueous slurry has a predetermined fiber consistency. A second conduit is connected to one of the lateral sides of the headbox and a second aqueous slurry is directed therethrough into the headbox at a different flow rate than through the first conduit. The apparatus also includes a mechanism for drying or draining water from the aqueous slurry exiting the outlet to form a thin fibrous mat. The thin fibrous mat has increased strength adjacent to an edge located downstream from the second conduit.

Abstract: Method and apparatus for controlling the mixing proportions of feed streams being supplied to a headbox, using devices for sampling two or more of the feed streams upstream of the headbox and devices for measuring concentration of constituents in or other properties of those samples. A method of regulating one or more properties of a moving web, and especially a paper web during manufacture, employing the aforesaid method and apparatus are also disclosed.

Abstract: The present invention relates to transfer paper in electrophotography that shrinks by no more than 0.45% in a direction crossing a flow in making paper process and which has a two sideness shrinkage difference in a crossing direction ranging 0.02 to −0.02%. The present invention also relates a process for producing electrophotographic transfer paper comprising the steps of feeding pulp suspension liquid onto at least one wire to form a paper layer in making paper process, in which a ratio between feeding speed of the pulp suspension liquid and moving speed of wire is controlled to cause a propagating velocity ratio of longitudinal waves of a produced transfer paper in the range from 1.1 to 1.5.

Abstract: Sheet formation system and method for reducing wavy edges in a fourdrinier machine. The system includes a headbox having a nozzle bring adapted to produce a pulp suspension jet across a width of the machine, at least one rotating screen positioned to receive the pulp suspension jet, and at least two deckle plates adjacent to the screen. The deckle plates may be adjustably positionable such that a distance between the deckle plates and a centerline of the screen is adjustable in a machine direction over a substantial portion of a length of the side shields. The method includes directing a pulp suspension jet onto the rotating shield between the deckle plates to form a web sheet, moving the web sheet in a machine direction, and adjusting a distance between the deckle plates as the web sheet is moved in the machine direction.

Abstract: A headbox in a paper machine, which headbox has a stock outlet for a jet of stock having a specific length, angle of impact and point of encounter in relation to a nip in the wet section of the paper machine, which headbox has two stand parts, lifting arms with front and rear journalling means and a device for setting the position and alignment of the headbox so that the stock jet obtains said specific length, angle of impact and point of encounter, which setting device has two actuators mounted pivotably at the rear Journalling means of the lifting arms and at the stand parts, whereby the headbox is adjustable by means of a turning movement about said front bearing means of the lifting arms.

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.