Perforating apparatus and method for manufacturing a shaped line of weakness

A method of perforating a web, the method comprising:

• rotating a cylinder about a longitudinal cylinder axis, the cylinder comprising an outer circumferential surface, wherein the outer circumferential surface defines a plurality of recessed portions, wherein a plurality of anvil blocks are positioned within the plurality of recessed portions, wherein the plurality of anvil blocks are radially disposed about the outer circumferential surface and define cavities therebetween, and wherein each of the plurality of anvil blocks comprise an anvil bead;
• operatively engaging a blade with the anvil beads, wherein the blade is substantially parallel to the longitudinal cylinder axis, and wherein at least one of the blade and the anvil comprise a plurality of teeth;
• feeding a web between the cylinder and the blade while the blade cooperates in contacting relationship with the anvil bead;
• perforating the web to form a shaped line of weakness;
• generating debris from perforating the web;
• controlling the debris such that the debris is drawn into the cavities between the anvil blocks and away from the web;
• expelling the debris from the cavities of the rotating cylinder,
• wherein the cylinder comprises a cylinder diameter,
• wherein the anvil block comprises an anvil block surface, the anvil block surface having an anvil block diameter,
• wherein the anvil bead comprises an anvil bead tip, the anvil bead tip having an anvil bead diameter,
• wherein the difference of the cylinder diameter and a diameter of an outer boundary circumferential surfaces of the anvil blocks is from 0.6 inches to 0.8 inches, and
• wherein the difference of a diameter of an outer boundary circumferential anvil beads and the diameter of the outer boundary circumferential surfaces of the anvil blocks is from 0.2 inches to 0.4 inches,
• wherein the difference of the anvil bead diameter and the anvil block diameter is from 0.2 inches to 0.4 inches.