Process and system for reorienting fibers in a foam forming process

A system for producing webs comprising:

• an enclosed mixing chamber for receiving a foamed suspension of fibers, the enclosed mixing chamber including a top, a bottom, and at least one sidewall, the mixing chamber having a height and a width, the mixing chamber further comprising a front slice wall that terminates a distance from the bottom of the mixing chamber forming a narrow constriction, wherein a foamed suspension of fibers deposited into the mixing chamber is directed out of the mixing chamber through the narrow constriction;
• a moving forming surface in operative engagement with the mixing chamber, the forming surface moving in a machine direction and receiving the foamed suspension of fibers for conveying the foamed suspension of fibers downstream;
• a forming zone positioned adjacent to the narrow constriction of the mixing chamber, the forming zone having a length and being defined by the moving forming surface and a top forming surface, the top forming surface being spaced from the moving forming surface;
• and
• a drying device positioned downstream from the forming zone for drying a web formed in the forming zone.