Methods and apparatus for forming fluff pulp sheets

A process for making a fluff pulp sheet, comprising:

• creating a pulp slurry which includes pulp fibers suspended in a liquid, the pulp slurry containing multiple fiber bundles formed from pulp fibers which are bonded together and dispersed within the pulp slurry;
• applying the pulp slurry onto a moving bottom forming wire which moves the deposited pulp slurry in a forward direction to form a web, the pulp slurry being dispensed by a headbox;
• and
• adjusting the cross-directional weight basis of the pulp slurry by diluting at least a portion the concentration of the pulp slurry as it is being deposited from the headbox onto the bottom forming wire.

A process for making a fluff pulp sheet, comprising:

• creating a pulp slurry which includes pulp fibers suspended in a liquid, the pulp slurry containing multiple fiber bundles formed from pulp fibers which are bonded together and dispersed within the pulp slurry;
• placing the pulp slurry into a headbox having dilution control which allows the concentration of the pulp slurry to be diluted as the pulp slurry exits the headbox;
• applying the pulp slurry onto a moving bottom forming wire which moves the deposited pulp slurry in a forward direction to form a web;
• contacting the web with a top forming wire which cooperates with the bottom forming wire to dewater liquid from the web;
• contacting the web with a dewatering machine which contacts the web to remove some of the liquid from the web;
• and
• applying heat to the web to evaporate additional liquid from the web.

A process for making a fluff pulp sheet, comprising:

• creating a first pulp slurry which includes pulp fibers suspended in a liquid, the pulp slurry containing multiple fiber bundles formed from pulp fibers which are bonded together and dispersed within the pulp slurry;
• creating a second pulp slurry which includes pulp fibers suspended in a liquid, the pulp slurry containing multiple fiber bundles formed from pulp fibers which are bonded together and dispersed within the pulp slurry;
• applying the first pulp slurry and second pulp slurry onto a bottom forming wire which moves the deposited pulp slurries in a forward direction to form a multilayered web;
• contacting the multilayered web with a top forming wire which cooperates with the bottom forming wire to dewater some of the liquid from the multilayered web forming a fiber layer against the top and bottom forming wire;
• contacting the multilayered web with a dewatering machine which extracts additional liquid from the multilayered web;
• and
• applying heat to the multilayered web to evaporate additional liquid from the multilayered web.