Foam-Based Manufacturing System and Process

A system comprising:

• a pulper configured to (i) accept surfactant, a liquid and a fiber stock, and (ii) provide a foam in which the fiber stock is suspended, and (iii) mix the surfactant, the liquid, and the fiber stock to provide the foam;
• a headbox configured to receive the foam-suspended fiber stock from the pulper and displace the foam-suspended fiber stock onto a forming wire;
• a conduit connecting the pulper to the headbox, wherein the conduit is configured to move the foam-suspended fiber stock from the pulper to the headbox in a foam state, further wherein the conduit connecting the pulper to the headbox is configured such that the foam to fiber stock consistency between the pulper and the headbox does not change by more than 50%;
• a foam return device that removes at least some of the foam from the forming wire and returns the at least some of the foam to the pulper, the at least some of the foam remaining in a foam state from the forming wire to the pulper.

A method comprising:

• providing a foam in a pulper containing a surfactant, water, and a fiber stock mixture;
• transporting the foam in which the fiber stock is suspended through a conduit to a headbox in a foam state;
• displacing the foam and fiber stock on a forming wire;
• and
• returning at least a portion of the foam from the forming wire to the pulper in a foam state, wherein the conduit connecting the pulper to the headbox is configured such that the foam to fiber stock consistency between the pulper and the headbox does not change by more than 50%.