Method and machine for manufacturing paper products using Fourdrinier forming

A paper making process of producing paper having fibers that are cross machine direction aligned, said process comprising:

• operating a forming fabric of a Fourdrinier machine in a square mode to promote an initial cross-machine direction alignment of the paper fibers;
• adjusting foil blade angles and foil blade heights along with vacuum levels of vacuum assisted dewatering elements in an early sheet forming zone to substantially retard drainage in the early sheet forming zone so that a paper web has a consistency within a range of 0.1% to 2%, wherein the angle and height of the foil blades are adjusted to produce a turbulence to prevent the filers from entangling and to generate random orientation of the fibers so that the fibers have the cross-machine direction fiber alignment;
• and
• wherein after a consistency of 2% is achieved in the early sheet forming zone, the foil blades' angles and heights are adjusted in a second zone to maintain a high level of turbulence until a consistency of 5% is achieved;
• wherein an early drainage is sustained in the paper web along with the high level of turbulence until a consistency of 5% is achieved so that the cross-machine direction fiber alignment is created.

A method of creating paper by actively controlling the orientation of fibers at a wet end of a Fourdrinier, said method comprising:

• providing a forming board section a forming board section including a formline element that comprises:
• three fixed blades and
• three height adjustable blades which are arranged alternately with the three fixed blades, wherein said three height adjustable blades each include a control subassembly that controls a height of each respective height adjustable blade relative to an underside of a forming fabric;
• providing a hydrofoil section having:
• a fixed blade,
• three angle adjustable blade, and
• three height adjustable blades alternatively arranged with the three angle adjustable blades, said three height adjustable blades each including a control subassembly that controls a height of each respective height adjustable blade relative to the underside of the forming fabric;
• and
• providing a low-vacuum section comprising:
• at least one vacuum assisted foil unit and
• at least one vacuum unit,
• wherein said at least one vacuum assisted foil unit comprise:
• one fixed blade and
• six adjustable height blades, in said six height adjustable blades each include:
• a control subassembly that controls a height of each respective height adjustable blade relative to the underside of the forming fabric,
• wherein said at least one vacuum unit comprises seven angle adjustable blades sandwiched by two fixed blades, said seven adjustable angle blades each including a control subassembly that controls an angle of a respective blade relative to the underside of the forming fabric;
• operating the forming fabric of the Fourdrinier machine in a rush or drag mode to promote an initial machine direction alignment of paper fibers within a paper web deposited onto the forming fabric or in a square mode to promote an initial cross machine direction alignment of the paper fibers,
• adjusting blade angles and heights along with vacuum levels on vacuum assisted dewatering units to produce a drainage rate so that the paper web has a consistency in an initial sheet dewatering zone within a range of 0.1% to 2%, wherein the blades are adjusted so that the blade angles produce turbulence to keep the paper fibers mobile and prevent entanglement of the paper fibers in the paper web, and
• adjusting blade angles and heights and vacuum levels after the initial sheet dewatering zone to gradually achieve a consistency of 5%;
• and
• wherein the blades' angles and heights are adjusted to create turbulence levels which prevent disruption of the machine direction fiber orientation achieved in the initial sheet dewatering zone.