Method and machine for manufacturing paper products using fourdrinier forming

1. A paper making process comprising:

operating a forming fabric of a Fourdrinier machine in a rush mode or a drag mode to promote an initial machine direction alignment of paper fibers within a paper web deposited onto the forming fabric, the Fourdrinier machine including:

1. a forming board section having a plurality of height adjustable blades; and

2. a hydrofoil section having a plurality of height adjustable blades and a control subassembly that controls a height of a respective blade relative to an underside of the forming fabric, wherein the hydrofoil section is a gravity drainage section;

adjusting heights of the plurality of height adjustable blades in the forming board section on to produce a drainage rate so that the paper web has a consistency in the forming board section within a range of 0.1% to 2% to immediately freeze the machine direction alignment of paper fibers and to produce turbulence so that the paper fibers are kept mobile and entanglement of the paper fibers is prevented; and,

adjusting heights of the plurality of height adjustable blades and vacuum levels in the hydrofoil section to gradually achieve a consistency of 5%.

2. The paper making process of claim 1 , wherein the papermachine includes a low-vacuum section and the method includes a step of adjusting a level of vacuum in the low-vacuum section.

3. The paper making process of claim 2 , wherein the low-vacuum section includes a plurality of vacuum assisted foil units and a fixed blade at each end of each of the plurality of vacuum assisted foil units.

4. The paper making process of claim 1 , wherein during the step of adjusting the height of the plurality of height adjustable foil blades the plurality of height adjustable blades are set at a setting of 0 mm so that the height adjustable blades are in the same plane as the forming fabric and the height of the height adjustable foil blades are lowered from the fabric so that the amount of drainage increases.

5. The papermaking process of claim 1 , wherein the hydrofoil section includes a plurality of angle adjustable blades and the process includes a step of adjusting an angle of the plurality of angle adjustable blades.

6. The papermaking process of claim 5 , wherein each of said angle adjustable blades comprise an angle adjustment mechanism arranged therein, an underside of the angle adjustment mechanism being secured to a frame and said angle adjustment mechanism includes an adjustable T-bar that extends across the frame of the Fourdrinier machine, and the method includes a step of rotating a drive so that a leading edge of the angle adjustable blade over a range of angles.

7. The paper making process of claim 5 , wherein the foil blades that are height adjustable and the foil blades that are angle adjustable are alternatingly arranged.

8. The paper making process of claim 5 , wherein the foil blades that are angle adjustable can be varied between an angle of +2 degrees and −4 degrees.

9. The paper making process of claim 1 , wherein the process includes a step of adjusting vacuum levels.

10. The paper making process of claim 1 , wherein the papermachine includes a high-vacuum section located between the low-vacuum section and a couch roll and the low-vacuum section does not include angle adjustable blades or height adjustable blades.

11. A papermaking process comprising:

operating a forming fabric of a Fourdrinier machine in a rush mode or a drag mode to promote an initial machine direction alignment of paper fibers within a paper web deposited onto the forming fabric, the Fourdrinier machine including:

1. a forming board section having a plurality of angle adjustable blades; and

2. a hydrofoil section having a plurality of angle adjustable blades and a control subassembly that controls an angle of a respective blade relative to an underside of the forming fabric, wherein the hydrofoil section is a gravity drainage section;

adjusting angles of the plurality of angle adjustable blades in the forming board section to produce a drainage rate so that the paper web has a consistency in the forming board section within a range of 0.1% to 2% to immediately freeze the machine direction alignment of paper fibers and to produce turbulence so that the paper fibers are kept mobile and entanglement of the paper fibers is prevented; and,

adjusting angles of the plurality of angle adjustable blades and vacuum levels in the hydrofoil section to gradually achieve a consistency of 5%.

12. The paper making process of claim 11 , wherein the papermachine includes a low-vacuum section that includes a plurality of vacuum assisted foil units and a fixed blade at each end of each of the plurality of vacuum assisted foil units, and the method includes a step of adjusting a level of vacuum in the low-vacuum section.

13. The papermaking process of claim 12 , wherein each of said angle adjustable blades comprise an angle adjustment mechanism arranged therein, an underside of the angle adjustment mechanism being secured to a frame and said angle adjustment mechanism includes an adjustable T-bar that extends across the frame of the Fourdrinier machine, and the method includes a step of rotating a drive so that a leading edge of the angle adjustable blade over a range of angles.

14. The paper making process of claim 12 , wherein hydrofoil section includes a plurality of height adjustable blades and the height adjustable blades and the angle adjustable blades are alternatingly arranged, and the angle adjustable blades can be varied between an angle of +2 degrees and −4 degrees.

15. The paper making process of claim 11 , wherein the process includes a step of adjusting vacuum levels, and the papermachine includes a high-vacuum section located between the low-vacuum section and a couch roll and the low-vacuum section does not include angle adjustable blades or height adjustable blades.

16. A paper making process comprising:

operating a forming fabric of a Fourdrinier machine in a square mode to promote an initial cross-machine direction alignment of paper fibers, the Fourdrinier machine including:

1. a forming board section having:

a. a lead blade and

b. a plurality of trailing blades that are height adjustable blades;

2. a gravity assisted hydrofoil section comprising:

a. a plurality of angle adjustable blades that generate a vacuum pulse that dewaters ta stock slurry;

b. a plurality of adjustable T-bars that extend from a first side of the Fourdrinier machine to a second side of the Fourdrinier machine;

3. a low-vacuum section comprising:

a. a vacuum assisted drainage elements; and

b. a plurality of height adjustable blades;

adjusting a height of the plurality of height adjustable blades in the low-vacuum section to create turbulence and water drainage of the paper fibers;

adjusting a height of the height adjustable blades in the forming board section; and

adjusting an angle of the angle adjustable blades in the gravity assisted hydrofoil section to control an amount of drainage.

17. The paper forming process of claim 16 , wherein the forming board section includes a plurality of angle adjustable blades and the process includes a step of adjusting an angle of the plurality of angle adjustable blades.

18. The paper forming process of claim 16 , wherein the forming board section includes a lead blade that is fixed.

19. The paper forming process of claim 16 , wherein the Fourdrinier machine includes a high vacuum system and the process includes a step adjusting vacuum of the high vacuum system.

20. The paper forming process of claim 19 , wherein the high vacuum system is located downstream of the low-vacuum system and upstream of a couch roll, and wherein the high vacuum system is free of angle adjustable blades and height adjustable blades.