A system for forming a facer includes a hydroformer that receives a first fluid and a second fluid. A first fluid line is configured to deliver the first fluid to a first inlet pipe and a second fluid line configured to deliver the second fluid to a second inlet pipe. The first fluid line includes a first fiber source that stores a first type of fibers and a first thick stock pump that pumps the first type of fibers to the first inlet pipe. The second fluid line includes a second fiber source that stores a second type of fibers and a second thick stock pump that pumps the second fluid to the second inlet pipe. The first fluid and second fluid are simultaneously poured or delivered onto a porous belt or surface to form the facer.

A method of forming a fibrous web on a papermaking machine including the steps of depositing a dilute fiber slurry out of a headbox to a forming area comprising a forming surface made up of a structured fabric, wherein the structured fabric is supported by a breast roll and a forming roll, and the forming area is devoid of any additional fabrics or belts other than the structured fabric, draining the dilute fiber slurry through the structured fabric, and drying the fiber slurry.

A deckle board system comprising: (a) one or more deckle boards; (b) one or more shower systems; (c) a stand assembly that supports both the one or more deckle board and the one or more shower systems, the stand assembly including: (i) a vertical stand and (ii) a horizontal stand; and (d) one or more actuators connected to the vertical stand, the horizontal stand, or both; and wherein at least one of the one or more actuators is automated so that the at least one of the one or more actuators actuates the vertical stand, the horizontal stand, or both.

An apparatus includes: a defibrating unit that defibrates a material to turn it into fibers; a fiber piling-up unit that piles up the fibers to form a second web; a pressing portion that presses the second web to turn it into a sheet; and a humidifying mechanism that supplies humidified air to the fiber piling-up unit. The fiber piling-up unit includes a rotating portion that stirs the fibers supplied from the defibrating unit, a case in which the rotating portion is housed, and a mesh belt that is provided under the case and transports the second web in a transportation direction. The second web is formed on the mesh belt by piling up the fibers on the mesh belt. The humidifying mechanism includes an upstream-side nozzle that is provided upstream of the fiber piling-up unit in the transportation direction and supplies the humidified air to the fiber piling-up unit.

Methods and apparatuses for producing a zoned and/or layered substrate are described. A method can include providing a first supply of fibers, providing a second supply of fibers, and providing a headbox. The headbox can include a machine direction, a cross-direction, and a first cross-directional divider that separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner. The method can further include transferring the first supply of fibers and the second supply of fibers to the headbox. The method can also include transferring the first supply of fibers and the second supply of fibers through the headbox to provide the substrate.

Methods and apparatuses for producing a zoned and/or layered substrate are described. A substrate can include a first layer including a first zone, a second zone, and an interface between zones. The first zone can include a plurality of fibers. The second zone can include a plurality of fibers and can be offset from the first zone in a cross-direction. The interface can include at least some of the plurality of fibers of the first zone and at least some of the plurality of fibers of the second zone to provide a purity gradient with a transition width less than 3.8 cm as defined by the Purity Gradient Test Method as described herein.

Methods and apparatuses for producing a zoned and/or layered substrate are described. A substrate can include a first layer including a first zone, a second zone, and an interface between zones. The first zone can include a plurality of fibers. The second zone can include a plurality of fibers and can be offset from the first zone in a cross-direction. The interface can include at least some of the plurality of fibers of the first zone and at least some of the plurality of fibers of the second zone to provide a purity gradient with a transition width less than 3.8 cm as defined by the Purity Gradient Test Method as described herein.