Disclosed are single ply creped webs and products made therewith. The webs and products are generally durable, flexible In and highly dispersible. For example, the creped single ply tissue products have a Slosh time less than 1 minute, and more preferably less than about 30 seconds, and a wet cross-machine direction (CD) tensile strength greater than about 100 g/3″. The foregoing properties are achieved even in those instances where the products comprise a latex binder disposed on an outer surface. For example, the tissue products may be produced by a print crepe process that disposes a non-crosslinked latex binder on at least one of the product's outer surfaces.

Toilet paper includes at least two sheets on which embossments are formed and that are joined together in a nested manner. The area of a top part of an embossed protrusion of each of the embossments is between 0.8 mm.sup.2 and 1.5 mm.sup.2, and the area percentage of top parts of embossed protrusions of the embossments is between 5% and 10%.

Toilet paper includes at least two sheets on which embossments are formed and that are joined together in a nested manner. The area of a top part of an embossed protrusion of each of the embossments is between 0.8 mm.sup.2 and 1.5 mm.sup.2, and the area percentage of top parts of embossed protrusions of the embossments is between 5% and 10%.

A method of making a molded paper web. The method includes forming a nascent web from an aqueous solution of papermaking fibers, moving a dewatered web on a transfer surface, and applying a vacuum at a molding zone defined between the transfer surface and a molding roll. The molding roll includes a permeable patterned surface on an exterior of the molding roll. The method also includes transferring the dewatered web from the transfer surface to the permeable patterned surface at the molding zone. The vacuum is applied during the transferring of the dewatered web, and the papermaking fibers of the dewatered web are (i) redistributed on the permeable patterned surface and (ii) drawn into a plurality of recess of the permeable patterned surface, in order to form the molded paper web.

Disclosed are tissue products comprising a single ply tissue web that has been prepared by a creping process and more preferably by a print creping process adapted to dispose a non-crosslinked latex polymer on at least one of the outer surfaces of the tissue web. The creped single ply tissue products generally have a low degree of stiffness, such as a Stiffness Index less than about 8.00, and are highly durable, such as a Durability Index greater than about 12.0. In other instances, the tissue products may have very low levels of lint or dust, such as a Slough less than about 4.00 mg, even at basis weights from about 45 to about 55 grams per square meter (gsm) and tensile strengths from 600 to 1,200 g/3″.

Disclosed are multi-ply tissue products comprising a non-crosslinked binder that are durable and dispersible. The products generally have a Slosh time less than 2 minutes, such as less than about 60 seconds, such as less than about 45 seconds. Surprisingly, the foregoing Slosh times are achieved despite the tissue products having relatively high cross-machine direction (CD) wet tensile strength, such as greater than about 100 g/3″. Typically, increasing wet tensile strength, particularly wet CD tensile strength, negatively effects dispersability and increases Slosh time. Despite this trend, the present invention surprisingly provides a tissue product having a relatively high degree of wet strength and good dispersability.

Disclosed are multi-ply tissue products comprising a non-crosslinked binder that are durable, smooth and with low levels of Slough. In certain instances the creped tissue product have a geometric mean tensile (GMT) from about 700 to about 1,500 g/3″ a basis weight from about 45 to about 60 gsm and a Slough less than about 2.00 mg, more preferably less than about 1.50 mg, such as from about 0.10 to about 2.00, such as from about 0.25 to about 1.50 mg. The inventive tissue products also have good durability, such as a Durability Index from about 10.0 to about 20.0, smooth surfaces, such as a TS750 value from about 15.0 to 40.0 and low stiffness, such as a Stiffness Index less than about 10.0.

A system and method is provided for proactive process intervention in manufacturing creped products via a chemical feed stage and a Yankee dryer stage. The method includes generating signals from a plurality of online sensors, corresponding to directly measured variables for respective process components such as, e.g., pH, conductivity, and Yankee blade vibration. Models are developed including retrievable information relating combinations of certain directly measured variables to respective quality characteristics of the creped product. The method further includes indirectly determining quality characteristics (e.g., softness, bulk) for the creped product, substantially in real time, based on, e.g., signals corresponding to directly measured variables, and optionally a predicted natural coating potential. An output feedback signal is automatically generated corresponding to a detected intervention event based on the indirectly determined one or more quality characteristics and respective predetermined targets. The feedback signal may automatically regulate chemistry feed characteristics, substantially in real time.

Disclosed are multi-ply tissue products comprising a non-crosslinked binder that are durable and dispersible. The products generally have a Slosh time less than 2 minutes, such as less than about 60 seconds, such as less than about 45 seconds. Surprisingly, the foregoing Slosh times are achieved despite the tissue products having relatively high cross-machine direction (CD) wet tensile strength, such as greater than about 100 g/3″. Typically, increasing wet tensile strength, particularly wet CD tensile strength, negatively effects dispersability and increases Slosh time. Despite this trend, the present invention surprisingly provides a tissue product having a relatively high degree of wet strength and good dispersability.

A method of making a fibrous sheet. The method includes forming a nascent web from an aqueous solution of papermaking fibers, moving a dewatered web on a transfer surface, and applying a vacuum at a molding zone defined between the transfer surface and a molding roll. The molding roll includes a permeable patterned surface on an exterior of the molding roll. The method also includes transferring the dewatered web from the transfer surface to the permeable patterned surface at the molding zone. The vacuum is applied during the transferring of the dewatered web, and the papermaking fibers of the dewatered web are (i) redistributed on the permeable patterned surface and (ii) drawn into a plurality of recess of the permeable patterned surface, in order to form a molded paper web. The method further includes drying the molded paper web in a drying section to form a fibrous sheet.