Methods for forming embossed packaging materials

Abstract

A paper conditioning system is configured to process unembossed raw paper sheets—after a paper conditioning cycle or process—into embossed paper sheets. Embossed paper sheets can be used to manufacture paper packaging materials for hygiene products intended for human use.

Description

[0001] Priority requirements

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 597,488, filed November 9, 2023, pursuant to 35 USC § 119(e), which is expressly incorporated herein by reference in its entirety. Background Technology

[0003] This disclosure relates to a manufacturing method and system, specifically to a conditioning system and a method for conditioning articles. More specifically, this disclosure relates to a paper or viscose nonwoven fabric conditioning system and a method for conditioning the sheet. Summary of the Invention

[0004] According to this disclosure, a conditioning system is configured to prepare an unembossed sheet—after a conditioning cycle or process—into an embossed sheet. The embossed sheet can be used to manufacture packaging materials for hygiene products intended for human use. In some examples, the sheet may be paper or viscose nonwoven fabric.

[0005] In an illustrative embodiment, a method of forming embossed paper packaging material for hygiene products includes: feeding an unembossed raw paper sheet into a printing operation station. The method may further include: applying a deposit to the unembossed raw paper sheet to provide a coated, unembossed paper sheet. The method may further include: drying the coated, unembossed paper sheet. The method may further include: after the drying step, humidifying the coated, unembossed paper sheet to provide a moistened, unembossed paper sheet. The method may further include: embossing the moistened, unembossed paper sheet to provide an embossed paper sheet.

[0006] In an illustrative embodiment, the paper conditioning system includes a printing station configured to apply one or more deposits to an unembossed paper sheet. The paper conditioning system may further include a drying station configured to cure the one or more deposits on the unembossed paper sheet to provide a coated, unembossed paper sheet. The paper conditioning system may further include a wetting station configured to increase the moisture content of the coated, unembossed paper sheet and provide a wetted, coated, unembossed paper sheet. The paper conditioning system may further include an embossing station configured to emboss the wetted, coated, unembossed paper sheet to provide an embossed paper sheet.

[0007] Additional features of this disclosure will become apparent to those skilled in the art after considering the illustrative embodiments, which illustrate what is currently known as the best mode for carrying out this disclosure. Attached Figure Description

[0008] For detailed explanation, please refer to the attached diagram, which shows:

[0009] Figure 1 The diagram below illustrates a paper conditioning system configured to condition unembossed paper sheets during a conditioning process to produce embossed paper sheets suitable for use as packaging materials for hygiene products. The paper conditioning system includes: a printing station configured to apply one or more deposits to the unembossed paper sheet; a drying station configured to solidify the one or more deposits; a wetting station configured to increase the moisture content of the unembossed paper sheet; and an embossing station configured to emboss the paper sheet.

[0010] Figure 2 It shows the use of Figure 1 A flowchart of the steps involved in the process of preparing unembossed paper sheets into embossed paper sheets using a paper conditioning system;

[0011] Figure 3 It is a perspective view of an unembossed paper sheet; and

[0012] Figure 4 It is by Figure 1 Paper conditioning system and Figure 2 The flowchart shows a perspective view of the embossed paper sheet. Detailed Implementation

[0013] A conditioning system 10 according to the present disclosure is shown in Figure 1 The conditioning system 10 is configured to: after a conditioning cycle or process 100, [the following will be applied / processed]. Figure 3 The unembossed plain sheet 12 shown is prepared as follows Figure 4 The embossed sheet 14 is shown. In one example, the embossed sheet 14 has an embossing shown as parallel dashed lines extending parallel to the longitudinal sides of the embossed sheet 14. In another example, the embossed pattern may be perpendicular to... Figure 4 The pattern shown is illustrated. In yet another example, the embossed pattern can be any suitable pattern or combination of patterns. Embossed sheet 14 can be used to manufacture packaging materials for, for example, hygiene products (i.e., feminine hygiene products) intended for human use. In some examples, the sheet is made of paper or adhesive nonwoven fabric.

[0014] The paper conditioning system 10 includes multiple rollers 14, such as Figure 1 As shown. At least some of the rollers are configured to rotate (i.e., by one or more motors) to pull the unembossed plain paper sheet through a plurality of operating stations. Each of the plurality of operating stations is configured to provide one or more conditioning functions on or to the paper sheet to transform the unembossed plain paper sheet 12 into an embossed paper sheet 14 at the end of process 100.

[0015] like Figure 1 As shown, multiple operation stations include a printing operation station 16, a drying operation station 18, a humidifying operation station 20, and an embossing operation station 22. The printing operation station 16 is configured to provide one or more deposits on an unembossed plain paper sheet 12. The drying operation station 18 is configured to cure the one or more deposits. The humidifying operation station 20 is configured to add moisture to the paper sheet before embossing. The embossing operation station 22 is configured to emboss the paper sheet. Illustratively, the paper sheet is embossed after all deposits (e.g., attachment parts, illustrations, additives, etc. for attaching the final product to the user) have been applied to the unembossed sheet to facilitate the application of these deposits. Other comparative systems use pre-embossed paper, which may require more robust and complex systems and planning to handle the brittle state of the pre-embossed paper due to the embossing process.

[0016] Process 100 illustratively begins with step 102—the feeding of an unembossed sheet of paper 12 into the printing station 16. In the illustrative embodiment, the unembossed sheet of paper 12 is initially in a roll 30, which is unrolled by the plurality of rollers. The printing station 16 may include or be any suitable means for applying the deposit, such as a rotary printing apparatus, transfer roller, sprayer, inkjet printer, offset printer, etc.

[0017] Process 100 further includes step 104: at printing operation station 16, applying one or more deposits to an unembossed plain paper sheet 12 to provide a coated, unembossed paper sheet 40. Step 104 of applying the deposits illustratively includes: applying a primer layer 43 to the unembossed plain paper sheet 12. The primer layer 43 may be applied to all or only a portion of the unembossed plain paper sheet 12. Step 104 of applying the deposits illustratively includes: applying a release layer 45 to the primer layer 43. The release layer 45 may be applied to all or only a portion of the primer layer 43. Step 104 of applying the deposits further includes: applying a heat-sealing layer 47 to the release layer 45. The heat-sealing layer 47 may be applied to all or only a portion of the release layer 45. Illustratively, each layer is applied by separate transfer rollers 42, 44, 46. The printing station 16 may further include an additional roller 48, and the step 104 of applying the deposit may further include applying an ink layer to any portion of the paper sheet or any layer thereof.

[0018] In an illustrative embodiment, system 10 further includes a flipping station 17 configured to flip the coated, unembossed paper sheet after receiving a primer layer 43, a release layer 45, a heat-sealing layer 47, and / or an ink layer on one side of the coated, unembossed paper sheet for further printing on the opposite side of the coated, unembossed paper sheet. Therefore, step 104 may include flipping the coated, unembossed paper sheet 40 and applying one or more additional deposits to the other side of the paper sheet. The additional deposits may include—using second sets of rollers 42', 44', 46', and / or 48'—a second primer layer, a second heat-sealing layer, and / or a second ink layer on the opposite side of the coated, unembossed paper sheet. Pre-embossed paper sheets are typically thicker and more absorbent than unembossed paper sheets. Therefore, this disclosure allows for a reduction in deposit levels because the deposits are applied to the paper sheet prior to embossing. The tensile strength of pre-embossed paper sheets is often lower than that of unembossed paper sheets. Therefore, using unembossed paper sheets allows for the application of tensile loads to improve printing accuracy and throughput.

[0019] Process 100 may further include step 106: drying the coated, unembossed paper sheet 40. The drying step 106 is illustratively performed in an oven 50 having one or more heating elements. The oven 50 is configured to cure deposits on the coated, unembossed paper sheet 40. In step 106, one or more of conductive heating, convection heating, and / or radiant heating may be used via the oven 50 and / or the heating elements. In some embodiments, the flipping operation station 17 may also include one or more heating elements to provide a first oven—configured to dry a first set of deposits from rollers 42', 44', 46', 48'—and the oven 50 is a second oven—configured to dry a second set of deposits from rollers 42', 44', 46', 48'.

[0020] Process 100 may further include step 108: after drying step 106, humidifying the coated, unembossed paper sheet 40 to provide a moistened, unembossed paper sheet 60. Illustratively, the humidifying step 108 is performed in two stages using a wetting station 62 and a spray station 64. Humidifying step 108 includes: advancing the coated, unembossed paper sheet 40 through a reservoir 66 of liquid (containing water) at the wetting station 62. In some embodiments, the liquid may include one or more additives as well as water. Humidifying step 108 further includes: after advancing the coated, unembossed paper sheet through the liquid reservoir 66, spraying a liquid containing water onto the coated, unembossed paper sheet 40 at the spray station 64 using one or more nozzles 68. In some embodiments, humidifying step 108 may be performed using only one of the wetting station 62 and the spray station 64.

[0021] The wetting station 62 and spraying station 64 are configured to apply a predetermined amount of liquid to the coated, unembossed paper sheet 40. Illustratively, the step of advancing the coated, unembossed paper sheet 40 through a reservoir includes selecting the amount of time the coated, unembossed paper sheet is immersed in the reservoir 66 such that the wetted, unembossed paper sheet 60 has a predetermined moisture content. For example, the length of the reservoir 66 can be selected based on the velocity of the paper sheet flowing through it, such that the paper sheet is exposed to the liquid for a predetermined amount of time. The step of spraying liquid onto the coated, unembossed paper sheet may include discharging a predetermined amount of liquid from one or more nozzles 68 such that the wetted, unembossed paper sheet 60 has a predetermined moisture content. Rollers or other means of conveying the sheet through the system can be synchronized with the flow rate of the liquid sprayed onto the sheet, such that a predetermined amount of liquid is deposited on the sheet during the spraying step.

[0022] A predetermined moisture content facilitates embossing in subsequent steps of process 100. In illustrative embodiments, the predetermined moisture content ranges from about 3 g liquid / m² (gsm) to about 10 gsm. In some embodiments, the predetermined moisture content ranges from about 4 gsm to about 8 gsm. In some embodiments, the predetermined moisture content ranges from about 5 gsm to about 7 gsm. In some embodiments, the predetermined moisture content is about 6 gsm. The term "about" means, for example, within 5%.

[0023] Process 100 further includes step 110: embossing the wetted, unembossed paper sheet 60 to provide an embossed paper sheet 70. Embossing step 110 includes rolling the wetted, unembossed paper sheet 60 between a rigid roller (i.e., a metal / steel roller) 72 and a flexible (compliant) roller (i.e., a rubber roller) 74, the rigid roller having a plurality of protrusions projecting toward the wetted, unembossed paper sheet 60. The protrusions are configured to provide embossing on the paper sheet as the wetted, unembossed paper sheet 60 passes between the rigid roller 72 and the flexible roller 74.

[0024] Process 100 further includes step 112: drying the embossed paper sheet 70. The drying step 112 is carried out in an oven 80—separate from oven 50, although oven 50 may be used in some embodiments. Each oven 50, 80 may differ from one another in at least one aspect of heat intensity / magnitude and length to cause different drying behaviors. After drying, the embossed paper sheet 70 may be rewound into a roll 90 awaiting further processing to form, for example, paper packaging material for hygiene products. In some examples, the paper packaging material may be plastic-free, which may contribute to recyclability and / or compostability. In some embodiments, the paper forming the packaging material is a nonwoven paper sheet.

[0025] In another example using viscose nonwoven sheet, process 100 may use a processing step comprising two stages—using a first heating stage and a second heating stage. This processing step replaces step 104. In the first heating stage, the viscose nonwoven sheet may pass through a pair of heated rollers. In one example, the heated rollers are approximately 100 degrees Celsius. In the second heating stage, the heated viscose nonwoven sheet is further heated by an infrared heater. In one example, the infrared heater applies approximately 60 kW to the heated viscose nonwoven sheet before embossing.

[0026] The following numbered clauses include both contemplated and non-limiting embodiments.

[0027] Clause 1. A method for forming embossed packaging material for hygiene products, the method comprising the step of feeding an unembossed sheet into a printing operation station.

[0028] Clause 2. The method described pursuant to Clause 1 or any other suitable clause or any combination of suitable clauses, wherein the unembossed sheet comprises paper.

[0029] Clause 3. The method described under Clause 2 or any other suitable clause or any combination of suitable clauses further comprises: applying a deposit to an unembossed sheet to provide a coated, unembossed sheet.

[0030] Clause 4. The method described in accordance with Clause 3 or any other suitable clause or any combination of suitable clauses further includes: drying the coated, unembossed sheet.

[0031] Clause 5. The method described under Clause 4 or any other suitable clause or any combination of suitable clauses further comprises: humidifying the coated, unembossed sheet after the drying step to provide a moistened, unembossed sheet.

[0032] Clause 6. The method described pursuant to Clause 5 or any other suitable clause or any combination of suitable clauses further comprises: embossed, unembossed sheets to provide embossed sheets.

[0033] Clause 7. The method described pursuant to Clause 6 or any other suitable clause or any combination of suitable clauses further includes: drying embossed sheets.

[0034] Clause 8. The method described in accordance with Clause 7 or any other suitable clause or any combination of suitable clauses, wherein each drying step is performed in an oven.

[0035] Clause 9. The method described in accordance with Clause 7 or any other suitable clause or any combination of suitable clauses, wherein each drying step is carried out in a separate oven.

[0036] Clause 10. The method described pursuant to Clause 9 or any other suitable clause or any combination of suitable clauses, wherein the individual ovens differ from each other in at least one aspect of heat intensity / amplitude and length.

[0037] Clause 11. The method pursuant to Clause 6 or any other suitable clause or any combination of suitable clauses, wherein the step of applying the deposit comprises: applying a primer layer to an unembossed plain sheet.

[0038] Clause 12. The method pursuant to Clause 11 or any other suitable clause or any combination of suitable clauses, wherein the step of applying the deposit comprises: applying a release layer onto the primer layer.

[0039] Clause 13. The method pursuant to Clause 12 or any other suitable clause or any combination of suitable clauses, wherein the step of applying the deposit comprises: applying a heat-sealing layer onto a release layer.

[0040] Clause 14. The method pursuant to Clause 13 or any other suitable clause or any combination of suitable clauses, wherein the step of applying the deposit includes applying an ink layer.

[0041] Clause 15. The method described pursuant to Clause 13 or any other suitable clause or any combination of suitable clauses further comprises: flipping the coated, unembossed sheet and applying a second primer layer and a second heat-sealing layer to the opposite side of the coated, unembossed sheet.

[0042] Clause 16. The method described pursuant to Clause 15 or any other suitable clause or any combination of suitable clauses further comprises: applying a first ink layer on a first side of the embossed sheet and applying a second ink layer on the opposite side of the coated, unembossed sheet.

[0043] Clause 17. The method pursuant to Clause 6 or any other suitable clause or any combination of suitable clauses, wherein the humidification step comprises: pushing a coated, unembossed sheet through a reservoir of liquid, wherein the liquid contains water.

[0044] Clause 18. The method pursuant to Clause 17 or any other suitable clause or combination of any suitable clauses, wherein the humidification step further comprises: spraying a liquid containing water onto the coated, unembossed sheet after advancing the coated, unembossed sheet through a reservoir of liquid.

[0045] Clause 19. The method pursuant to Clause 17 or any other suitable clause or combination of suitable clauses, wherein advancing the coated, unembossed sheet through the reservoir comprises: selecting an amount of time for which the coated, unembossed sheet is immersed in the reservoir, such that after the step of advancing the coated, unembossed sheet through the reservoir of liquid, the wetted, unembossed sheet has a predetermined moisture content.

[0046] Clause 20. The method pursuant to Clause 18 or any other suitable clause or combination of suitable clauses, wherein spraying liquid onto the coated, unembossed sheet comprises: discharging a predetermined amount of liquid from one or more nozzles toward the coated, unembossed sheet such that, after the step of spraying the water-containing liquid onto the coated, unembossed sheet, the wetted, unembossed sheet has a predetermined moisture content.

[0047] Clause 21. The method according to Clause 6 or any other suitable clause or any combination of suitable clauses, wherein the embossing step comprises: rolling a wetted, unembossed paper sheet between a metal roller and a rubber roller, wherein the metal roller has a plurality of protrusions that project toward the wetted, unembossed sheet.

[0048] Clause 22. The method according to Clause 1 or any other suitable clause or any combination of suitable clauses, wherein the unembossed sheet is wound in a roll prior to the step of advancing the unembossed sheet to the printing operation station, and the step of advancing the unembossed sheet to the printing operation station comprises: applying a tensile force—greater than the tear strength of the embossed sheet—to the unembossed sheet.

[0049] Clause 23. The method described pursuant to Clause 22 or any other suitable clause or any combination of suitable clauses further includes the step of rewinding the embossed sheet into a second roll.

[0050] Clause 24. The method described under Clause 4 or any other suitable clause or any combination of suitable clauses further comprises: heating the coated, unembossed sheet after the drying step to provide a conditioned, unembossed sheet.

[0051] Clause 25. The method pursuant to Clause 24 or any other suitable clause or combination of any suitable clauses, wherein the heating step includes a first heating step in which the coated, unembossed sheet passes between two heating rollers.

[0052] Clause 26. The method pursuant to Clause 25 or any other suitable clause or combination of any suitable clauses, wherein the heating step further includes a second heating step in which the coated, unembossed sheet is further heated by a heater.

[0053] Clause 27. The method described pursuant to Clause 26 or any other suitable clause or any combination of suitable clauses, wherein the heater is an infrared heater.

[0054] Clause 28. The method described pursuant to Clause 27 or any other suitable clause or any combination of suitable clauses, wherein the heater emits approximately 60 kW.

[0055] Clause 29. The method described pursuant to Clause 25 or any other suitable clause or any combination of suitable clauses, wherein the heating roller is heated to about 100 degrees Celsius.

[0056] Clause 30. A conditioning system configured to form an embossed sheet, the conditioning system comprising: a printing station configured to apply one or more deposits onto an unembossed sheet.

[0057] Clause 31. The conditioning system described in Clause 30 or any other suitable clause or combination of suitable clauses further includes a drying station configured to cure the one or more deposits on the unembossed sheet to provide a coated, unembossed sheet.

[0058] Clause 32. The conditioning system described in Clause 31 or any other suitable clause or combination of suitable clauses further includes a conditioning operation station configured to receive coated, unembossed sheets and provide conditioned, unembossed sheets.

[0059] Clause 33. The conditioning system described in Clause 32 or any other suitable clause or any combination of suitable clauses further includes an embossing operation station configured to emboss the conditioned, unembossed sheet to provide embossed sheet.

[0060] Clause 34. A conditioning system pursuant to Clause 33 or any other suitable clause or combination of any suitable clauses, wherein the unembossed sheet is made of paper.

[0061] Clause 35. The conditioning system described in Clause 34 or any other suitable clause or combination of suitable clauses, wherein the conditioning operation station includes a wetting operation station configured to increase the moisture content of the coated, unembossed sheet and to provide the conditioned, unembossed sheet.

[0062] Clause 36. The conditioning system described in Clause 35 or any other suitable clause or combination of suitable clauses, wherein the wetting operation station includes a reservoir and a sprayer, the reservoir containing liquid and configured to immerse the coated, unembossed sheet in the liquid, and the sprayer configured to spray the liquid onto the coated, unembossed sheet.

[0063] Clause 37. A conditioning system pursuant to Clause 33 or any other suitable clause or combination of any suitable clauses, wherein the unembossed sheet is made of viscose nonwoven fabric.

[0064] Clause 38. The conditioning system described in Clause 37 or any other suitable clause or combination of suitable clauses, wherein the conditioning station includes a first heating station configured to pass coated, unembossed sheet between two heating rollers.

[0065] Clause 39. The conditioning system described in Clause 38 or any other suitable clause or combination of suitable clauses, wherein the conditioning station includes a second heating station in which the coated, unembossed sheet is further heated by an infrared heater after the first heating station to provide a conditioned, unembossed sheet.

[0066] Clause 40. The conditioning system described in accordance with Clause 39 or any other suitable clause or any combination of suitable clauses, wherein the heater is an infrared heater.

[0067] Clause 41. The conditioning system described in accordance with Clause 40 or any other suitable clause or any combination of suitable clauses, wherein the heater emits approximately 60 kW.

[0068] Clause 42. A conditioning system as described in Clause 39 or any other suitable clause or combination of any suitable clauses, wherein the heating roller is heated to about 100 degrees Celsius.

[0069] The first example is described in Table 1. Table 1 describes various properties and characteristics of an example of embossed paper sheet 14 produced by process 100 and paper conditioning system 10.

[0070] Table 1: .

[0071] A second example is described in Table 2. Table 2 describes various properties and characteristics of an example of viscose nonwoven sheet 12, which can be used in process 100 and paper conditioning system 10 to produce embossed sheet 14. The plain sheet 12 described in Table 2 is 100% viscose nonwoven.

[0072] Table 2: .

[0073] A third example is described in Table 3. Table 3 describes various properties and characteristics of another example of raw paper sheet 12, which can be used in process 100 and paper conditioning system 10 to produce embossed paper sheet 14. The raw paper sheet 12 described in Table 3 is 100% adhesive.

[0074] Table 3: .

[0075] A fourth example is described in Table 4. Table 4 describes various properties and characteristics of another example of raw paper sheet 12, which can be used in process 100 and paper conditioning system 10 to produce embossed paper sheet 14.

[0076] Table 4: .

[0077] A fifth example is described in Table 5. Table 5 describes various properties and characteristics of another example of raw paper sheet 12, which can be used in process 100 and paper conditioning system 10 to produce embossed paper sheet 14.

[0078] Table 5: .

[0079] A sixth example is described in Table 6. Table 6 describes various properties and characteristics of another example of raw paper sheet 12, which can be used in process 100 and paper conditioning system 10 to produce embossed paper sheet 14.

[0080] Table 6: .

[0081] The seventh example is described in Table 7. Table 7 describes various properties and characteristics of another example of raw paper sheet 12, which can be used in process 100 and paper conditioning system 10 to produce embossed paper sheet 14.

[0082] Table 7: .

Claims

1. A method for forming embossed packaging material for hygiene products, the method comprising the following steps: The unembossed sheet of paper is pushed into the printing station. The deposit is applied to the unembossed plain paper sheet to provide a coated, unembossed paper sheet. Dry the coated, unembossed paper sheet. Following the drying step, the coated, unembossed paper sheet is humidified to provide a moistened, unembossed paper sheet. Embossing refers to the moistened, unembossed paper sheet to provide embossed paper sheet.

2. The method according to claim 1, further comprising: Dry the embossed paper sheet.

3. The method according to claim 2, wherein, Each drying step is carried out in an oven.

4. The method according to claim 2, wherein, Each drying step is carried out in a separate oven.

5. The method according to claim 4, wherein, The individual ovens differ from each other in at least one aspect of heat intensity / amplitude and length.

6. The method according to claim 1, wherein, The step of applying the deposit includes applying a primer layer to the unembossed plain paper sheet.

7. The method according to claim 6, wherein, The step of applying the deposit includes applying a release layer onto the primer layer.

8. The method according to claim 7, wherein, The step of applying the deposit includes applying a heat-sealing layer onto the release layer.

9. The method according to claim 8, wherein, The steps for applying the deposit include: applying an ink layer.

10. The method of claim 8, further comprising: The coated, unembossed paper sheet is flipped over, and a second primer layer and a second heat-sealing layer are applied to the opposite sides of the coated, unembossed paper sheet.

11. The method of claim 10, further comprising: A first ink layer is applied to a first side of the embossed paper sheet, and a second ink layer is applied to the opposite side of the coated, unembossed paper sheet.

12. The method according to claim 1, wherein, The humidification step includes: pushing the coated, unembossed paper sheet through a reservoir of liquid, wherein the liquid contains water.

13. The method according to claim 12, wherein, The humidification step further includes: after pushing the coated, unembossed paper sheet through the liquid reservoir, spraying a liquid containing water onto the coated, unembossed paper sheet.

14. The method according to claim 12, wherein, Propelling the coated, unembossed paper sheet through the reservoir includes selecting an amount of time for which the coated, unembossed paper sheet is immersed in the reservoir, such that after the step of propelling the coated, unembossed paper sheet through the liquid reservoir, the wetted, unembossed paper sheet has a predetermined moisture content.

15. The method according to claim 13, wherein, Spraying liquid onto the coated, unembossed paper sheet includes: discharging a predetermined amount of liquid from one or more nozzles toward the coated, unembossed paper sheet such that after the step of spraying the water-containing liquid onto the coated, unembossed paper sheet, the wetted, unembossed paper sheet has a predetermined moisture content.

16. The method according to claim 1, wherein, The embossing step includes: rolling a wet, unembossed paper sheet between a metal roller and a rubber roller, wherein the metal roller has a plurality of protrusions that protrude toward the wet, unembossed paper sheet.

17. The method according to claim 1, wherein, Before the step of feeding the unembossed plain paper sheet into the printing station, the unembossed plain paper sheet is wound in a roll, and the step of feeding the unembossed plain paper sheet into the printing station includes: applying a tensile force greater than the tear strength of the embossed paper sheet to the unembossed plain paper sheet.

18. The method of claim 17, further comprising the step of rewinding the embossed paper sheet into a second roll.

19. A conditioning system configured to form embossed sheets, the conditioning system comprising: A printing station configured to apply one or more deposits onto an unembossed sheet. A drying station configured to cure the one or more deposits on the unembossed sheet to provide a coated, unembossed sheet. A conditioning station configured to receive the coated, unembossed sheet and provide conditioned, unembossed sheet. An embossing station configured to emboss the prepared, unembossed sheet to provide embossed sheets.

20. The conditioning system according to claim 19, wherein, The unembossed sheet is made of viscose nonwoven fabric, and the conditioning station includes: a first heating station configured to pass the coated, unembossed sheet between two heating rollers; and a second heating station in which the coated, unembossed sheet is further heated by an infrared heater after the first heating station to provide the conditioned, unembossed sheet.

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