A method for manufacturing an embossed sheet of substrate, the method being configured to produce a controlled thickness of the embossed sheet of substrate embossed in a congruency nip, and to reduce a content of first and second types of clusters initially present in a non-embossed sheet of substrate. The method comprises providing an
embossing roller
system comprising at least a first and a second
embossing roller, comprising first
embossing structures protruding from or recessed in a first base surface of the first embossing roller, each of the protruding first embossing structures protruding from the first base surface and comprising rising flanks oriented away from the first base surface towards a
summit that tops the protruding first embossing structure, and each of the recessed first embossing structures recessing from the first base surface and comprising recessing flanks oriented from the first base surface inside of the first embossing roller towards a bottom that delimits the recessed first embossing structure, second embossing structures protruding from or recessed in a second base surface of the second embossing roller, congruent according to the congruency nip separating each of the second embossing structures during embossing at least along the rising and recessing flanks from respective corresponding first embossing structures of the first embossing roller, and forming a
summit nip between each of the summits of the first embossing structures and a corresponding counter side on the second embossing structures, with a value of the
summit nip at least greater than the congruency nip. The method further comprises adjusting the first embossing roller and the second embossing roller for embossing with a base nip between a portion of the first base surface and a corresponding portion of the second base surface, and the congruency nip, whereby the congruency nip has a value smaller than the average starting thickness of the non-embossed substrate; inserting the non-embossed sheet of substrate in a roller nip comprising at least base nip zones of the base nip, congruency nip zones of the congruency nip and summit nip zones of the summit nip; embossing the non-embossed sheet of substrate, thereby producing the controlled thickness value of the embossed sheet of substrate smaller than the average starting thickness for parts of the sheet of substrate embossed in the congruency nip zones; compressing in the congruency nip zones at least one of the first type of clusters inside the embossed sheet of substrate; and
processing at least one of the second type of clusters by compressing in the congruency nip zones the at least one second type of cluster inside the embossed sheet of substrate and for each one of the at least one second type of cluster either maintaining the at least one second type of cluster inside the embossed sheet of substrate; or causing the at least one second type of cluster to emerge from the embossed sheet of substrate, by migrating it from the congruency nip zones to one of the summit nip zones, and to remain as debris in proximity of the second roller's counter side of the one of the summit nip zones.