Method for making a throughdried tissue sheet

A method for making a throughdried tissue sheet is disclosed. The method includes the steps of depositing an aqueous suspension of papermaking fibers onto an endless forming fabric to form a wet web. The wet web is then transferred to a throughdrying fabric such that the wet web has a fabric side in contact with the throughdrying fabric and an opposite air side facing away from the throughdrying fabric. The wet web is routed over a throughdryer to dry the web. The web is then transferred to a Yankee dryer for further drying and is creped from the Yankee dryer to obtain a creped web having a basis weight of about 15.2 pounds per 2880 square feet. The creped web in then calendered in a calendering unit that includes a smooth calender roll and a resilient calender roll. The resilient calender roll has an exterior covering formed of ethylene propylene diene polymer and the creped web is oriented such that the fabric side is disposed toward the resilient calender roll. The finished tissue exhibits improved softness while retaining adequate strength.

FIELD OF THE INVENTION
 The present invention relates to a method for making a throughdried tissue
 sheet exhibiting improved softness while retaining adequate strength. More
 particularly, the present invention relates to a method for making a
 creped throughdried tissue sheet using a resilient calender roll having an
 exterior covering formed of ethylene propylene diene polymer.
 BACKGROUND OF THE INVENTION
 A wide variety of product characteristics must be given attention in order
 to provide a tissue product with the appropriate blend of attributes
 suitable for the product's intended purposes. Contributing to this variety
 is the vast array of different product forms, such as facial tissue, bath
 tissue, napkins, and towels. Regardless of product form, however, improved
 softness of the product has long been one major objective, especially for
 premium products. In general, the major components of softness include
 stiffness and bulk, with lower stiffness and higher bulk generally
 improving perceived softness.
 A throughdrying process can be used to improve the bulk of tissue products.
 Throughdrying is a relatively noncompressive method for removing water
 from a web. Specifically, a wet laid web is transferred from a forming
 fabric to a coarse, highly permeable throughdrying fabric and retained on
 the throughdrying fabric until it is dried by hot air passing through the
 web.
 Throughdried sheets can be quite harsh and rough to the touch, however, due
 to their inherently high stiffness and strength and also due to the
 coarseness of the throughdrying fabric. For this reason, creping has been
 used to improve the softness of throughdried tissue sheets. Creping
 removes some of the stiffness of the uncreped sheet, albeit at the expense
 of the sheet strength.
 Despite the improvements in softness that can be gained from creping,
 however, additional improvements in softness would be beneficial to
 consumers. Therefore, what is lacking and needed in the art is a process
 for further improving the softness of creped throughdried tissue products.
 SUMMARY OF THE INVENTION
 It has now been discovered that the texture of creped, throughdried tissue
 products can be improved by processing the tissue web through a soft-nip
 calendering unit with the fabric side of the web oriented toward a
 resilient roll and the air side of the web oriented toward a smooth roll.
 More specifically, in one embodiment the invention concerns a method for
 making a throughdried tissue sheet comprising the steps of depositing an
 aqueous suspension of papermaking fibers onto an endless forming fabric to
 form a wet web, and then transferring the wet web to a throughdrying
 fabric. The wet web is described herein as having a fabric side, which is
 the surface that is in contact with the throughdrying fabric, and an
 opposite air side, which is the surface that is facing away from the
 throughdrying fabric. The wet web is then carried over a throughdryer to
 dry the web, transferred to a Yankee dryer, and creped from the Yankee
 dryer. The creped web is then calendered in a calendering unit comprising
 a smooth calendering roll and a resilient calendering roll having a Shore
 A surface hardness of about 75 to about 100 Durometer (approximately 55 to
 about 0 Pusey & Jones, respectively). During calendering, the creped web
 is oriented such that the fabric side is disposed toward the resilient
 calendering roll.
 In another embodiment, the method of making a throughdried tissue sheet
 also comprises the step of embossing the creped web in an embossing unit
 comprising a pattern roll and a backing roll. In the embossing unit, the
 creped web is oriented such that the fabric side of the web is disposed
 toward the pattern roll.
 The improved softness is particularly pertinent to creped throughdried
 tissue products, which typically have larger creping features than a
 comparable wet pressed sheet. Moreover, the oriented soft-nip embossing is
 advantageously used in conjunction with oriented embossing of the tissue
 web. In particular, the resilient backing roll of the embossing unit is
 against the opposite surface of the tissue sheet as is the resilient
 calendering roll.
 The texture of tissue products has been examined to determine the
 attributes that result in a tissue product being considered soft. One
 attribute of a surface of a tissue that is indicative of the softness of
 the tissue is referred to as the Fuzzy attribute of the tissue surface.
 Contrariwise, attributes of a tissue surface that are counter-indicative
 of the softness of the tissue are referred to as the Gritty and Grainy
 attributes of the tissue surface.
 The methods disclosed herein have been found to increase the Fuzzy
 attribute of the fabric side of the tissue product and reduce the Gritty
 and Grainy textures of the air side of the tissue product. The Fuzzy
 attribute is increased, particularly on the fabric side, as a result of
 frictional forces in the calendering nip caused by the speed differential
 at the contact point between the resilient calendering roll and the steel
 calendering roll. The creping process causes the air side of the tissue
 web to have pointed crepe structures such as ripples or ridges which
 result in Gritty and Grainy textures, and that contact between the steel
 calendering roll and the air side tends to flatten the pointed crepe
 structures present on the air side, thereby reducing the Gritty and Grainy
 textures. In addition, it is hypothesized that the clarity of the
 embossing pattern is improved because of an increase in opacity caused by
 calendering the sheet. The result of the selective orientation and
 distinctive treatment of the opposite surfaces of the creped throughdried
 tissue is an embossed tissue web with enhanced softness.
 For purposes herein, a "tissue web" or "tissue sheet" is a cellulosic web
 suitable for making or use as a facial tissue, bath tissue, paper towels,
 napkins, or the like. It can be layered or unlayered, creped or uncreped,
 and can consist of a single ply or multiple plies. In addition, the tissue
 web can contain reinforcing fibers for integrity and strength. Tissue webs
 suitable for use in accordance with this invention are characterized by
 being absorbent, of low density and relatively fragile, particularly in
 terms of wet strength. Densities are typically in the range of from about
 0.1 to about 0.3 grams per cubic centimeter. Absorbency is typically about
 5 grams of water per gram of fiber, and generally from about 5 to about 9
 grams of water per gram of fiber. Wet tensile strengths are generally
 about 0 to about 300 grams per inch of width and typically are at the low
 end of this range, such as from about 0 to about 30 grams per inch. Dry
 tensile strengths in the machine direction can be from about 100 to about
 2000 grams per inch of width, preferably from about 200 to about 350 grams
 per inch of width. Tensile strengths in the cross-machine direction can be
 from about 50 to about 1000 grams per inch of width, preferably from about
 100 to about 250 grams per inch of width. Dry basis weights are generally
 in the range of from about 5 to about 60 pounds per 2880 square feet. The
 tissue webs referred to above are preferably made from natural cellulosic
 fiber sources such as hardwoods, softwoods, and nonwoody species, but can
 also contain significant amounts of recycled fibers, sized or
 chemically-modified fibers, or synthetic fibers.
 Tissue sheets that particularly benefit from the method of this invention
 are premium quality throughdried tissue sheets that have a relatively high
 degree of resiliency and low stiffness. The basis weight of the tissue
 sheet can be from about 5 to about 70 grams per square meter.
 Referring now to the tissue making process of this invention, the forming
 process and tackle can be conventional as is well known in the papermaking
 industry. Such formation processes include Fourdrinier, roof formers such
 as a suction breast roll, gap formers such as twin wire formers and
 crescent formers, and other suitable formers. A twin wire former may be
 preferred for higher speed operation. Forming wires or fabrics can also be
 conventional, the finer weaves providing greater fiber support and a
 smoother sheet and the coarser weaves providing greater bulk. Headboxes
 used to deposit the fibers onto the forming fabric can be layered or
 nonlayered, although layered headboxes are advantageous because the
 properties of the tissue can be finely tuned by altering the composition
 of the various layers. The throughdryers and throughdrying fabrics can
 also be of a conventional nature.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
 Referring to FIG. 1, a schematic details the method for carrying out the
 present invention. A headbox 10 is used to deposit an aqueous suspension
 of papermaking fibers onto the surface of a forming fabric 11. The
 resulting wet web 12 is transferred to an optional fine mesh transfer
 fabric 13 and thereafter is transferred to a coarse mesh throughdryer
 fabric 14. In the illustrated process, two throughdryers 16 and 17 are
 used to dry the web 12. The web 12 may be partially dried in the first
 throughdryer 16 to a consistency of about 45 percent. The partially dried
 web 12 is then routed around at least a portion of the circumference of
 the second throughdryer 17 and further dried to a consistency of about 85
 to about 95 percent.
 The tissue web 12 has opposite major planar surfaces 18 and 20 which are
 referred to as the air side surface 18 and the fabric side surface 20. The
 air side surface 18 faces away from the throughdryer fabric 14 and towards
 the surfaces of the throughdryers 16 and 17. Correspondingly, the fabric
 side surface 20 faces toward the throughdryer fabric 14 and is in contact
 with it.
 Upon exiting the second throughdryer 17, the tissue web 12 is transferred
 to a fine mesh fabric 21 and is pressed against the surface of a Yankee
 dryer 22 for final drying, if necessary. The fabric side surface 20 of the
 tissue web 12 is disposed against the surface of the Yankee dryer 22. The
 Yankee dryer 22 will further dry the tissue web 12 to a consistency of
 about 100 percent. The tissue web 12 is dislodged from the Yankee dryer 22
 with a doctor (creping) blade 23 to produce a dried, creped tissue web 24
 that is wound into a parent roll 26. The tissue web 12 is creped off the
 Yankee dryer 22 to obtain the creped tissue web 24 having a basis weight
 of about 15.2 pounds per 2880 square feet.
 For simplicity, the various tensioning rolls schematically used to define
 the several fabric runs are shown but not numbered. It will be appreciated
 that variations from the apparatus and method illustrated in FIG. 1 can be
 made without departing from the scope of the invention. For example,
 additional dewatering of the wet tissue web 12 can be carried out, such as
 by vacuum suction, while the wet tissue web 12 is supported by the forming
 fabric 11. Furthermore, only a single throughdryer 16 may be used, if
 desired. Other changes to the process are also possible and will be
 recognized by those skilled in the art without departing from the spirit
 and scope of the present invention.
 Referring to FIG. 2, an off-line converting operation to calender and
 emboss the creped tissue web 24 is illustrated. The creped tissue web 24
 is unwound from the parent roll 26 and transported in sequence to a
 calendering unit 30 and then to an embossing unit 40. The calendered and
 embossed tissue web 24 may then be wound at a rewinding unit 60. For
 example, the tissue web 24 may be wound onto tissue roll cores to form
 logs, which are subsequently cut to appropriate widths and the resulting
 individual tissue rolls can then be packaged (not shown).
 Referring to FIG. 3, exemplary calendering and embossing units 30 and 40
 are shown in greater detail. Note that in the winding and unwinding
 processes of FIGS. 1 and 2, the orientation of the creped tissue web 24 in
 the illustrated embodiment has been reversed so that the fabric side
 surface 20 is shown on the top and the air side surface 18 is shown on the
 bottom in FIGS. 2 and 3. Arrows are used to designate the direction of
 travel of the creped tissue web 24 through the calendering and embossing
 units 30 and 40.
 The calendering unit 30 includes a pair of calendering rolls 32 and 34 that
 together define a calendering nip 36 therebetween. A spreader roll 38 is
 shown preceding the calendering nip 36, although other details of the
 calendering unit 30 are not shown for purposes of clarity.
 The calendering nip 36 is a "soft-nip" wherein the calendering rolls 32 and
 34 have different surface hardnesses and at least one of the rolls 32 and
 34 has a resilient surface. In FIG. 3, the calender roll 32 is a smooth
 resilient roll and the calender roll 34 is a smooth steel roll. The
 resilient calendering rolls are sometimes referred to as soft covered
 calendering rolls. The actual material used to cover the exterior surface
 of the resilient calender roll 32 can include natural rubber, synthetic
 rubber, composites, as well as other compressible surfaces. A preferred
 material for the exterior surface of the resilient calender roll 32 is
 ethylene propylene diene polymer. This material is compressible and holds
 up well under pressure. Suitable resilient calendering rolls should have a
 Shore A surface hardness of from between about 65 to about 100 Durometer
 (approximately 75 to about 0 Pusey & Jones, respectively), preferably,
 from between about 75 to about 100 Durometer (approximately 55 to about 0
 Pusey and Jones, respectively), and most preferably, from between about 85
 to about 95 Durometer (approximately 35 to about 10 Pusey & Jones
 respectively). The use of a resilient calender roll 32 having an ethylene
 propylene diene polymer outer surface with a Shore A surface hardness of
 about 90 Durometer (approximately 25-30 Pusey & Jones) is particularly
 suited to the present process.
 The pressure exerted by the calendering nip 36 is preferably less than
 about 225 pounds per linear inch, preferably, from between about 30 to
 about 200 pounds per linear inch, and most preferably, from between about
 75 to about 175 pounds per linear inch. The creped tissue web 24 can be
 calendered to a caliper of about 0.01 inches (about 0.254 millimeters).
 Upon exiting the calendering unit 30, the creped tissue web 24 is
 transported to an embossing unit 40. The embossing unit 40 includes a
 pattern roll 42 and a backing roll 44. The pattern and backing rolls, 42
 and 44 respectively, together define an embossing nip 46 therebetween. A
 spreader roll 48 is shown preceding the embossing nip 46, although other
 details of the embossing unit 40 are not shown for purposes of clarity.
 Embossing is a well-known mechanism to increase tissue sheet caliper, and
 it also provides an additional benefit by imparting a decorative pattern
 to the tissue web 24. Such decorative patterns are commonly formed by
 "spot embossing", which involves discrete embossing elements that are
 about 0.5 inch by 0.5 inch (about 1.27 by about 1.27 centimeters) to about
 1 inch by 1 inch (about 2.54 by about 2.54 centimeters) in size, and thus
 form from between about 0.25 to about 1 square inch (about 0.635 to about
 2.54 centimeters) in surface area. These discrete embossing elements are
 typically spaced about 0.5 inch to about 1 inch apart (about 1.27 to about
 2.54 centimeters). The spot embossing elements are formed on the pattern
 roll 42, which is also referred to as an embossing roll, and are pressed
 into the creped tissue web 24.
 The creped tissue web 24 can be embossed in the embossing unit 40 at a nip
 pressure of from between about 80 to about 150 pounds per linear inch.
 Referring to FIG. 4, a plan view of a portion of the surface of an
 exemplary pattern roll 42 is shown. The surface of the pattern roll 42
 includes a plurality of discrete male spot embossing elements 50 that are
 separated by smooth land areas 52. The male spot embossing elements 50
 define a decorative pattern, which in the illustrated embodiment is a
 series of cotton balls. The male spot embossing elements 50 may include a
 plurality of separate embossing element segments 54 which are raised above
 the surface of the land areas 52. In FIG. 4, each cotton ball is a spot
 embossing element 50 made up of ten individual embossing element segments
 54.
 The spaced-apart discrete spot embossing elements 54 can depict flowers,
 leaves, birds, animals, and the like. The embossing elements 54 can be
 formed on the pattern roll 42 by engraving or other suitable techniques
 known to those skilled in the art.
 In particular embodiments, the male embossing element segments 54 protrude
 from the surface of the pattern roll 42 a distance or height which should
 be greater than about 0.04 inch (about 1.02 millimeters). Preferably, the
 male embossing element segments 54 will protrude above the surface of the
 pattern roll 42 a distance or height of from between about 0.045 inch to
 about 0.060 inch (about 1.143 to about 1.524 millimeters). Most
 preferably, the male embossing element segments 54 will protrude above the
 surface of the pattern roll 42 a distance or height of about 0.045 inch
 (about 1.143 millimeters). This relatively large distance or height
 enhances the embossing pattern definition. The width of the embossing
 element at its tip can be from between about 0.005 to about 0.50 inches
 (about 0.127 to about 12.7 millimeters). The sidewall angle of the male
 embossing element segments measured relative to a plane drawn tangent to
 the surface of the pattern roll 42 at the base of the embossing element is
 suitably from between about 90 degrees to about 130 degrees.
 As disclosed in U.S. Pat. No. 5,904,812 issued May 18, 1999, and filed on
 even date herewith by Z. Salman et al. and entitled "Calendered And
 Embossed Tissue Products," high-bulk tissue products can be embossed with
 improved pattern clarity by processing the high bulk tissue webs
 sequentially through separate calendering and embossing units. This
 multiple step converting process provides a method of optimizing the
 balance between sheet caliper for winding tension and embossing element
 height for pattern definition. The result is an embossed, high-bulk tissue
 product with improved embossing pattern clarity.
 As used herein, the term "pattern definition" refers to the extent to which
 the embossed pattern can be immediately identified by distinct impressions
 made by the embossing element. The term "pattern clarity" as used herein
 refers to the clearness of the pattern in the final product.
 The backing roll 44 can be a smooth rubber covered roll, an engraved roll
 such as a steel roll matched to the pattern roll 42, or the like. The
 bonding nip may be set to a pattern roll 42/backing roll 44 loading
 pressure of from between about 80 to about 150 pounds per linear inch. For
 example, a loading pressure of about 135 pounds per linear inch work well
 such that the embossing pattern is imparted to the creped tissue web 24.
 The backing roll 44 can be any material that meets the process
 requirements. Typical materials used to form the exterior surface of the
 backing roll 44 include natural rubber, synthetic rubber and other
 compressible materials known to those skilled in the art. The backing roll
 44 can have an exterior surface with a Shore A surface hardness of from
 between about 65 to about 85 Durometer, preferably, about 75 Durometer
 (approximately 75 to about 35 Pusey & Jones, respectively, and preferably
 about 55 Pusey & Jones).
 EXAMPLES
 The following Examples are provided to give a more detailed understanding
 of the invention. The particular amounts, proportions, compositions and
 parameters are meant to be exemplary, and are not intended to specifically
 limit the scope of the invention. In order to compare the effects of the
 orientation of the fabric and air side surfaces of the throughdried tissue
 24, none of the Example sheets were embossed. The converting lines all ran
 at 10,000 feet per minute (at 3048 meters per minute).
 Example 1
 (Comparative)
 A throughdried and creped tissue sheet was manufactured having a caliper of
 about 0.01 inch (about 0.254 millimeters) and a basis weight of about 15.2
 pounds per 2880 square feet. The tissue sheet was slit into narrow rolls
 for use on converting lines. A narrow roll of the throughdried and creped
 tissue was unwound and then rewound as a control. Basesheet samples were
 prepared for sensory evaluation from this converted roll. Thus, the tissue
 sheet of Example 1 was not calendered.
 Example 2
 (Comparative)
 For Example 2, a narrow roll of throughdried and creped tissue as described
 in Example 1 was unwound, calendered, and then rewound. Basesheet samples
 were prepared for sensory evaluation from this converted roll.
 The calendering unit included a smooth steel calendering roll and a smooth
 resilient calendering roll. The resilient calendering roll had an exterior
 covering formed of a composite polymer from Stowe Woodward Company,
 U.S.A., under the tradename MULTICHEM, with a Shore A hardness of 90
 Durometer (approximately 25 Pusey & Jones). The calendering nip was set to
 30 pounds per linear inch.
 The tissue sheet was processed through the calendering nip such that the
 fabric side surface of the tissue sheet was disposed against the steel
 calendering roll and the air side surface was disposed against the
 resilient calendering roll.
 Example 3
 For Example 3, a narrow roll of throughdried and creped tissue as described
 in Example 1 was unwound, calendered, and then rewound. Basesheet samples
 were prepared for sensory evaluation from this converted roll. The
 components of the calendering unit and the operating conditions were the
 same as described in Example 2, although the positions of the steel
 calendering roll and the resilient calendering roll were transposed.
 Thus, in Example 3 the tissue sheet was processed through the calendering
 nip such that the fabric side surface of the tissue sheet was disposed
 against the resilient calendering roll and the air side surface was
 disposed against the steel calendering roll.
 The bath tissue sheets of Examples 1, 2 and 3 were submitted for sensory
 panel evaluation. The sensory panel utilized eleven individuals trained to
 compare tissue products and evaluate tactile properties. The panelists
 were asked to render numerical values for each sample tissue regarding the
 "Fuzzy, Gritty and Grainy" attributes. The "Fuzzy, Gritty and Grainy"
 attributes were recorded for both the air side surfaces and the fabric
 side surfaces. The stiffness and thickness of each sample was also
 recorded. For each Example, the tissue samples were die cut from the rolls
 to 8 by 4.5 inches (20.32 by 11.43 centimeters).
 The Fuzzy attribute was ranked on a scale from 0 described as none/bald to
 7 described as much/fuzzy. The panelists were asked to consider the amount
 of fibers, pile, fiber, nap, and fuzz on the tissue surface. The panelists
 were instructed to: place a single tissue sample flat on a smooth tabletop
 with the side to be tested facing up; and using the pads of the index and
 middle fingers, move in quarter-sized circular motions very lightly across
 several areas of the sample.
 The Gritty attribute was ranked on a scale from 0 described as smooth to 7
 described as gritty. The panelists were asked to consider the amount of
 sharp, prickly, abrasive particles or fibers felt on the surface of the
 sample. The panelists were instructed to place a single tissue sample on a
 table with the side to be tested facing up. With forearms/elbows resting
 on the table and using the full length of the fingers, the panelists
 slowly glided their fingers lightly across the entire surface 1 inch (2.54
 centimeters) from the edge moving left to right. Each panelist used their
 other hand to rotate the tissue sample and stroke along all four
 directions. Each evaluated the grittiest direction.
 The Grainy attribute was ranked on a scale from 0 described as smooth to 7
 described as grainy. The panelists were asked to consider the pebbly
 texture of the tissue sample (feeling of grains of sand, rice), and to
 evaluate by considering the frequency, size, and
 hardness/firmness/rigidity of grains. It was noted that the panelist's
 perception could include shape, orientation and size of texture
 (pattern/embossing), small rounded particles, fibers, etc. The panelists
 were instructed to place a single tissue sample on a table with the side
 to be tested facing up. With their forearms/elbows resting on the table,
 each panelist used the pads of their index and middle fingers and slowly
 and gently moved the pads of their fingers across the surface going
 slightly into the surface of the sample. Each panelist moved the pads of
 their fingers across the entire surface 1 inch (2.54 centimeters) from the
 edge, moving left to right. The other hand of each panelist was used to
 rotate the tissue sample and stroke along all four directions. Each
 evaluated the grainiest direction.
 Stiffness was ranked on a scale from 0 described as pliable/flexible to 7
 described as stiff/rigid. The panelists were asked to consider the amount
 of pointed, rippled or cracked edges or peaks felt from the sample while
 turning in your hand. The panelists were instructed to place two tissue
 samples flat on a smooth tabletop. The bath tissue samples overlapped one
 another by 0.5 inches (1.27 centimeters) and were flipped so that opposite
 sides of the tissue samples were represented during testing. With
 forearms/elbows of each panelist resting on the table, they placed their
 open hand, palm down, on the samples. Each was instructed to position
 their hand so their fingers were pointing toward the top of the samples,
 approximately 1.5 inches (approximately 3.81 centimeters) from the edge.
 Each panelist moved their fingers toward their palm with little or no
 downward pressure to gather the tissue samples. They gently moved the
 gathered samples around in the palm of their hand approximately 2 to 3
 turns.
 Thickness was ranked on a scale from 0 described as thin to 7 described as
 thick. The panelists were asked to consider the relative depth of tissue
 (perceived distance between thumb and one/two fingers). The panelists were
 instructed to take a single tissue sample and gently hold the tissue
 sample with their thumb between their index and second fingers. Each
 panelist used their other hand to gently pull the tissue sample out of
 their first hand. This procedure was repeated several times on the lower
 edge of the tissue to evaluate the degree of thickness as their fingers
 came together off the edge of the tissue.
 The data collected from the sensory panel analysis is presented in Table 1
 below and is graphically displayed in FIG. 5. The attribute values
 represent averages of all of the panelists.
 TABLE 1
 Sensory Panel Profile
 Attribute Example 1 Example 2 Example 3
 Fuzzy 3.94 4.74 5.49
 (air side)
 Fuzzy 5.43 5.75 5.85
 (fabric side)
 Gritty 3.56 2.25 1.98
 (air side)
 Gritty 2.11 1.77 1.98
 (fabric side)
 Grainy 2.55 1.41 1.35
 (air side)
 Grainy 1.95 1.28 1.37
 (fabric side)
 Stiffness 5.84 6.01 5.89
 Thickness 4.31 4.26 4.35
 Thus, the sensory panel comparisons indicate that soft-nip calendering with
 the fabric side oriented toward the resilient roll, represented by Example
 3, increases the Fuzzy attribute of softness more than soft-nip
 calendering with a transposed orientation of the calendering rolls,
 represented by Example 2. As noted previously, increasing the Fuzzy
 attribute indicates improved softness. Because the Fuzzy value is greater
 on both the air side and the fabric side when the fabric side is oriented
 toward the resilient roll (Example 3), it follows that the overall
 softness of the tissue is better using this orientation.
 The reduction of the Gritty and Grainy values on the air side of the tissue
 is a result of flattened crepe folds. Soft-nip calendering with the fabric
 side oriented toward the resilient roll (Example 3) increases the Fuzzy
 attribute at a 95 percent confidence level and directionally decreases the
 Gritty and Grainy attributes, resulting in a less two-sided sheet as
 compared to both Examples 1 and 2.
 Example 4
 A resilient roll having an exterior covering of ethylene propylene diene
 polymer was analyzed by measuring the penetration at varied loading levels
 of a hard mating roll into the resilient roll. For this analysis,
 penetration is defines as "the difference in position of the hard mating
 roll when it was just touching the resilient roll covering under no load
 (0 pounds per linear inch), and the distance the hard mating roll traveled
 into the resilient roll in a loaded state." The penetration was measured
 using a resilient roll with a total outside diameter of 21 inches (53.34
 centimeters) and an exterior cover thickness of 0.625 inch (1.5875
 centimeters). The mating roll and the resilient roll were analyzed at 2500
 feet per minute (762 meters per minute) without water cooling.
 The data collected from the analysis is presented in Table 2 below.
 TABLE 2
 Penetration of a Mating Roll into a Resilient Roll
 Resilient Roll Penetration:
 Loading (Pounds. Hardness (Shore A Hard/Soft
 Per Linear Inch) Durometer) (Inches)
 30 100 .002
 80 95 .005
 150 75 .016
 200 65 .029
 Table 2 shows that the smooth calender roll can penetrate the exterior
 covering of the resilient calender roll by a distance of from between
 about 0.002 inches to about 0.029 inches, specifically, a distance of from
 about 0.005 inches to about 0.029 inches, and more specifically, a
 distance of from about 0.005 inches to about 0.016 inches.
 It will be appreciated that the foregoing examples, given for purposes of
 illustration, are not to be construed as limiting the scope of this
 invention, which is defined by the following claims and all equivalents
 thereto.