Patent ID: 7387064

Claim:
A method of forming a calendered paper web comprising the steps of: manufacturing and drying a paper web, moisturizing the dried paper web to a moisture content of 4-7% and reeling the paper web into a machine reel; un-reeling the paper web and calendering the paper web in a multinip calender whose roll assembly is formed of a first set of rolls and a second set of rolls, the second set of rolls arranged after, and separate from the first set of rolls in a travel direction defined by the travel of the paper web, the paper web traveling over guide rolls between rolls of the first set of rolls and the second of rolls; wherein the paper web is calendered in the first set of rolls arranged to form first successive nips between superimposed rolls having a flexible coating and heated metal rolls having a smooth surface following each other alternately in the travel direction; wherein the paper web is calendered in the second set of rolls arranged to form second successive nips between superimposed rolls having a flexible coating and heated metal rolls having a smooth surface following each other alternately in the travel direction; moisturizing one surface of the paper web with at least one pre-moisturizer and raising the paper web to a moisture content of 8-12%, and thereafter passing the paper web to a first calender nip of the first successive nips of the first set of rolls, and then through said first successive nips of the first set of rolls; moisturizing an opposite surface of the paper web with at least one intermediate moisturizer and raising the paper web to a moisture content of 6-10%, and thereafter passing the paper web to a first calender nip of the second successive nips of the second set of rolls, and then through said second successive nips of the second set of rolls; wherein the at least one pre-moisturizer is spaced from the first calender nip so that the travel of the paper web in the travel direction toward the first calender nip of the first successive nips of the first set of rolls defines a first absorption time of the moistening medium sprayed by the pre-moisturizer and wherein the intermediate moisturizer on the opposite surface of the paper web is spaced from the first calender nip of the second successive nips of the second set of rolls so that the travel of the paper web in the travel direction toward the first calender nip of the second set of rolls defines a second adsorption time substantially the same as the first adsorption time; wherein the paper web is calendered to a roughness of 1.0-1.1 μm and a gloss of 54-57%.