The present invention provides a process for producing a deep-nested
embossed paper product comprising the steps of delivering one or more
plies of paper to an embossing apparatus and embossing the one or more
plies of the paper between two opposed embossing cylinders. The one or
more plies of paper have a first direction and a second direction that is
perpendicular to the first direction where both the first and second
directions are in the plane of the paper and the one or more plies of
paper have a stretch characteristic in the first direction that is higher
than the stretch characteristic in the second direction. Each of the
embossing cylinders having a plurality of protrusions, each of which have
a height, where the embossing protrusions are disposed in an overall
non-random pattern where the respective overall non-random patterns on
the cylinders are coordinated to each other and the two embossing
cylinders are aligned such that the respective coordinated overall
non-random patterns of embossing protrusions nest together such that the
protrusions engage each other to a depth of greater than about 1.016 mm.
The overall non-random pattern of protrusions comprises a plurality of
emboss regions where each of the emboss regions comprising a fraction of
the total number of protrusions in the overall non-random pattern. All of
the protrusions within an embossing region have about the same height and
the pattern of protrusions within an emboss region creates a localized
primary line of stress on the paper as the plies of paper are embossed
where the line of stress has a component in the first direction and a
component in the second direction. The height of the protrusions within
an embossing region having a higher line of stress component in the first
direction is greater than the height of the protrusions in an embossing
region having a lower line of stress component in the first direction.