It has previously been shown that MD streaks are created in the headbox jet, which is closely connected to the appearance of waves on the jet surface. The fundamental mechanism behind this break-up is presented. This has been achieved by implementing state-of-the-art methods for determining the characteristics and evolution of hydrody-namic instabilities. The methodology also allows the headbox slice to be designed in order to minimise jet break-up. This possibility has been evaluated in pilot-scale.