Disposable diapers making machine

Full Servo Two Piece Pullpants Production Line

What is a disposable diapers Making Machine?

disposable diapers making machine is a specialized device and system designed for the production of disposable diapers. This machine is part of the hygiene product manufacturing industry and is primarily used for large-scale, automated production processes. Its purpose is to improve production efficiency, reduce labor costs, and ensure that the products meet relevant hygiene standards.

Typically, a disposable Diaper Making Machine includes a series of automated processes and equipment to efficiently, precisely, and on a large scale produce disposable diapers.

Primary Raw Materials Used

Absorbent Layer Materials:
Typically, materials with high absorbency are used. These include high-absorbency polymers, five-layer absorbent paper, expanded paper, and sanitary paper.

Bottom Film and Backsheet Materials:
These are mainly used to manufacture the thin film materials for the outer and inner layers of diapers. The outer layer usually uses breathable and leak-proof materials, while the inner layer may use softer materials in contact with the skin. Examples include PE film, composite bottom film, release film, and breathable bottom film.

Top Sheet Materials:
Usually perforated film and non-woven fabric.

Frontal Tape Materials:
Mainly used for positioning and securing diapers when worn. It is placed at the front of the diaper, with magic tapes on the rear wings of the diaper. When in use, the diaper is fastened by attaching the magic tapes to the frontal tape. Materials include PP, non-woven fabric, etc.

Side Tape Materials:
The left and right side tapes of diapers are mainly used to adhere to the frontal tape, ensuring the diaper stays in place. These are typically magic tapes.

Other Materials:
Spandex, elastic waistbands, adhesive, quick-release paper, and other materials.
To learn more about diaper raw materials, please click the button below.

Size and Weight

Size:
The size describes the space occupied by the disposable diaper making machine, including length, width, and height, It includes overall dimensions (footprint) and equipment dimensions. It is typically measured in meters.

Weight:
Usually measured in tons.

The size and weight of the disposable diaper making machine are two crucial parameters that impact transportation, installation, and the overall layout of the production line. When purchasing a diaper manufacturing machine, customers should choose one that suits their factory’s planning and layout based on these factors.

Production Process

What is the production process of a disposable diaper making machine?

Material Preparation:
Firstly, various raw materials need to be prepared, including absorbent materials (such as superabsorbent resin), non-woven fabric, backsheet film (PE film), top sheet, etc. These raw materials play different roles in different parts of the diaper.

Cutting and Shaping:
The manufacturing machine cuts the prepared raw materials into the appropriate shapes and sizes. This may involve cutting and positioning non-woven fabric, absorbent materials, etc., to ensure the consistency of the final product.

Stacking and Assembling:
Various parts of the diaper are stacked together in a specific order, including the absorbent core, non-woven fabric, backsheet, etc. This process ensures that each part is properly assembled to form a complete diaper structure.

Sealing and Cutting:
The complete diaper structure is sealed by heating or pressure to ensure tight bonding of each layer. Subsequently, the diaper is cut to the required size.

Installation of Elastic Components:
For diapers with waistband elasticity, elastic elements (such as waist elastic) are installed at the appropriate positions. This typically requires some automated systems to ensure accurate installation positions and stretch.

Packaging:
The produced diapers are packaged using an automated packaging system. This may involve stacking, folding, and placing diapers in bags or boxes. Packaging is usually done automatically to enhance efficiency.

The entire production process should be monitored by a control system to ensure that each step is carried out according to the designed standards. A fully automated production process significantly improves production efficiency and product quality.

Automation and Control

Automation Control System of Disposable Diaper Manufacturing Machine
PLC Control System:
Most disposable diaper manufacturing machines utilize Programmable Logic Control (PLC) systems. PLC is a computer system specifically designed for industrial control, capable of executing various control tasks, including monitoring sensor data and controlling actuators such as motors and cylinders.

Touchscreen Interface:
Manufacturing machines are typically equipped with user-friendly touchscreen interfaces. Through this interface, operators can monitor and adjust the production process. This intuitive interface allows operators to easily set and control production parameters.

Sensor Technology:
Automation systems employ various sensors to monitor and provide feedback on information related to the production process. For instance, sensors can detect real-time measurements of diaper length, width, humidity, etc., transmitting this data to the control system for corresponding adjustments.

Precision Motor Control:
Motor control in manufacturing machines often involves servo motors or stepper motors to achieve more precise control. This is crucial for ensuring the accuracy of key steps such as cutting and positioning.

Real-time Monitoring and Alarm System:
Automation systems are usually equipped with real-time monitoring features to display production status and performance. Additionally, the system can generate alarms based on preset conditions, alerting operators to potential issues for timely intervention and maintenance.

Network Connection and Remote Monitoring:
Some advanced manufacturing machines are equipped with network connectivity, enabling remote monitoring and maintenance via the internet. This allows manufacturers to track production in real-time, make remote adjustments, and provide support when needed.

Automated Quality Inspection:
Automation systems typically integrate automatic quality inspection functions. Using technologies such as image recognition and sensor detection, the system performs quality checks on the manufactured products to ensure they meet standards.

Adjusting Production of Diapers in Different Sizes and Shapes
Disposable diaper manufacturing machines possess flexibility, allowing easy adjustment of diaper size and shape. This capability enables a swift transition from producing one type of diaper to another, greatly enhancing diaper production efficiency.

Digital Size Adjustment:
Advanced diaper manufacturing machines are often equipped with digital control systems. Operators can input the desired size parameters, including length and width, through a touchscreen or computer interface. These digital systems can quickly and accurately adjust the machine’s configuration.

Servo Motor Control:
Servo motors are commonly used in manufacturing machines to drive critical components such as cutting mechanisms and positioning systems. Servo motors offer precise position control, allowing easy adjustment of diaper sizes by modifying motor positions and speeds.

Die-cutting Roller Adjustment:
Manufacturing machines typically use die-cutting rollers to shape and cut diapers. Adjusting the position and shape of these rollers can change the diaper’s shape and size.

Adjustable Conveying System:
The conveying system plays a crucial role in shaping and moving diapers. Some machines feature adjustable conveyors or rollers, allowing operators to adapt to different product sizes and shapes by adjusting these components.

Quick Mold Change:
Some manufacturing machines are designed with a rapid mold change system. This means operators can quickly change molds, facilitating a swift transition in the production line.

Adjustable Folding System:
For diapers with folding structures, machines are usually equipped with adjustable folding systems to accommodate different folding methods and shapes.

Real-time Monitoring and Adjustment:
Advanced manufacturing machines typically include real-time monitoring features. Through sensors and monitoring systems, production parameters can be adjusted at any time to ensure consistency in product size and shape.

Quality Control

How does a disposable diaper manufacturing machine ensure that the produced diapers meet hygiene standards?

  1. Raw Material Quality Control:
    Strict testing and validation of raw materials used in diaper manufacturing, including paper, absorbent materials, tapes, elastic materials, etc. Only raw materials meeting specified standards are used in production.
  2. Production Process Monitoring:
    Real-time monitoring of various stages of the manufacturing machine to ensure that parameters (such as temperature, humidity, speed, etc.) stay within specified ranges. The automated control system helps adjust these parameters to ensure product consistency.
  3. Quality Sampling:
    Periodic testing of products on the production line through random sampling. This may involve laboratory tests such as absorbency performance, tensile strength, size accuracy, etc. Sampling results can be used to adjust production parameters or determine the need for process improvements.
  4. Hygiene Condition Control:
    Maintaining cleanliness and hygiene conditions in the production workshop. This includes regular cleaning and disinfection of production equipment, maintaining personal hygiene of operators, and ensuring a clean working environment.
  5. Employee Training:
    Regular training of operators to ensure they understand and follow relevant hygiene and quality control procedures. Training may also cover the use of new technologies and equipment to ensure efficient production line operation.
  6. Traceability System:
    Establishing a traceability system to record detailed information for each production batch, including raw material batches, production dates, production parameters, quality inspection results, etc. This helps quickly trace and resolve issues when quality problems occur.
  7. Continuous Improvement:
    Regular internal reviews of the quality management system to identify improvement opportunities. This may include adopting new technologies, improving processes, enhancing efficiency, etc., to ensure continuous improvement in product quality.

Monitoring and Control Mechanism for Scrap Rate

  • Real-time Production Data Monitoring:
    Implementing a real-time monitoring system to track key parameters during the production process. This includes temperature, humidity, speed, pressure, machine status, etc. Abnormal data may be an early indicator of an increase in the scrap rate.
  • Quality Sampling:
    Conducting regular quality sampling on the production line to inspect key product characteristics such as absorbency, size accuracy, strength, etc. Sampling results help assess whether the product meets specifications, allowing for scrap rate determination.
  • Scrap Classification and Root Cause Analysis:
    Classifying and recording the specific reasons for scrap. This helps the production team quickly identify and address issues, reducing the occurrence of similar problems in the future.
  • Traceability System:
    Using a traceability system to record production parameters, raw material information, quality inspection results, etc., for each production batch. If the scrap rate deviates from the norm, the traceability system can help quickly locate the stage where the problem occurred, expediting issue resolution.
  • Fault Alarm System:
    Implementing a fault alarm system on the production line to issue timely alerts when anomalies or potential issues are detected. This helps reduce the production of non-conforming products and prevents a continuous increase in the scrap rate.
  • Employee Training:
    Training operators to better understand product quality standards and the quality control process, reducing human-induced increases in the scrap rate.
  • Regular Scrap Rate Analysis:
    Establishing a regular analysis mechanism for the scrap rate to thoroughly understand its changing trends. This helps discover potential problems and take preventive measures for continuous improvement in the production process.

Packaging Process

Does the disposable diaper manufacturing machine include an automatic packaging system?

Disposable diaper manufacturing machines typically include an automatic packaging system. The automatic packaging system is the final stage of the manufacturing process, responsible for packaging the produced diapers into the final sales units. The automation of this process helps improve production efficiency, reduce labor costs, and ensure consistent packaging quality.

The automatic packaging system usually consists of the following components:

  • Conveyor System: Transports the produced diapers from the manufacturing line to the packaging line.
  • Packaging Material Supply System: Supplies materials such as cardboard boxes, plastic bags, or other packaging materials to ensure proper protection of diapers during the packaging process.
  • Automatic Packaging Machine: Uses mechanical arms, conveyor belts, and other equipment to arrange diapers into packaging materials according to predetermined specifications. This may include packaging individual diapers or a combination of multiple diapers.
  • Sealing Machine: Seals the packaging to ensure product integrity and hygiene.
  • Labeling and Batch Traceability System: Adds labels during the packaging process containing information such as production date, batch number, etc. This aids in tracing the production history of products for quality control and after-sales service.
  • Weight Detection System: Checks the weight of packaged products to ensure that each packaging unit meets specified quantity and quality standards.
  • Automatic Stacking System: Stacks packaged products onto pallets for storage and transportation.

Does the packaging process meet the requirements of transportation and sales?

The design of the packaging process is crucial for meeting the demands of transportation and sales. An effective packaging system should consider the following aspects to ensure the safety, convenience, and hygiene of the product throughout the entire supply chain:

  • Protective Performance: The packaging must effectively protect diapers, preventing damage, deformation, or moisture during transportation.
  • Durability: Packaging materials should have sufficient durability to prevent tearing, abrasion, or other damage during transportation and storage, especially considering the long shelf life of diapers.
  • Adaptability: Packaging design should adapt to different modes of transportation, including land, sea, air, etc. It should also adapt to various temperature and humidity conditions to ensure stability in different environments.
  • Ease of Handling: Packaging should be easy to handle and transport, reducing labor costs in warehousing and retail.
  • Packaging Labels: Clear and accurate labeling on the packaging, including product information, specifications, quantity, production date, batch number, etc. This facilitates supply chain management and provides necessary information for consumers.
  • Retail Display: Packaging design should consider the display and presentation requirements in retail environments, attracting customers and promoting sales.
  • Environmental Friendliness: Consideration of eco-friendly materials and designs to reduce the environmental impact of packaging. This aligns with the increasing focus on sustainability and environmental concerns today.

Maintenance and After-Sales Service

Does the disposable diaper manufacturing machine provide after-sales service, such as remote or on-site support from engineers?

Suppliers of disposable diaper manufacturing machines typically offer after-sales services, including remote or on-site support from engineers. This service helps ensure that the manufacturing machine operates smoothly and can be promptly resolved if issues arise. The following are support methods that may be included in after-sales services:

  • Remote Support: Engineers can provide remote support through technologies such as the internet or telephone. This support can be used for diagnosing issues, adjusting equipment settings, troubleshooting, etc. Remote support is often quick to respond, minimizing downtime.
  • On-Site Support: In certain situations, issues may require engineers to personally visit the site for resolution. Suppliers usually offer on-site support services to ensure that professional personnel can be dispatched to the location of the manufacturing machine when needed.
  • Training Services: Suppliers may provide operator training to ensure that operators can operate the manufacturing machine correctly and safely. Training services may be conducted initially after purchase and may also be provided as periodic refresher training.
  • Spare Parts Supply: To ensure equipment reliability and convenient maintenance, suppliers typically provide original spare parts. These spare parts can be quickly delivered when needed, minimizing downtime.
  • Regular Maintenance: Providing regular maintenance services to ensure the long-term stable operation of the manufacturing machine. This may include cleaning, lubrication, replacement of wear parts, and other maintenance tasks.
  • Upgrade Services: In cases of technological advancements or changes in customer requirements, suppliers may offer upgrade services, including hardware and software updates, to improve equipment performance and functionality.

What steps are involved in the maintenance of a disposable diaper manufacturing machine?

  • Regular Cleaning: Cleaning is a fundamental step in maintenance. Regularly clean various parts of the machine, including conveyors, blades, forming components, etc. Removing dust, paper scraps, and other debris helps prevent equipment malfunctions and improves production efficiency.
  • Lubrication: Regularly lubricate moving parts of the equipment to reduce friction and wear. Use appropriate lubricants to ensure that oil or grease covers critical areas, extending the lifespan of bearings and moving parts.
  • Check Transmission Systems: Regularly inspect transmission systems, including gears, chains, belts, etc. Ensure they are free from wear, breakage, or looseness, and replace or adjust them as necessary.
  • Inspect Electrical Systems: Periodically inspect electrical systems, including cables, switches, sensors, etc. Ensure proper connections to avoid electrical failures.
  • Replace Wear Parts: Based on the usage of the manufacturing machine, regularly replace wear parts such as blades, sealers, rubber pads, etc. This helps maintain machine performance and reduces the risk of sudden failures.
  • Adjust Equipment Parameters: Regularly check and adjust the operating parameters of the equipment, including speed, temperature, tension, etc. Ensure that the equipment operates in optimal conditions and prevents issues during the production process.
  • Inspect Safety Devices: Ensure that safety devices, such as emergency stop buttons, safety sensors, are in working order. This helps ensure the safety of operators.
  • Clean and Calibrate Sensors: If the manufacturing machine uses sensors to monitor product quality or equipment status, regularly clean and calibrate these sensors to ensure accuracy and stability.
  • Record Maintenance Activities: Record the date, content, and personnel for each maintenance activity. This helps establish a maintenance schedule, track the maintenance history of the equipment, detect problems in a timely manner, and prevent future failures.
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