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bopp tape making machine how is a diaper machine work

bopp tape making machine how is a diaper machine work

How disposable diaper is made

  A disposable diaper consists of an absorbent pad sandwiched between two
sheets of nonwoven fabric. The pad is specially designed to absorb and
retain body fluids, and the nonwoven fabric gives the diaper a comfortable
shape and helps prevent leakage. These diapers are made by a multi-step
process in which the absorbent pad is first vacuum-formed, then attached
to a permeable top sheet and impermeable bottom sheet. The components are
sealed together by application of heat or ultrasonic vibrations. Elastic
fibers are attached to the sheets to gather the edges of the diaper into
the proper shape so it fits snugly around a baby's legs and crotch.
When properly fitted, the disposable diaper will retain body fluids which
pass through the permeable top sheet and are absorbed into the pad.

  Disposable diapers are a relatively recent invention. In fact, until the
early 1970s mothers had no real alternative to classic cloth diapers.
Cotton diapers have the advantage of being soft, comfortable, and made of
natural materials. Their disadvantages include their relatively poor
absorbency and the fact that they have to be laundered. Disposable diapers
were developed to overcome these problems. The earliest disposables used
wood pulp fluff, cellulose wadding, fluff cellulose, or cotton fibers as
the absorbent material. These materials did not absorb very much moisture
for their weight, however. Consequently, diapers made from these materials
were extremely bulky. More efficient absorbent polymers were developed to
address this issue.

  Since the 1970s, disposable diaper technology has continued to evolve. In
fact, nearly 1,000 patents related to diaper design and construction have
been issued in the last 25 years. Today's diapers are not only
highly functional, they include advanced features such as special sizing
and coloring for specific gender and age, color change indicators to show
when the child is wet, and reattachable VelcroTM-type closures. These
innovations have enabled disposables to capture a large share of the
diaper market. In 1996, disposable diaper sales exceeded $4 billion in the
United States alone. Proctor and Gamble and Kimberly Clark are the two
largest brand name manufacturers, and their sales account for nearly 80%
of the market. Private label manufacturers that produce store brands and
generic diapers account for most of the remaining 20%.

  The single most important property of a diaper, cloth or disposable, is
its ability to absorb and retain moisture. Cotton material used in cloth
diapers is reasonably absorbent, but synthetic polymers far exceed the
capacity of natural fibers. Today's state-of-the-art disposable
diaper will absorb 15 times its weight in water. This phenomenal
absorption capacity is due to the absorbent pad found in the core of the
diaper. This pad is composed of two essential elements, a hydrophilic, or
water-loving, polymer and a fibrous material such as wood pulp. The
polymer is made of fine particles of an acrylic acid derivative, such as
sodium acrylate, potassium acrylate, or an alkyl acrylate. These polymeric
particles act as tiny sponges that retain many times their weight in
water. Microscopically these
polymer molecules resemble long chains or ropes. Portions of these
chemical "ropes" are designed to interact with water
molecules. Other parts of the polymer have the ability to chemically link
with different polymer molecules in a process known as cross linking. When
a large number of these polymeric chains are cross linked, they form a gel
network that is not water soluble but that can absorb vast amounts of
water. Polymers with this ability are referred to as hydrogels,
superabsorbents, or hydrocolloids. Depending on the degree of cross
linking, the strength of the gel network can be varied. This is an
important property because gel strength is related to the tendency of the
polymer to deform or flow under stress. If the strength is too high the
polymer will not retain enough water. If it too low the polymer will
deform too easily, and the outermost particles in the pad will absorb
water too quickly, forming a gel that blocks water from reaching the inner
pad particles. This problem, known as gel blocking, can be overcome by
dispersing wood pulp fibers throughout the polymer matrix. These wood
fibers act as thousands of tiny straws which suck up water faster and
disperse it through the matrix more efficiently to avoid gel blocking.
Manufacturers have optimized the combinations of polymer and fibrous
material to yield the most efficient absorbency possible.

  The absorbent pad is at the core of the diaper. It is held in place by
nonwoven fabric sheets that form the body of the diaper. Nonwoven fabrics
are different from traditional fabrics because of the way they are made.
Traditional fabrics are made by weaving together fibers of silk, cotton,
polyester, wool, etc. to create an interlocking network of fiber loops.
Nonwovens are typically made from plastic resins, such as nylon,
polyester, polyethylene, or polypropylene, and are assembled by
mechanically, chemically, or thermally interlocking the plastic fibers.
There are two primary methods of assembling nonwovens, the wet laid
process and the dry laid process. A dry laid process, such as the
"meltblown" method, is typically used to make nonwoven
diaper fabrics. In this method the plastic resin is melted and extruded,
or forced, through tiny holes by air pressure. As the air-blown stream of
fibers cools, the fibers condense onto a sheet. Heated rollers are then
used to flatten the fibers and bond them together. Polypropylene is
typically the material used for the permeable top sheet, while
polyethylene is the resin of choice for the non-permeable back sheet.

  There are a variety of other ancillary components, such as elastic
threads, hot melt adhesives, strips of tape or other closures, and inks
used for printing decorations.

  1 The absorbent pad is formed on a movable conveyer belt that passes
through a long "forming chamber." At various points in
the chamber, pressurized nozzles spray either polymer particles or
fibrous material onto the conveyor surface. The bottom of the conveyor
is perforated, and as the pad material is sprayed onto the belt, a
vacuum is applied from below so that the fibers are pulled down to
form a flat pad.

  At least two methods have been employed to incorporate absorbent
polymers into the pad. In one method the polymer is injected into the
same feed stock that supplies the fibers. This method produces a pad
that has absorbent polymer dispersed evenly throughout its entire
length, width, and thickness. The problems associated with method are
that loss of absorbent may occur because the fine particles are pulled
through the perforations in the conveyor by the vacuum. It is
therefore expensive and messy. This method also causes the pad to
absorb unevenly since absorbent is lost from only one side and not the
other.

  A second method of applying polymer and fiber involves application of
the absorbent material onto the top surface of the pad after it has
been formed. This method produces a pad which has absorbent material
concentrated on its top side and does not have much absorbency
throughout the pad. Another disadvantage is that a pad made in

this way may lose some of the polymer applied to its surface.
Furthermore, this approach tends to cause gel blocking, since all the
absorbent is on the outside of the pad. The moisture gets trapped in
this outer layer and does not have a chance to diffuse to the center.
This blockage holds moisture against the skin and can lead to
discomfort for the wearer.

  These problems are solved by controlling the mixture polymer and
fibrous material. Multiple spray dispensers are used to apply several
layers of polymer and fiber. As the fiber is drawn into the chamber
and the bottom of the pad is formed, a portion of the polymer is added
to the mix to form a layer of combined polymer and fiber. Then more
pure fiber is pulled on top to give a sandwich effect. This formation
creates a pad with the absorbent polymer confined to its center,
surrounded by fibrous material. Gel blockage is not a problem because
the polymer is concentrated at core of pad. It also solves the problem
of particle loss since all the absorbent is surrounded by fibrous
material. Finally, this process is more cost effective because it
distributes the polymer just where it is needed.

  2 After the pad has received a full dose of fiber and polymer, it
proceeds down the conveyor path to a leveling roller near the outlet of
the forming chamber. This roller removes a portion of the fiber at the
top of the pad to make it a uniform thickness. The pad then moves by the
conveyor through the outlet for subsequent operations to form the
competed diaper.

3 Sheets of nonwoven fabric are formed from plastic resin using the
meltblown process as described above. These sheets are produced as a
wide roll known as a "web," which is then cut to the
appropriate width for use in diapers. There is a web for the top sheet
and another for the bottom sheet. It should be noted that this step
does not necessarily occur in sequence after pad formation because the
nonwoven fabrics are often made in a separate location. When the
manufacturer is ready to initiate diaper production these large bolts
of fabric are connected to special roller equipment that feeds fabric
to the assembly line.

  4 At some point in the process, stretched elastic bands are attached to
the backing sheet with adhesive. After the diaper is assembled, these
elastic bands contract and gather the diaper together to ensure a snug
fit and limit leakage.

5 At this point in the process there are still three separate
components, the absorbent pad, the top sheet, and the backing sheet.
These three components are in long strips and must be joined together
and cut into diaper-sized units. This is accomplished by feeding the
absorbent pad onto a conveyor with the polyethylene bottom sheet. The
polypropylene top sheet is then fed into place, and the compiled sheets
are joined by gluing, heating, or ultrasonic welding. The assembled
diaper may have other attachments, such as strips of tape or Velcro

, which act as closures.

6 The long roll is then cut into individual diapers, folded, and
packaged for shipping.

Diaper production does not produce significant byproducts; in fact the
diaper industry uses the byproducts of other industries. The absorbent
polymers used in diaper production are often left over from production
lines of other chemical industries. The polymer particles are too small
for other applications, but they are well suited for use in diapers. In
diaper production, however, considerable amounts of both nonwoven material
and polymer particles are wasted. To minimize this waste, the industry
tries to optimize the number of diapers obtained from every square yard
(meter) of material. Furthermore, every attempt is made to recover the
excess fiber and polymer material used in the forming chamber. However,
this is not always possible due to clogging of filters and other losses.

  There are several methods used to control the quality of disposable
diapers, and most of these relate to the product's absorbency.
One key is to make sure the polymer/fiber ratio in the absorbent pad is
correct. Too much variation will impact the diaper's ability to
soak up moisture. Industry trial and error has shown that for optimal
performance and cost, the fiber to particle ratio should be about 75:25 to
90:10. Even more critical than this ratio are the size and distribution of
these particles. It has been established that particles with mass median
particle size greater than or equal to about 400 microns work very well
with the fibers to enhance the rate at which the fluid is transported away
from the body. If the particles vary much outside this range, gel blocking
may occur.

  There are several standard tests the industry uses to establish diaper
absorbency. One is referred to as Demand Wettability or Gravimetric
Absorbance. These tests evaluate what is are commonly referred to as
Absorbance Under Load (AUL). AUL is defined as the amount of 0.9% saline
solution absorbed by the polymers while being subjected to pressure
equivalent to 21,000 dynes, or about 0.30 lb/sq in (0.021 kg/sq cm). This
test simulates the effect of a baby sitting on a wet diaper. If the diaper
has an absorbency of at least 24 ml/g after one hour, the quality is
considered acceptable.

  Other quality control factors besides absorbency are related to the
diaper's fit and comfort. Particular attention must be paid to the
melt characteristics of the nonwoven fabrics used to form the
diaper's shell. If materials with different melting points are
used, the material that melts the quickest may become too soft and stick
to the assembly apparatus. When the fabric is pulled off it may be left
with a rough surface that is uncomfortable to the user. Finally, the
alignment of the components must be carefully checked or leakage may
result.

  Disposable diaper manufacture is a high technology field which has
consistently shown innovation over the last few decades. Nonetheless,
there are still a number of areas which require additional improvement.
One such area is that of leakage reduction. It is likely that
manufacturers will develop improved elastic bands to hold the waist more
tightly without causing chafing or discomfort. It is also likely that
current concern regarding the role of disposable diapers in landfills will
impact manufacturing and formulation. This concern may to lead to the
development of diapers which are less bulky and more biodegradable.

  "Dueling diapers."

The Edell Health Letter,

August 1993, p. 6.

  McAloney, Regina. "Thin is in."

Nonwovens Industry,

November 1994 p.52.

  Lenzner, Robert, and Carrie Shooc. "The Battle of the
Bottoms."

Forbes,

March 24, 1997, p. 98.

  Ohmura, Kin. "Superabsorbent Polymers in Japan."

Nonwovens Industry,

January 1995, p. 32.

  —

Randy

Schueller

How to buy your first disposable diaper machine.

  Every disposable diaper manufacturer knows that the most difficult machine to buy is always the first one. Based on their earned experience with this first machine, diaper manufacturers become more knowledgeable and more cautious when buying their second or third machine. If only this level of knowledge was available to them from the beginning, they would have saved tens of thousands and in many cases even hundreds of thousands of dollars. Let us review some of the important steps that need to be checked before you rush with your hard earned money to place your first purchase with a diaper machine vendor; lets review the common mistakes usually committed by most first timers. 

  Lets start with a few key steps.

  Do you really want to be a diaper manufacturer? Be absolutely sure, most times there is no way to go back once you pass the point of no return. It is amazing how many excellent traders end up being lousy manufacturers just because they did not understand where they were getting into, or nobody told them. Get all the facts! People often say that the grass looks greener on the other side of the fence. Make sure it is really greener before you move to the other side. If you already own a private label, once your diaper suppliers know that you are planning to become a manufacturer, they will treat you very differently, like a future competitor instead of a client; I have seen it happening many times. For this reason, unless you have a close relation with your supplier, one that is filled with trust (the kind that I always prefer to have), it may be better to keep it a secret. If you do not trust them, then it may be better to have other alternatives ready, just in case. If something goes wrong, and you want to get back to your trading business, your previous suppliers would never trust you again. Basically you would have to start from scratch.Analyze your market well. Sometimes it may be easier to make a diaper than to sell it, especially with a new “ugly duckling” brand that nobody knows, or when you end up offering a diaper with the wrong set of features for your market. Trust your own marketing instincts on top of those of your machine vendor. They make diaper machines, but they don’t sell diapers. In this case, the market is the king and your only boss. Before you can choose a good diaper design, you have to understand how your competitor’s diapers are constructed. Start with a diaper performance benchmark, and then continue with a professional and detailed reverse engineering report; to reduce costs, do it for those brands that look most promising, or choose only one size and then select more brands. Understand what features are truly needed and why one brand may be better accepted in your local market than the others. If you don’t know how to do a diaper performance benchmark or a reverse engineering analysis, seek expert help (I am here to help you, but other consultants can also do it for you). There is no better time to invest in good know-how than just before you decide what product to make or which machine you may want to buy. If you don’t know the exact composition of your competitor’s products, how do you expect to know their manufacturing costs and your own potential margins ahead of time? How do you know it will be a good profitable business?Now you are ready to define all the product features that you want to order from the machine vendor.

  You need to define your required machine speed. You should look at the market potential data and your own budget limitations. A simple criterion is to define the speed based on an estimate for your own sales volume after 6 months from start-up, being sure you can sell at least one shift of production at the expected cruise speed and rated capacity of the machine you plan to buy. If the required speed of the machine is slow against modern machine speed standards, for example, if you need less than 300 baby diapers per minute (or 150 adult diapers per minute); chances are you will never be able to buy directly from the raw material suppliers. This is due to your low purchasing volume; your costs will probably be much higher. There is always a minimal critical volume you need to pass, this quantity depends on your location; mature markets require much larger volumes (in the tens of millions each month), emerging markets much less (a few million per month may be enough), below this critical volume, you are basically doomed. You must think carefully if you want to become a micro-manufacturer (small garage size machine), your chances for survival by buying from intermediaries could be slim. At this stage of your project, it is a good time to go to the industry shows to familiarize yourself with equipment suppliers and all the raw materials. The most important industry shows usually rotate between Miami or Boston (IDEA, already happened last May last year 2019), then Geneva (INDEX, it will be next year 2021 as the 2020 edition had to be canceled due to Covid19), and finally China (in 2021); every three years the cycle is restarted.Make sure you ask for the same exact items or the same diaper machine modules from all potential vendors; make sure each machine module is really equivalent in terms of the technology and process control; the acceptable performance for your equipment has to be well defined as part of the purchasing contract. It is easy to promise, some vendors do whatever it takes to try to close a deal, but to deliver against a well-defined contract is something else, few will take the risk.  It is always better to visit an actual factory running the equipment instead of just visiting the equipment manufacturer. Of course, this is not always possible, but at least try.In this industry, the variable cost of production is more important than the investment capital, for this reason, it justifies to pay more for equipment if you are convinced you will be able to manufacture exactly the same product with a lower unitary cost and/or with better quality. This is usually the reason why people want to get rid of their old equipment to exchange with a new one. For example, depending on the number of working shifts, a high-speed machine, working just 10 minutes more per hour, with 3% better conversion efficiency than other similar equipment, may pay for itself in just 1.5 years (and this is just from the savings). If in addition, it also ends up with a better standard deviation on key diaper performance variables, your savings could be even higher. Based on this fact, price differences between equipment may be less relevant than you imagined. Make sure you have a good fit between the technology offered and the quality of the power source and the technical skills of the local people. If you are ever tempted to buy a second-hand machine, just be sure the equipment runs well at an acceptable efficiency, and that you will be provided with the required training and technical documentation. Buying a used line without knowing what you are buying, or without a formal basic training program is plain dumb. A well-maintained machine may be better than a “like new or refurbished” if they only changed a few bearings and belts and applied new painting to make it look appealing in exchange for a big price and no serious guarantees. Be extra careful. In my opinion, it may be better to buy from the original owner if the machine is still in good running condition. Keep in mind that as soon as a machine is stopped or disassembled, it loses at least 60% of its original market value, if not more. Make sure it will be restarted.Make sure you have enough money left after the purchase of the machine to use for working capital. Keep in mind that the diaper machine and the building are probably just half of the total investment you will need to operate your new business, that is unless you already have excellent credit ratings to use for working capital. Starting up a new diaper factory without money in your pocket is the very worst thing you can do.Make sure you have a good technical team, with solid manufacturing experience. Choose each profile carefully. People that you can trust. You must have them ready before you are being called for the acceptance test by the vendor. Hiring key personnel under time pressure is a bad business decision. Going to the final acceptance test without a good technical team (production, maintenance, electric & electronic, and quality) is a total waste of your money. The cost of learning by error at your location will prove to be extremely expensive. It may be a good idea to hire an industry consultant to help you during the acceptance test at the OEM; at least for a few days, just to make sure the machine complies with your requirements and those critical areas are pointed out to you.Make sure that the acceptance test at the vendor’s factory takes into account all your basic training needs, like product size changes, electronic calibrations, PLC calibrations for ejecting splices, maintenance, and spare part changes, and stack count changes. Buy enough material to complete the run test according to negotiated performance in at least two sizes and at least for one full hour each. If the contract was written correctly, the pressure should be on both (vendor and buyer). A common mistake is to be forced by the vendor to take the machine away without even passing the acceptance test, just because you ran out of material and sometimes because they misused the materials during a long or painful start-up process. Penalties must be considered as part of the contract to avoid having you pay for the broken dishes. Do not believe the common promise that they will have the machine fixed later during installation at your own factory; most times this is never the case. If it was not fixed at the vendor’s premises, with all resources available nearby, it is much less likely it will be fixed later. In extreme situations, some machines never run once installed at their designated locations.Make a special budget for your installation, for the auxiliary equipment like air dryer and compressor, ducting, wiring, dust reclaiming, laboratory equipment, etc. Make a plan for the start-up and the time required for your learning curve. Make sure the team the vendor sends to your factory for initial set up and calibration is, in fact, able to communicate with your local team in a clear way; if this is hard, at least have a good translator at your disposal. Make sure you have a quality control laboratory and that you have trained all your staff about what makes a good diaper with the correct work instructions. Don’t be tempted to accept any new product unless it satisfies all product quality requirements. The machine should never be started if you don’t have a quality manual, with product tolerances. If you already have a private label brand and are planning to substitute with your own production, you should be extra careful or you may lose your brand during the learning process. In other words, you can’t afford a learning curve; it can be extremely expensive unless you start with another brand. Another good reason that justifies an expert consultant. Starting a successful diaper plant is a complex process, but not impossible. If anything can be said, it creates a good entrance barrier, making it difficult for others to enter. It is not just a matter of money in your pocket as it is of having the correct profile; being in the right place at the right time, and feeling sure about your knowledge of your market. You need a building and the equipment layout that does not only take into account your present installation but your future growth for at least the next 5 years. You need to have good chemistry with a vendor you can trust. Don’t be afraid to spend some money in exchange to ensure that you will get the strategic learning you need in order to understand the diaper business; you go to school to learn a profession; you may also need to go to school to learn the facts of this industry. Considering the size of the investment, this will be petty cash.  Many investors have failed, but also many have created huge emporiums. Most of these successful factories have one thing in common; they are all passionate about what they do and they learned what they needed to know. A diaper factory is an absorbent business, but it can also be very rewarding. I serve as an example, even after 32 years I still enjoy doing what I do, helping new diaper industry investors. After helping the industry in 28 countries, I can’t think of a better thing to do.

How To Choose A Suitable Diaper Machine For Diaper Manufacturing

  According to the sales performance of baby diapers in developing countries in recent years, we have analyzed the baby diapers market in developing countries. We believe that Africa, the Middle East, Central Asia, and Southeast Asia are the markets with the fastest growth and the greatest potential for all daily necessities. Baby diapers and The adult diaper market have just started. This is the best time to invest in this industry, a good opportunity to seize the market, investing in diaper manufacturing projects.

      For a good diaper project, strong market demand is a necessary condition for the success of the project, and a diaper converting machine is the basic condition for the completion of the project. Therefore, choosing the right diaper machine determines the material conditions. We must fully understand the current status, manufacturing level, and R&D direction of the current baby diaper converting machine manufacturing industry, and understand the machine structure and configuration (mechanical, electrical, pneumatic, process control, and automation) Level), performance, select multiple diaper machine manufacturers for comparison, consult different diaper machine factories, see how they promote their products, find out the common points and differences, and choose the right diaper machine after comprehensive analysis. There are industry experts. Several Chinese machinery manufacturing companies have been screened and compared carefully. The following points are provided for reference when choosing a diaper-making machine.

  diaper machine

  1) The current level of China’s domestic baby diaper manufacturing industry

      The Diaper converting machine was first developed and manufactured in Europe and the United States, and introduced in Japan to deepen the improvement. Therefore, the current diaper machine manufacturing level is the best: Italy Fameccanica and GDM, and Japan Zuiko. These brand-name baby diaper machines are expensive, a huge one-time investment and maintenance costs are too high, and ordinary small and medium-sized companies will not buy them. At present, several major companies selling diapers in the domestic market (P&G, Kimberly-Clark, HENGAN group, BJBEST) have entered the diaper machine since 2012. From old to new, semi-automatic to semi-servo, semi-servo to full-servo, low-speed to high-speed During the replacement period, the current diaper-making machine pursues high speed, stability, less waste, and smart and simple operation. The manufacture of China’s diaper machine has changed from the introduction of European and American equipment to be transformed into localization, but the key function configuration still retains the international famous brand, which can ensure the stable performance of the Chinese diaper machine, the increase of speed, the reduction of failure rate, the improvement of automatic control accuracy, and the basic satisfaction Production demand. Low prices and easy maintenance are the preferred conditions for small and medium-sized companies, so domestic diaper machines are favored by small and medium-sized companies. Domestic companies that manufacture mid-to-high-end diaper converting machines are mainly concentrated in Anhui Province and Zhejiang Province, China. Italy’s Fameccanica and GDM have also set up manufacturing bases and joint ventures in China, but their diaper converting machines are more expensive than Chinese diaper converting machines. . We recommend buying a Chinese diaper machine. There are several excellent diaper machine manufacturing companies in China, Anhui RCH Machinery Co., Ltd. is one of them.  RCH diaper machine

  2) Process and composition of baby diaper converting machine

       The baby diaper making machine production line is divided into four processes according to the completed process combination: 1. Forming and wrapping process. The main production equipment includes fans, recycling machines, glue machines, crushers, forming drums, transition rollers, flat belts, conveying mechanisms, etc.; Second, a full set of packaging procedures for the absorbent core. The main equipment includes fans, recycling machines, glue machines, pressure rollers, adsorption, cutters, rubber, tension transition rollers, unwinding mechanisms, drive shafts, flat belts, etc.; 3. Three-dimensional leak-proof accessories installation procedures. The main equipment includes glue machine, enterprise identity slitting, left and right waist cutting knives, front waist cutting knives, arc knives, tail knives, tension transition rollers, etc.; 4. Finished product packaging process. The main equipment has one or two rows of mouths, blades, stacking machines, three-folding, automatic sorting and packaging machines (the machine manufacturing company does not provide it, but the buyer can choose it by himself).

     3) Web guiding control system

  In the diaper converting machine, apart from the hot melt adhesive which is in the melt flow state and the SAP which is in the granular state, dozens of other materials are soft coils and all have different stretch rates. Therefore, in the production, the speed, position, tension, deviation and other values of each coil must be controlled to ensure the stable production of the machine. At present, the pursuit of production machinery continues to increase speed and improve product quality, while continuously reducing energy consumption and raw material consumption, reducing the number of machine failures and shutdowns during production. Therefore, a set of coil guide and correction system is one of the guarantees of modern machine technology and craftsmanship. It is very important for Diaper machine to choose a corrective control system with fast response, accuracy and stable work. According to different materials, there are various drive structures and types of the correction system, and there are also many kinds of electric eyes for detection. The controller should adopt a digital controller. The detailed and technical requirements are not mentioned in detail. Diaper machine manufacturers generally configure Taiwan-made correction control systems for diaper making machines. The quality is better in Japan, Germany, and the United States (like MAXCESS, TOYO, E+L (ERHARDT+LEIMER)).

  4) Servo-motor control system

        The high-speed fully automatic diaper machine can complete multiple processes at high speed and stably, so that the diaper can be integrated organically and completely, relying on the development and application of the servo control system. The servo control system makes the mechanism of the assembly line production machine simpler, the actuator transmission and speed adjustment are simple, and a large number of transmission points are reduced, so that the friction points of the machine are reduced to a minimum, and the machine runs more smoothly, with low noise and low energy consumption. The complex actuators replaced by servo motors (like two-, three-, and four-bar linkage mechanisms, convex-concave gear mechanisms, planetary mechanisms, feeding mechanisms, etc.) are output by the servo control system suitable for the digital mechanical language of each servo motor of the dialer making machine. Servo motor control completes the technological functions set by the program. Therefore, it is very important for the servo control system to ensure that each function point of the dialer converting machine completes the process. Domestically manufactured diaper machines are equipped with Japanese MITSUBISHI (PLC + touch screen + servo control system + frequency conversion control system). If users want to match German SIEMENS, American AB, they must increase the price by more than 30%. Japan’s MITSUBISHI servo control system is widely used, with reliable quality and moderate price. I think choosing MITSUBISHI can meet the technical requirements of the diaper machine.

  diaper machinediapers machinediaper making machine

  5) Hot melt machine

          Diaper is a coated product made up of more than ten kinds of raw materials, so the material needs to be wrapped, bonded, and compounded to form the function of the product. Adhesive is indispensable, hot melt machine is a supporting machine that provides this function. Accurate location, optimal glue volume, spraying form that meets product process requirements, continuous or intermittent time control, optimal melting temperature and thermal insulation control of the glue box, frequency conversion control of the glue pump, wear resistance, high temperature resistance Deformation, high-precision nozzles that are not easy to be blocked, sensitive and accurate nozzle control system. The quality and failure rate of the melter are directly related to the genuine rate of the diaper and the stable production of the diaper machine. Therefore, the melter is one of the key components of the diaper converting machine. If the user does not specify a melter manufacturing company, the diaper machine factory will generally provide you with domestically produced melters (NDC, Taiwan Yihe, HuangSang, HuangXin, etc.). The glue pump, nozzle and nozzle control system of the domestic hot melt machine work stably. But many buyers specify the brand hot melt machine. Like ITW Dynatec and Nordson in the United States, the price is very expensive, each melter is about 50,000 US dollars.ITW-Dynatec-logo Nordson

       6) Fluff-pulp board crusher

          The Fluff-pulp board crusher

  It is the top machine of the diaper making machine. Its main function is to tear the fluff-pulp board into a fluff state to ensure that the fluff pulp is fully lifted up on the forming roller during air delivery. Therefore, the diaper absorber has no lumps, hard blocks, no broken waist, and a comfortable feel to touch with the machine. This machine has the highest power of the diaper converting machine. The machine speed is also very high. Very loud noise is its biggest disadvantage. The tearing pulp board and fluff flowers rely on high-speed and wear-resistant saw blades. The teeth of the saw blade must be Wear resistance can ensure a long replacement cycle, high quality of pulp board fluffing, and the material of the saw blade and the uniform quality must be good. The diaper machines made in China are matched with domestic crushers, which can basically meet the requirements. The price abroad is definitely expensive. I think choosing a Chinese-made grinder can basically meet the requirements of use.

  Based on the above experience:

  1) Because the diaper Converting machine is composed of multiple functional processes, the fully automatic control system of PCL+ touch screen + servo + frequency conversion should be selected to ensure the stable production of the machine and keep low failure rate and high qualified rate.

  2) The key supporting machines must be famous brand components, such as hot Melt Machine, Web Guider and servo Motor.

  3) Electric control configuration should choose MITSUBISHI, SIEMENS, AB, Schneider, OMRON).

  4) Mechanical transmission accessories should be made from Germany, Japan and Sweden (bearings). The tool used in the whole production line can choose FINKL from the United States.

  5) The choice of manufacturing company must pay attention to the advanced degree of the company’s machine manufacturing machine, which is related to the accuracy of the manufactured machine parts and the stability of the assembly line.

  6) To understand the configurations of the diaper making machine in detail, it was necessary to know the configurations to evaluate the machine and estimate the overall quality of the machine.

  Please check RCH diaper machine working video from YouTube channel :

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