Baby Pull Up Diaper（2pc Leg Shape ) Production Line With Auto Bagger

Full Servo 2pc type diaper : Leg Shape Baby Pull Up Diaper Production Line With Auto Bagger

Main Parameter
1. Overall size:39.2m x 10.5mx4.5m (for reference only)
2. Machine size:28.3m x 2.2m x 3.5m (based on the product provided by client)
3. Design speed:1000pcs per minute
4. Work speed:450-1000pcs per minute
5. Rejection rate:=2%(excluding scrap caused by hot melt, materials splicing or joint)
6. Power source:380V,50/60HZ(3phase,4lines+ground wire)
7. Machine capacity:380KW approximately
8. Air pressure:0.6-0.8Mpa
9. Machine weight: 86.5 Tons approximately

Configuration

1. Product structure: Upper & lower tissue (or airlaid ), Cotton core(mix with SAP), Topsheethydrophilic nonwoven, ADL nonwoven, Leak cuff hydrophobic nonwoven.3D core coating.Back sheet, Waist nonwoven, Printed cartoon tissue, Waist elastic.S elastic, Easy tape.
2. Product size:4 sizes(M,L, XL, XXL),to be customized.
3. Program System: Servo driven, intelligent HMI touch screen man-machine interface.
4. Tension system: Tension control with buffer system, automatic web guiding system, to
ensure materials stable working at ZERO speed splice.
5. Driven system: Servo drive, digital size change, ensure run synchronously at full process.
6. Safety system: Safety guard for operating side, emergency stop switch, security identifier,
safety pull wire at driven side.
7. Packaging system: Auto stackerldual push dual exitland auto bagger to be defined by customer need8, Web guiding system: Germany BST/USA FIFE.Customized function available.

Two‑Piece Baby Pull‑Up Pants Full‑Servo Production Line

This is a highly automated production line for manufacturing baby pull‑up pants (diaper pants). Its defining features are the “two‑piece” structure and “full‑servo” drive system.

• “Two‑piece” means the product consists of two main components: an absorbent chassis and an elastic waistband that are combined during production. Compared with traditional one‑piece designs, this structure offers a better fit, superior comfort, and more efficient material utilisation.

• “Full‑servo” means that every critical motion unit on the line is independently driven by servo motors, synchronised precisely by a central control system. This ensures extremely high accuracy and stability even at high speeds, and enables digital, recipe‑based size changes.

Core Equipment Composition

A typical full‑servo two‑piece baby pull‑up pants line consists of the following main systems:

• Raw Material Handling & Forming System
  Includes multiple full‑servo unwinding stands for precise feeding of nonwoven fabrics, PE films, etc. The core section comprises a pulveriser, negative‑pressure suction unit, demoulding former, and SAP (Super Absorbent Polymer) dosing unit, which together form the absorbent core from fluff pulp and SAP.

• Core & Waistband Laminating System
  This section accurately joins the formed absorbent chassis with the elastic waistband. Key processes include dual ultrasonic welding units and a waistband alignment device to ensure bonding accuracy.

• Converting & Folding System
  The laminated web is folded by a product folding unit, then cut into individual pants by a final cutting assembly.

• Quality Inspection & Packaging System
  Integrated vision inspection systems monitor product quality on‑line and automatically reject defects. Accepted products proceed to an automatic stacker and packaging machine.

• Central Control System
  The entire line is governed by a PLC (Programmable Logic Controller) with an intelligent HMI touchscreen for full automation and production data management.

 Main Technical Features & Parameters

• Drive & Control: Full‑servo drives enable digital size changeovers and synchronous running across all stations. Operators can recall recipes via HMI for rapid product‑size switching.

• Tension & Guiding: Equipped with tension control with buffer system and automatic edge guides, supporting zero‑speed splicing to maintain stable tension and web alignment.

• Safety & Packaging: Machine safety guards, emergency stops, etc. The automatic stacker and packer can be customised per customer requirements.

• Key Performance Parameters (varies by model):

  • Design Speed: up to 600 – 1,000 pieces/min; stable operating speed typically 500 – 900 pieces/min. Advanced lines using dual‑servo differential control have reached 800 pieces/min.

  • Product Qualification Rate: usually ≥ 97%.

  • Reject Rate: controlled within 3%; advanced models can achieve < 1%.

  • Machine Dimensions (L×W×H): approx. 32m × 10m × 4m.

  • Installed Power: approx. 320 kW.

  • Machine Weight: approx. 80 – 85 tons.

  • Air Consumption: approx. 1,800 – 4,800 L/min.

Advanced Technologies & Process Highlights

• Floating Welding Technology: High‑end models use one embossing roll for two pieces and a synchronous floating variable‑speed mechanism, combined with dual ultrasonic units to extend welding time – ensuring both strong bonding and softness at the waist.

• Modular & Custom Design: Modern lines are modular for easy maintenance and future upgrades. Manufacturers often offer tailor‑made solutions.

• Data Management & Remote Support: Supports Ethernet remote assistance for fast troubleshooting and diagnostics.