Adult Diaper Production Line With Auto Bagger

Adult Diaper Production Line With Auto Bagger

Main Parameter
1. Overall size :35.3mx10.5mx3.5m(for reference only)
2. Machine Size :31.5mx2.6mx3.5m
3. Design speed : 400-800pcs per minute
4. Stable work speed : 300-800pcs 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 : 450KW approximately
8. Air pressure :0.6-0.8Mpa
9.  Machine weight : 93Tons approximately

ConfigurationI

1. Product structure: Leak cuff hydrophobic nonwoven, Top sheet hydrophilic nonwoven, ADL,Cotton core (SAP mixed), Side tape, Waistband, Frontal tape, Back sheet.

2. Product size:(mm)M : 680 x 450 L:800 x 650 XL:950 x 760(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 need
8. Web guiding system: Germany BST/USA FIFE.Customized function available

Full-Servo Adult Diaper Production Line

This is a high-speed, fully automated production line designed for manufacturing disposable adult diapers (incontinence briefs). Its defining feature is the "full-servo" drive system, which ensures precise synchronisation, digital size changeovers, and superior product quality at high production speeds.

• "Full-servo" means that every critical motion unit on the line is independently driven by servo motors, synchronised precisely by a central PLC control system. This enables digital, recipe-based size changeovers for different product sizes (S, M, L, XL)-, ensures stable operation even at speeds up to 800 pieces per minute-, and allows for multi-axis coordinated control – advanced models can achieve up to 95 axes of synchronised motion.

Core Equipment Composition

A typical full-servo adult diaper production line consists of the following main systems:

• Raw Material Handling & Unwinding System
  Includes multiple full-servo unwinding stands for precise feeding of nonwoven fabrics (hydrophilic NW for topsheet, hydrophobic NW for leg cuffs), PE film, tissue paper, elastic materials, and other raw materials. Equipped with automatic tension control with buffer system, automatic edge guide systems (e.g., BST from Germany, FIFE from USA), and zero-speed splicing to ensure stable material travel and non-stop roll changes.

• Absorbent Core Forming System – the heart of the line that determines product performance.

  • Pulverising & Forming: A high-efficiency hammer mill breaks down the pulp board into fluff. The fluff is then mixed with Super Absorbent Polymer (SAP) dispensed by a precise dosing mechanism in a drum forming unit to form a uniform absorbent core-.

  • Key components: Includes high-speed pulverising and forming chamber, compacting device, web pressing device, and inner cutting & transfer layer cutting device-.

• Diaper Assembly & Laminating System
  This section assembles the various components into a finished diaper. Key processes include:

  • Waist elastic assembly for secure and comfortable fit-

  • Hot-melt adhesive application for laminating multiple layers-

  • Arc cutting and outer cutting stations for precise shaping-

  • Ultrasonic welding (optional, for advanced models)

• Converting, Folding & Cutting System
  The assembled web is folded and cut into individual diapers by a final cutting assembly-. Advanced models feature continuous folding and stacking capabilities.

• Quality Inspection & Rejection System
  Integrated automatic quality control system with automatic defect rejection monitors product quality online and automatically removes defective items. Advanced systems can automatically display fault names and solutions to reduce manual intervention.

• Packaging System
  Includes a high-speed stacker and automatic packaging machine. The packaging system can be customised based on customer requirements.

• Central Control System
  The entire line is governed by a PLC (Programmable Logic Controller) with an intelligent HMI touchscreen for full automation, recipe management, and production data monitoring. Advanced systems feature USB interface program input for easy updates-.

• Safety System
  Equipped with operator-side safety guards, emergency stop switches, safety signage, and non-drive-side safety pull-cords. Designed and manufactured in compliance with European CE standards.

• Remote Support & Data Management
  Supports remote monitoring and troubleshooting, enabling real-time fault analysis and resolution. The system can establish full life-cycle health records for the equipment.

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 (S, M, L, XL).

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

• Precision Manufacturing: Core mechanical parts are manufactured by CNC precision machining for superior accuracy and durability.

• Modular Design: Modular structure allows for future upgrades and customisation-.

• Customisation: Supports tailored solutions including 3D core forming, online topsheet embossing, and custom product specifications.

• CE Certification: Designed and manufactured in compliance with CE regulations and standards.

• Automatic Data Management: Automatically calculates and records all production data.

Key Performance Parameters (varies by model):

Advanced Technologies & Process Highlights

• Multi-Axis Synchronised Control: Advanced models feature up to 95 axes of coordinated motion control for superior precision and efficiency.

• Digital Motion Control System: Uses digital control and drive systems with full-servo motors for precise, repeatable performance-.

• Zero-Speed Splicing: Enables non-stop roll changes without reducing production speed, significantly improving efficiency.

• Automatic Defect Rejection: Integrated quality control system automatically detects and removes defective products.

• Remote Diagnostics: Supports remote monitoring and troubleshooting, enabling fast fault analysis and resolution.

• Quick Size Changeover: Rapid recipe-based switching between sizes (S, M, L, XL) minimises downtime-.

• High Automation: Reduces manual labour requirements and increases production efficiency by over 50%.

• Modular & Custom Design: Modern lines are modular for easy maintenance and future upgrades. Manufacturers offer tailor-made solutions based on customer requirements.

• CE Certification: Designed and manufactured in compliance with European CE regulations and standards.