Facial Tissue Machine Manufacturing Process Explained

Unveiling the Precision Journey: From Raw Pulp to Finished Tissue

Facial tissues, an essential part of daily life, are produced through a sophisticated process that integrates mechanical engineering, material science, and automation. This article delves into the manufacturing process of facial tissue machines, revealing how raw pulp is transformed into soft, absorbent finished products.

I. Core Manufacturing Stages: From Raw Material to Final Product

The production of facial tissues involves four key stages: raw material processing, forming, folding/cutting, and packaging, each relying on high-precision machinery and automation.

1. Raw Material Processing: Pulp Preparation and Web Formation

• Pulp Preparation: Wood pulp or recycled fibers are broken down, screened, and bleached to create a uniform pulp suspension.
• Web Formation: The pulp is evenly sprayed onto a forming wire via a headbox, then dewatered and pressed to form a wet web. Control over basis weight (18–30gsm) and uniformity directly impacts softness.
• Drying and Rewinding: The wet web is dried to ~5% moisture content using multi-cylinder dryers and rewound into jumbo rolls (1.5–3m diameter) for downstream processing.

2. Forming: Transforming Flat Sheets into Functional Products

• Rewinding and Slitting: Jumbo rolls are rewound to adjust tension and slit into specified widths (e.g., 100–200mm), with optional embossing for enhanced absorbency and texture.
• Folding and Cutting: Tissues are folded into C, Z, or V shapes for easy dispensing. High-speed folding mechanisms (600–1,200 folds/min) achieve ±0.5mm accuracy.
• Lamination: Premium tissues bond 2–3 layers using ultrasonic welding or adhesives, improving strength and softness.

3. Packaging: Automation Meets Customization

• Counting and Stacking: Folded tissues are counted (80–120 sheets/pack) and stacked to a fixed height.
• Packaging Formats:
  • Flow Wrap: Horizontal machines wrap tissues in film for travel packs or promotions.
  • Box Packing: Vertical machines fill pre-made cartons with tissues, supporting hot-melt sealing and labeling.
  • Single Pack: Heat-sealing technology encloses single tissues in foil or plastic for medical or luxury markets.
• Quality Control: Vision systems inspect seal integrity, label placement, and count accuracy, reducing defect rates to <0.1%.

II. Key Equipment and Technological Innovations

The performance of facial tissue machines hinges on the precision of core components and their协同 efficiency:

1. Fully Automatic Lines: Efficiency and Stability

• PLC+HMI Control: Real-time parameter adjustment via programmable logic controllers and touchscreens, with remote diagnostics.
• Servo Motors: Drive folding, cutting, and packaging modules at speeds up to 800 packs/min with synchronized motion.
• Tension Control: Closed-loop systems regulate web tension to prevent breaks or wrinkles, critical for thin tissues (16–18gsm).

2. Semi-Automatic and Custom Solutions: Flexibility for Diverse Needs

• Modular Design: Quick-change folding molds and packaging heads accommodate sizes from 10×10cm to 20×20cm.
• Manual Interfaces: Semi-automatic machines retain manual loading and quality checks, reducing upfront costs for SMEs.

3. Sustainability Technologies

• Energy-Efficient Dryers: Steam or thermal oil heating cuts energy use by 20% vs. traditional systems.
• Waste Recycling: Trimmings are repulped, boosting material utilization to 98%.
• Biodegradable Packaging: Some machines support PLA film, meeting EU environmental standards.

III. Industry Trends: Intelligence and Personalization

1. AI-Driven Optimization: Machine learning analyzes historical data to auto-adjust parameters and minimize waste.
2. Flexible Manufacturing: Modular equipment enables "on-demand" production of small batches with diverse specifications.
3. Digital Packaging: Inkjet printing allows personalized patterns or QR codes on each pack.

IV. Conclusion: The Industrial Value Behind Precision Engineering

The manufacturing process of facial tissue machines represents a fusion of mechanical design, material science, and market responsiveness. From high-speed lines producing thousands of packs hourly to flexible systems catering to hotel customization, innovation continues to elevate this traditional industry. As intelligence and sustainability technologies advance, facial tissue machines will serve global consumers more efficiently and eco-consciously.