Wet wipes are essential self-hygiene items that are useful for everyone. They’re also known as baby wipes, as they’re mostly used by parents who want to clean the sensitive body parts of their little kids or babies.
The industry has several wet wipes manufacturers, and most of them have automatized their processes to increase production speed and improve their production quantity. For that, they utilize wet wipes-making machines, as these pieces of equipment make it possible to make the procedure quicker and more efficient.
Today, we will learn how to make the wet wipes manufacturing process automatic while also learning a bit more about the standard production process used in today’s industry.
How to make a wet wipe
Wet wipes are composed of non-woven fabrics or moistened paper. These disposable pieces of cloth go through three main stages before they are ready to be used by the final consumer.
First stage: Design
The first step in the manufacturing process implies the “overall” design of the product. Each package must have certain characteristics to assure the satisfaction of the consumer. Hence, it is important to choose a fabric that is both disposable and capable of withstanding forceful cleaning tasks. This fabric must also be absorbent.
However, the design of the packages is not the only thing that manufacturers must take care of – the packaging must be functional and efficient. The standard design allows the consumer to dispense one sheet at a time while also being capable of maintaining moisture in all the remaining towelettes.
It is very usual for companies to use thermos-formed plastic tubes for packaging wet wipes, as it makes for compact and useful packaging for preserving the functionality of the wipes.
Second stage: Materials
Once the decisions regarding the design have been made, the next step is to select the right materials for the manufacturing process. As mentioned, wet wipes are often made of non-woven fabrics, giving us a paper-like functionality that makes them resistant yet disposable.
Some of the most common materials for manufacturing these cloths include cotton, polyester, and polyethylene, but there are tons of other options. It can vary depending on what’s most convenient for the company.
Third stage: Manufacturing
Once the design and materials have been selected, it is time to start manufacturing the towelettes. Wet wipes are typically created through a “wet-laid” process.
The wet laid process consists in mixing the non-woven fibers with water and diverse chemicals, which then gives a paste as a result. Then, in the next step, such a paste then goes through rollers that press and dry it to form long rolls of material.
These rolls then go through a slitter rewinder, which cuts the sheets into smaller portions. Once this procedure is finished, a pneumatic cross cutter crosses to cut the material and begin the same process on a new roll. The smaller portions are discharged into a platform, which is where the next phase of manufacturing starts – it consists in slitting and perforating.
The newly formed sheets of non-woven fabric will then be slitted into several widths, depending on the needs of the manufacturer. Once the cloth is ready, then it goes into the coating equipment, which is where it is soaked in the cleansing solution before beginning the packaging process.
Once the product has been finished, the towelettes are folded, stacked, and then stored in their respective packages destined for commercial distribution.
How fast does a wet wipes making machine work?
It depends on different factors. A wet wipes-making machine is composed of several parts, each of which is in charge of a different stage, as we’ve previously mentioned. It also depends on the wet wipes-making machine that is being used for the process.
Semi-automatic wet wipes machine
Generally speaking, a semi-automatic wet wipes-making machine can only finish about 100 stacks of the finished product each minute. Typically, these machines are equipped with a touch-screen control that allows you to see every step of the process, including the web speed, the product count, and production rate, among other useful information.
Fully-automatic wet wipes machine
If the machine possessed is fully-automatic, then you can be sure it will have better functionality and efficiency. These machines are made to take broader loads of material and can be used for different processes, making them more versatile than semi-automatic options.
Since a great part of the manufacturing process is now automatic, the production rate and speed increase. Generally speaking, a fully automatic wet wipes-making machine can produce over 15,000 wipes per minute, allowing you to create massive quantities of the product in little time.
In addition, these machines are equipped with easy-to-use controls and friendly interfaces that allow non-stop operation without compromising efficiency.
How does a wet wipes making machine help with manufacturing?
Wet wipes-making machines can be useful in different instances. It can be an excellent help to automatize the process and optimize the production rate and speed. Furthermore, most of the material is utilized in the process, minimizing product waste.
If you’re using a fully-automatic wet wipes machine, then you have another advantage, which would be minimal human input. The design of these machines has been optimized to cater to the needs of all users, allowing the manufacturer to take as much advantage of the material as possible and making the whole process more efficient.
Conclusion
Wet wipes-making machines can be helpful in different instances. Although semi-automatic wet wipes making machines are still used in the world today, most manufacturers have started changing to fully-automatic wet wipes machines to minimize product waste and boost production speed. Either option can be quite useful depending on your needs and current load capacity.
Hence, it is important to invest in proper machinery that allows you to reach your goals. The machine you use should be able to manufacture wet wipes for all possible uses. Manufacturers are adding new features to these machines with each new model.