Secondary Tissue Roll Manufacturing With Inline Chemical Application
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Solution Overview
Problem
The manufacturing method for tissue paper products using a multi-stand type interfolder is costly and inefficient due to the need for separate facilities for applying chemicals, leading to high facility costs and difficulty in switching between producing chemically treated and untreated products.
Innovation Solution
A method that continuously manufactures secondary paper rolls by multi-ply forming, applying chemicals, slitting, and winding, with the chemicals application step performed between multi-ply forming and slitting, and optionally including calendering and ply bonding, to reduce facility costs and improve efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate chemicals applying step is provided in addition to the ply machine or multi-stand type interfolder, then chemicals can be applied to tissue paper products, but facility cost increases and operational complexity increases
Solution Approach 1:
The patent combines the chemicals applying function with the existing ply machine or multi-stand type interfolder by equipping them with chemicals applying units. This integration eliminates the need for separate chemicals application facilities, thereby reducing facility costs while maintaining the capability to apply chemicals to tissue paper products.
Solution Approach 2:
The ply machine or multi-stand type interfolder is designed to perform multiple functions: it not only folds and cuts the tissue paper but also applies chemicals through integrated chemicals applying units. This multi-functionality allows the same equipment to handle both structural processing and chemical treatment, reducing overall facility requirements.
2Ease of operation
If the chemicals applying step is performed separately, then chemicals can be applied, but it becomes difficult to switch between producing chemically treated and untreated products
Solution Approach 1:
The chemicals applying units are designed to be movable or adjustable, allowing them to be positioned near the tissue paper path when chemical treatment is needed and moved away or deactivated when producing untreated products. This dynamic configuration enables easy switching between different product types without permanent structural modifications.
Solution Approach 2:
The chemicals applying function is divided into separate, modular units that can be independently controlled and positioned. This segmentation allows the system to apply chemicals only when needed and to easily switch between treated and untreated production modes by simply adjusting or deactivating specific modules rather than reconfiguring the entire facility.
3Loss of substance
If chemicals are applied to the multi-ply continuous sheet before slitting, then chemical loss is minimized and tissue paper chipping is prevented, but the chemicals application system must be precisely positioned
Solution Approach 1:
The chemicals are applied to the multi-ply continuous sheet before it undergoes slitting. This preliminary application ensures that the chemicals are evenly distributed across the entire sheet surface, minimizing waste and preventing chipping during subsequent cutting operations. The chemicals are applied in advance when the sheet is still intact and easier to handle uniformly.
Solution Approach 2:
The chemicals applying units are positioned to apply chemicals locally to the multi-ply continuous sheet at specific locations where the sheet passes through the machine. This localized application approach, combined with the continuous motion of the sheet, achieves precise chemical distribution without requiring the entire system to be highly precise, as the chemicals are applied to a moving continuous sheet rather than to individual cut pieces.
Data Source
AI summary
The method of manufacturing the secondary paper roll for the tissue paper products including: a multi-ply forming step (51) of multi-ply forming single-sheets S11 and S12 from primary paper rolls, reeled out from the plural primary paper rolls JR in the continuous direction so as to form a multi-ply continuous sheet S2, a chemicals applying step (53) of applying chemicals to the multi-ply continuous sheet S2, a slitting step (55) of slitting the multi-ply continuous sheet S2 into each product width of the tissue paper products or several fold widths thereof, and a winding step (56) of coaxially winding the respective slit multi-ply continuous sheets S2 so as to form plural secondary paper rolls R of each product width of the tissue paper products or several fold widths thereof.