Tissue Paper Converting System for Mixed Wet Strength Packs
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Solution Overview
Problem
Current tissue paper production lines are inflexible, requiring significant downtime and increased costs to switch between producing paper with and without wet strength resins, as reels of different compositions must be finished or replaced, limiting productivity and efficiency.
Innovation Solution
A method and system that allows simultaneous production of tissue paper products with different wet strength characteristics on the same line by unwinding and rewinding multiple reels with distinct compositions on common winding cores, enabling the production of mixed packs containing products like kitchen towel and toilet paper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If reels of paper with different compositions (with/without wet strength resins) are produced on the same continuous production line, then production flexibility and productivity are improved, but the complexity of the production system increases due to the need to manage multiple reels with different characteristics simultaneously
Solution Approach 1:
The production line is segmented into multiple independent reel positions (first reel, second reel, third reel, fourth reel) that can operate independently. Each reel can be configured with different paper compositions (with or without wet strength resins), allowing simultaneous production of different product types without requiring the entire line to be reconfigured. This segmentation enables flexible mixing of product types in the output stream.
Solution Approach 2:
The production line is designed with universal capability to handle multiple reel configurations simultaneously. The system can process reels with different paper compositions (kitchen towel with wet strength, toilet paper without wet strength) on the same line, making the production system multi-functional and adaptable to various product requirements without dedicated single-purpose equipment.
2Productivity
If reels of different compositions are replaced or finished sequentially on the production line, then production simplicity is maintained, but productivity decreases due to line downtime during reel switching
Solution Approach 1:
The production line maintains continuous operation by having multiple reels (at least two, preferably four) loaded simultaneously. While one reel is being consumed, others are already in position or being prepared for immediate replacement. This eliminates idle time during reel transitions, ensuring the converting machines continuously process paper without interruption, thereby maximizing productivity and minimizing downtime losses.
Solution Approach 2:
Reels are pre-loaded and positioned on the production line before they are needed. The system allows for advance preparation of reel configurations, so when a reel is depleted, another is already in place or can be quickly installed without stopping the line. This preliminary arrangement of resources prevents downtime and maintains continuous production flow.
3Strength
If wet strength resins are added to the pulp for producing kitchen towel, then wet strength characteristics are improved, but the ability of the paper to disintegrate upon contact with water deteriorates
Solution Approach 1:
Different local qualities (wet strength characteristics) are applied to different reels of paper on the same production line. Reels intended for kitchen towel production contain wet strength resins, while reels for toilet paper do not. This allows each product type to have the appropriate local quality where needed, without compromising the other product type's disintegration properties.
Solution Approach 2:
The chemical composition parameter of the paper pulp is changed by adding or omitting wet strength resins depending on the desired product. This parameter change enables the production of paper with different wet strength characteristics - high wet strength for kitchen towel and low wet strength for easy disintegration in toilet paper - allowing both product types to be produced on the same line with appropriate compositional adjustments.
Data Source
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AI summary
A method and system are described for producing packs of tissue paper products having different characteristics to one another. More specifically, a system is described for producing packs comprising rolls (L) of toilet paper and kitchen towel.