Tissue Paper Converting System with Local Wet Strength Application
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Solution Overview
Problem
Current paper converting systems lack flexibility in producing tissue paper products with varying wet strength characteristics, requiring significant downtime and increased costs to switch between producing toilet paper and kitchen towels, as the composition of reels must be changed to alter product properties.
Innovation Solution
A converting system and method that applies a wet strength agent, such as a resin, to a portion of the tissue paper web downstream of the unwinder, allowing simultaneous production of products with different wet strength characteristics, like kitchen towels and toilet paper, by dividing the web into separate paths for distinct processing and packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wet strength resins are added to the pulp of cellulose fibers to produce kitchen towels or similar products, then the paper ply gains temporary mechanical strength when wet, but the production line becomes inflexible and requires long downtime to switch between different product types
Solution Approach 1:
The invention divides the continuous tissue paper web into separate longitudinal portions, applying wet strength resins to only the portions requiring them (e.g., kitchen towel sections) while leaving other portions (e.g., toilet paper sections) untreated. This segmentation allows the production line to produce multiple product types simultaneously without replacing reels, resolving the contradiction between providing wet strength where needed and maintaining production line flexibility.
Solution Approach 2:
The invention applies wet strength resins locally to specific portions of the tissue paper web rather than uniformly across the entire web. This local application allows different sections of the same continuous web to have different properties (wet strength vs. no wet strength), enabling the production of multiple product types from a single reel without stopping the production line.
2Adaptability or versatility
If the composition of reels is changed to produce different product types, then the production line can switch between toilet paper and kitchen towels, but this requires finishing existing reels or replacing partially used reels, complicating the operation and increasing downtime
Solution Approach 1:
The invention applies wet strength resins to portions of the tissue paper web before the web is wound into reels and during the converting process. This preliminary action allows the reels to be prepared in advance with the correct composition for different product types, eliminating the need to stop production to replace reels and reducing downtime when switching between product types.
Solution Approach 2:
The invention enables dynamic adjustment of product composition along the continuous web as it passes through the converting line. By applying or not applying wet strength resins to different longitudinal portions of the web in real-time, the system can dynamically produce different product types from the same reel without interruption, transforming a static reel-based system into a dynamic continuous production system.
3Stability of the object's composition
If wet strength resins are applied to the entire ply, then all products have uniform wet strength characteristics, but this prevents the production of mixed packs containing products with different functional characteristics
Solution Approach 1:
The invention segments the continuous tissue paper web into distinct longitudinal portions, applying wet strength resins to only the portions that will become kitchen towels while leaving toilet paper portions untreated. This segmentation enables the production of mixed packs containing both wet strength and no wet strength products from a single continuous web, resolving the contradiction between uniform composition and product diversity.
Solution Approach 2:
The invention implements local quality by applying wet strength resins selectively to specific portions of the web rather than uniformly across the entire web. This allows different longitudinal portions to have different functional characteristics (wet strength vs. no wet strength), enabling the production of mixed packs with diverse product types while maintaining stable composition within each portion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible and efficient production of mixed packs containing products with different functional characteristics without the need to replace reels, reducing downtime and increasing productivity by applying wet strength agents only where necessary, thus optimizing production line efficiency and product cost.
Implementation Method 1
at least one wet strength agent is applied to a portion of said web
Implementation Method 2
along said path at least one applicator to apply at least one wet strength agent to said tissue paper
Data Source
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AI summary
A method and system are described in which at least one wet strength agent, such as wet strength resin, is added to one or more plies of tissue paper or other cellulose product during the converting process.