What is the process of converting toilet paper?

What are the Manufacturing Process of Toilet Paper Roll Converting?

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1. Unwinding

Detailed Steps:

1. Loading: The

   The tissue parent roll is positioned onto the unwinding stand using a hydraulic lift to ensure it is securely in place.

2. Tension Control: The unwinding machine is equipped with tension control systems to maintain consistent pressure on the paper, preventing tears or wrinkles.

3. Alignment: Sensors and guides are used to align the paper accurately as it feeds into the next stage, ensuring the edges are straight and even.

2. Rewinding

Detailed Steps:

1. Core Insertion: Empty cardboard cores are automatically fed into the rewinding machine.

2. Paper Feeding: The tissue paper is guided onto the cores and begins to wind around them.

3. Tension Adjustment: Continuous monitoring and adjustment of tension are done to ensure a tight, even roll.

4. Perforation: As the paper is wound, perforation blades create small cuts at regular intervals, allowing users to tear off individual sheets easily.

3. Embossing

Embossing is an optional but common step in toilet paper manufacturing. The tissue paper is passed through embossing rollers that imprint patterns onto the paper. These patterns not only enhance the aesthetic appeal but also improve the paper&#;s softness and absorbency. Embossing can include brand logos, decorative designs, or functional textures.

Detailed Steps:

1. Pattern Selection: Choose the embossing pattern based on the brand&#;s design and functionality requirements.

2. Roller Preparation: Embossing rollers are engraved with the chosen pattern and installed in the machine.

3. Pressure Application: The tissue paper is passed between the embossing rollers, where precise pressure is applied to imprint the pattern onto the paper.

4. Quality Check: The embossed paper is inspected for pattern consistency and depth to ensure high-quality output.

4. Laminating

Detailed Steps:

1. Layer Alignment: Two or more layers of tissue paper are aligned and fed into the laminating machine.

2. Adhesive Application: A thin layer of adhesive is applied between the layers to bond them together.

3. Pressing: The layers pass through pressing rollers that apply pressure to ensure a strong bond without compromising the softness of the tissue.

4. Drying: The laminated paper is then dried to set the adhesive, creating a durable multi-ply product.

5. Perforating

Perforating is a critical process where small holes are punched along the width of the paper, creating tear lines. These perforations make it easy for users to tear off individual sheets. The spacing and quality of the perforations are meticulously controlled to ensure uniformity and ease of use.

Detailed Steps:

1. Blade Setting: Perforation blades are set to the desired spacing, typically around 4-5 inches apart.

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2. Roller Alignment: The paper passes through rollers equipped with the perforation blades.

3. Cutting: As the paper moves, the blades create tiny cuts at regular intervals.

4. Inspection: The perforations are checked for consistency to ensure that each sheet can be easily torn without tearing the entire roll.

6. Cutting

Detailed Steps:

1. Measurement: The large rolls are measured to determine the precise cutting points.

2. Cutting Mechanism: High-speed circular blades are used to cut the rolls into smaller sizes.

3. Edge Trimming: The edges of the rolls are trimmed to remove any uneven or rough edges.

4. Size Verification: The cut rolls are measured to ensure they meet the specified dimensions.

7. Packaging

The final stage of the converting process is packaging. The cut rolls are automatically counted and wrapped in plastic or paper packaging. This packaging protects the rolls from contamination and damage during transportation and storage. The rolls are then packed into larger boxes or pallets for distribution.

Detailed Steps:

1. Counting: The rolls are automatically counted and grouped according to packaging specifications.

2. Wrapping: The rolls are wrapped in plastic film or paper, which is heat-sealed to provide protection.

3. Labeling: Labels are applied to indicate the brand, product details, and other relevant information.

4. Boxing: The wrapped rolls are packed into boxes or shrink-wrapped onto pallets for transportation.

5. Sealing: The boxes or pallets are sealed to ensure the product remains secure during transit.

8. Quality Control

Throughout the entire manufacturing process, quality control checks are essential. These checks include inspecting the paper for defects, ensuring perforations are consistent, verifying the strength and softness of the tissue, and confirming the accuracy of roll dimensions. Quality control ensures that the final product meets industry standards and customer expectations.

Detailed Steps:

1. Visual Inspection: Regular visual inspections are conducted at various stages to identify any defects or inconsistencies.

2. Tensile Testing: The strength of the paper is tested to ensure it meets required standards.

3. Softness Testing: The softness of the tissue is evaluated to maintain product quality.

4. Dimensional Checks: The dimensions of the rolls, including length, width, and diameter, are measured for accuracy.

5. Performance Testing: Final product testing is conducted to ensure the rolls function as expected, including easy tearing at perforations and overall usability.

Conclusion

Learn how tissue paper is made

The toilet/tissue paper manufacturing process starts by creating a paper. There are 2 kinds of manufacturing processes for toilet/tissue paper;

1. Made with virgin paper products (formed from chipped wood)
2. Made from recycled paper.

Making toilet/tissue paper from the trees

Not all types of trees are used to manufacture toilet/tissue paper. Generally, it is made from &#;virgin&#; paper, which is a combination of softwood (approx. 30%) and hardwood trees (approx. 70%). In the final product, to achieve durability in the toilet/tissue paper, water, chemicals and bleaches are added.

1. To prepare it, softwood and hardwood trees are stripped of their bark with machines, leaving as much wood as possible.
2. The bare logs are then passed through machines to cut it into smaller pieces and then carefully separated into batches.
3. The wood chip batches are then cooked in a mixture of chemicals for a few hours.
4. The wood moisture is then evaporated and the mass is reduced to cellulose fibres, lignin (adhesive that binds fibres together) and other substances. The result is usable fibre, called pulp. The pulp is what paper is made from.
5. The lignin and the cooking chemicals are then washed out of the pulp.
6. The washed pulp is then bleached until all the colour is removed. The lignin must be removed from the pulp or the paper will become yellow over time.
7. The pulp is mixed with a lot of water to produce paper stock, which is sprayed onto screens of mesh to drain the water.
8. The paper is then pressed, dried, scraped off with metal blades, wound around jumbo reels and then moved to machines that cut it into long strips and perforate it into squares.
9. Finally, the paper logs are cut into rolls and wrapped toilet/tissue paper packages. Voila!

Making toilet/tissue paper from recycled materials

1. Waste paper is collected, sorted and brought to the paper plant mill, where it is mixed with water and chemicals, then pulped, filtered, refined and turned into pulp.
2. The treated pulp comes out of the paper mill on a jumbo roll, which is then transported to a converting tissue plant where it will be converted into the final product (i.e. toilet rolls/tissue paper).
3. The toilet/tissue paper is then embossed, perforated and transferred onto long toilet logs as per the correct sheet count.
4. The long toilet/tissue paper logs are then fed to the band saw which automatically cuts the toilet/tissue paper logs to the correct size, ready to be packed.
5. It is then fed into the various wrapping machines and shipped to the various riots retailers.

Jobs in Tissue Paper Converting

Do you have experience working in a tissue converting Plant?

Tissue Plant Manager Job in Angola

A leading importing, manufacturing, distribution and FMCG company is looking to hire a highly-skilled Plant/ Factory Manager. You will be responsible for directing and coordinating the daily operations of the manufacturing plant as well as, developing strategies to ensure the plant meets production goals and standards, etc.

Download Job Spec for Tissue Plant Manager Job in Angola

To apply: Send your CV to Lizette Pienaar at

Thank you for reading.

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