Revealed: The Step-by-Step Process of Making Z Fold Paper Towels with Point-to-Point Glue Lamination
In the rapidly evolving world of hygiene product manufacturing, Z Fold paper towels have become a staple for their durability and convenience. The integration of point-to-point glue lamination has revolutionized their production, enhancing both quality and efficiency. Here’s an exclusive look at the meticulous process behind creating these advanced paper towels.
Step 1: Raw Material Preparation and Web Formation
The journey begins with selecting high-quality paper pulp, typically derived from wood fibers or recycled materials. The pulp is mixed with water to form a slurry, which is then drained through a mesh belt to create a continuous paper web. Advanced systems ensure the web has uniform thickness and absorbency, with precision controls maintaining a pulp concentration of 0.5–1.5% for optimal texture.
Step 2: Precision Folding into Z Patterns
The paper web enters a folding unit equipped with servo-driven rollers and adjustable guides. These components work in tandem to create the characteristic Z-fold pattern, with machines like ACE MACHINERY CHINA’s models achieving a folding accuracy of ±1mm. High-speed motors (up to 30kW) power the system, enabling production speeds of up to 1,200 sheet per minute per lane (about 230 meters per minute) while maintaining fold consistency.
Step 3: Point-to-Point Glue Lamination Technology
The breakthrough stage involves point-to-point glue lamination, where a micro-control system dispenses glue in precise dots (1.5–3mm in diameter) at designated points on the folded towels. This technology reduces glue waste by 30% compared to traditional methods, while ensuring a strong bond between layers. High-pressure nozzles and real-time sensor feedback adjust glue application based on paper thickness, guaranteeing uniform adhesion and enhanced durability.
Step 4: Cutting, Counting, and Quality Control
After lamination, the folded towels are cut to the desired length (tolerance ±1mm) using carbide-tipped blades. An integrated digital counter tracks production in real time (accuracy ±1 piece), while AI-powered cameras inspect each towel for fold defects, glue consistency, and size uniformity. Defective units are automatically rejected, maintaining a quality standard of over 99.5%.
Step 5: Packaging and Distribution
Finished towels are stacked and packaged in plastic wraps or paper wraps or boxes, with automated systems handling everything from single-unit pouches to bulk industrial orders. Energy-efficient compressors and sealers reduce packaging time, while smart labeling systems integrate production dates and batch numbers for traceability.
Technical Parameters of Advanced Production Lines
- Production Speed: 800 –1,200 sheets per minute per lane x 14 lanes (jumbo reel width up to 3000mm.)
- Power Supply: 3-phase, 380V, 50/60Hz
- Glue Dispensing Precision: 1,200 dots/minute with <1% error rate
- Machine Dimensions: 9,000mm (L) × 3,000mm (W) × 2,200mm (H)
- Control System: PLC-based interface with 10-inch touchscreen
"Point-to-point lamination isn’t just a technology—it’s a game-changer for hygiene product manufacturers," says Dr. Fong, a senior engineer at ACE MACHINERY CHINA. "By minimizing glue usage while maximizing strength, we’re setting new standards for sustainability and performance."
As demand for eco-friendly and high-performance paper towels grows, this process exemplifies how innovation in manufacturing can balance efficiency, quality, and environmental responsibility. The next time you use a Z Fold paper towel, you’ll appreciate the precision engineering behind its creation.
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