NRC Toilet Roll Rewinding Line Manufacture

Types of Machines & Configurations

• Fully Automatic High-Speed Lines: The most common for large manufacturers. Fully integrated from unwinding to case packing. Speed: Can produce 100-200+ rolls per minute. Requires minimal operators.

• Semi-Automatic Lines: Some steps (like loading cores, or packing) may be manual. Lower output (e.g., 30-80 rolls/min), lower cost, suitable for medium-sized businesses.

• Small Scale / Startup Machines: Smaller, modular machines where logs are often transferred manually between the log saw and a separate wrapper. Output can be as low as 10-30 rolls/min.

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What is a Toilet Paper Rolls Making Machine?

It's not a single machine, but a complete production line that transforms large parent paper reels (jumbo rolls) into finished, packaged toilet paper rolls ready for consumer use. The line is highly automated and can run at high speeds.

Core Components of a Modern Production Line

A typical line consists of several integrated machines:

1. Jumbo Roll Stand (Unwinder): Holds the large, raw paper reels (often 1-2 meters in diameter). Modern lines use multiple stands for continuous production, automatically splicing a new reel when one runs out.

2. Core Making Machine (Optional but common): Creates the cardboard tubes (cores) from rolls of core board. It winds, glues, and cuts the board to the required length and diameter.

3. Log Saw (Multi-Log Saw / Cutting Machine): This is the heart of the operation.

   • Paper from the jumbo reels is threaded through the machine and wound onto the cores (fed from the core making machine or pre-made).

   • Multiple paper plies (usually 1-4) are combined and embossed with patterns for softness and bulk.

   • Perforation is added between sheets.

   • It winds a continuous, long "log" of paper (up to 1.8-2.5 meters long).

   • The long log is then simultaneously cut into individual "roll-length" logs (e.g., 10-15 cm diameter).

4. Log Sorting & Conveying System: Transports the individual logs to the wrapping machines.

5. Auto Wrapping & Packaging Machines:

   • Single Roll Wrapper: Wraps each individual roll in plastic or paper film.

   • Multi-Pack Wrapper: Bundles and wraps sets of 4, 6, 9, 12, 24, or 36 rolls in shrink film or paper.

   • Case Packer: Automatically places the multi-packs into cardboard shipping cases.

6. Control Panel (PLC): The computerized brain of the entire line, controlling speed, length, tension, and diagnostics.

Types of Machines & Configurations

• Fully Automatic High-Speed Lines: The most common for large manufacturers. Fully integrated from unwinding to case packing. Speed: Can produce 100-200+ rolls per minute. Requires minimal operators.

• Semi-Automatic Lines: Some steps (like loading cores, or packing) may be manual. Lower output (e.g., 30-80 rolls/min), lower cost, suitable for medium-sized businesses.

• Small Scale / Startup Machines: Smaller, modular machines where logs are often transferred manually between the log saw and a separate wrapper. Output can be as low as 10-30 rolls/min.