What is a Semi-Automatic Converting Machine?
It is a production line that performs the core functions of converting a jumbo tissue roll into finished toilet paper rolls, but requires manual intervention for specific steps. It automates the most complex parts (perforating, winding) but leaves simpler, yet labor-intensive tasks to operators.
Typical Workflow & Where Manual Labor is Involved
Let's follow the process and identify the manual steps:
Jumbo Roll Loading (Manual): An operator uses a forklift or a hoist to place the large jumbo roll onto the unwind stand.
Paper Threading (Manual): The operator must manually thread the leading edge of the paper through the various stations (embosser, rewinder).
Core Loading (Manual): This is a key manual step. One or more operators continuously feed the cardboard cores into the core holder on the rewinder by hand.
Automatic Process: The machine then automatically:
Perforates the paper.
Winds the paper onto the cores.
Cuts the long "log" into individual rolls (via a log saw).
Collection & Packaging (Manual): This is the most labor-intensive part. The finished rolls are collected from the output conveyor. Operators then manually:
Inspect the rolls.
Wrap them in plastic film (often using a separate, small sealing machine).
Pack them into bags or boxes for sale.
Core Components of a Semi-Automatic Line
A typical semi-automatic line includes:
Unwind Stand: Often a simple, single-stand without an automatic splicer. When one jumbo roll runs out, the line must be stopped to load a new one.
Embossing Unit: Adds patterns to the paper.
Rewinding Machine: The central unit that perforates the paper and winds it onto the manually loaded cores.
Log Saw: An automatic saw that cuts the log into individual rolls.
Control Panel: A simple PLC or manual controls to manage speed and tension.
What it often lacks compared to a fully automatic line:
Automatic core loading.
Automatic jumbo roll splicing.
Integrated automatic wrapping and packaging systems.
Advantages and Disadvantages
| Advantages | Disadvantages |
|---|---|
| ✔ Lower Initial Investment: Significantly cheaper than a fully automatic line. | ❌ Higher Labor Costs: Requires multiple operators (typically 3-6 people). |
| ✔ Flexibility: Easier to switch between different paper types or roll sizes for small batches. | ❌ Lower Output: Production speed is limited by manual steps, typically 80 to 150 rolls per minute. |
| ✔ Simpler Maintenance: Less complex machinery means easier troubleshooting and lower repair costs. | ❌ Inconsistent Packaging: Manual wrapping and packing can lead to a less uniform final product. |
| ✔ Lower Skill Requirement: Operators can be trained quickly without advanced technical knowledge. | ❌ More Production Downtime: Frequent stops to load new jumbo rolls and cores. |
Model | 1880mm ~2200mm |
Applicable Raw Paper | 2-3 plies 14~23g/㎡Wood pulp paper |
Finished product | Toilet rolls with core /without core |
Raw Paper Width | Max 2100mm |
Raw Paper Diameter | Max1300mm |
Finished Size | Φ60~130 mm |
Finished Core Diameter | Φ35mm-Φ50mm |
Raw Paper Core Diameter | 3”(76.2 mm) |
Perforation | Spiral perforating knife,Chain wheel positioning |
Production Speed | 200 m/min |
Power | 12kw |
Parameter Design | LCDTouch Screen |
Control | PLC |
Paper Feeding | 3 Unwinding stands,controlled by pneumatic |
Air Pressure | 0.5 Mps |
Power | 380V,50hz |
