Baby Pull Up Diaper（3pc H Shape ) Production Line With Auto Bagger

Full Servo Baby Pull Up Diaper（3pc H Shape )  production line. 

Main Parameter
1. Overall size:33.5m x 11.5m x4.5m (for reference only)
2. Machine size:26.6m x 2.3m x 3.7m (based on the product provided by client)
3. Design speed:800pcs per minute
4. Production speed:450-900pcs per minute
5. Rejection rate:≤2%(excluding scrap caused by hot melt, materials splicing or joint)
6. Power source:380V,50/60HZ(3phase,4lines+ground wire)
7.  Machine capacity:320KW approximately Air pressure:0.6-0.8Mpa
8.  Machine weight:76.5 Tons approximately

Configuration
1. Product structure: Upper & lower tissue (or airlaid ), Coton core (mix with SAP), Topsheet
hydrophilic nonwoven, ADL nonweven, Leak cuff hydrophobic nonwoven, Back sheet, Waist
nonwoven, Printed cartoon tissue, Waist elastic, Easy tape.
2. Product size:4 sizes(M,L, XL, XXL), to be customized.
3. Program system: Servo driven, intelligent HMI touch screon man-machine interface.
4. Tension system: Tension control with buffer system, automatic web guiding system, to ensure
materials stable working at ZERO speed splice.

5. Driven system: Servo drive, digital size change, ensure run synchronously at full process.

6. Safety system: Safety guard for operating side, emergency stop switch, security identifier,
safety pull wire at driven side.
7. Packaging system: Auto stackerldual push dual exitland auto bagger to be defined by customer need
8. Stacking range:16-36pcs/pack adjustable.
9. Web guiding system: Germany BST/USA FIFE.Customized function available.

Three-Piece Baby Pull-Up Pants Full-Servo Production Line

This is a high-speed, fully automated production line designed for manufacturing disposable baby pull-up pants (diaper pants). Its defining features are the "three-piece" product structure and the "full-servo" drive system.

• "Three-piece" means the product consists of three main components: an absorbent core, a front waist section, and a back waist section that are assembled during production. Compared with two-piece designs, the three-piece structure offers superior fit and comfort for premium baby pants, enjoys strong acceptance in mid-to-high-end markets, and provides higher brand differentiation potential. It also enables more efficient material utilisation and better body conformity.

• "Full-servo" means that every critical motion unit on the line is independently driven by servo motors, synchronised precisely by a central PLC control system-. This ensures extremely high accuracy and stability even at speeds exceeding 800–1000 pieces per minute, and enables digital, recipe-based size changeovers for different product sizes (S, M, L, XL, XXL).

Core Equipment Composition

A typical full-servo three-piece baby pull-up pants production line consists of the following main systems:

• Raw Material Handling & Unwinding System
  Includes multiple full-servo unwinding stands for precise feeding of nonwoven fabrics (hydrophilic NW for topsheet, hydrophobic NW for leg cuffs), PE films, elastic leg elastics, waist elastics, tissue paper, and other materials. Equipped with automatic tension control with buffer system, automatic edge guide systems (e.g., BST from Germany, FIFE from USA), and zero-speed splicing to ensure stable material travel and non-stop roll changes.

• Absorbent Core Forming System – the heart of the line that determines product performance.

  • Pulverising & Forming: A high-efficiency hammer mill breaks down the pulp board into fluff. The fluff is then mixed with Super Absorbent Polymer (SAP) dispensed by a precise dosing mechanism in a drum forming unit to form a uniform absorbent core.

  • Advanced features: Supports 3D core forming technology, positioned SAP application, and online topsheet embossing technology-.

• Three-Piece Assembly & Laminating System
  This section assembles the three main components – the absorbent chassis, the front waist section, and the back waist section. Key processes include:

  • Ultrasonic welding at multiple stations for waistband bonding-

  • Waistline elastic lamination with segment tension control for wearing comfort

  • 3D side-leakage-proof wall and elastic waistband composite mechanism

  • S-shape cut of left and right waist pastes

• Converting, Folding & Cutting System
  The assembled web is folded by a product folding unit, then cut into individual pull-up pants by a final cutting assembly with positioned cutting functions for back sheet and front waist paste.

• Quality Inspection & Rejection System
  Integrated automatic inspecting system with built-in defect elimination monitors product quality online and automatically rejects defective items.

• Packaging System
  Includes fully servo-driven stacker with staggered stacking of front and back pants, and automatic packaging mechanism.

• Central Control System
  The entire line is governed by a PLC (Programmable Logic Controller) with an intelligent HMI touchscreen for full automation, recipe management, and production data monitoring.

• Safety System
  Equipped with operator-side safety guards, emergency stop switches, safety signage, and non-drive-side safety pull-cords.

Main Technical Features & Parameters

• Drive & Control: Full-servo drives enable digital size changeovers and synchronous running across all stations. Operators can recall recipes via HMI for rapid product-size switching (S–XXL).

• Tension & Guiding: Equipped with tension control with buffer system and automatic edge guides, supporting zero-speed splicing to maintain stable tension and web alignment.

• Modular Design: Modular structure allows for future upgrades and customisation-.

• Customisation: Supports tailored solutions including 3D core forming technology, positioned SAP application technology, online topsheet embossing technology, ultrasonic welding at different stations, and fine-denier waist technology.

Key Performance Parameters (varies by model):

 Advanced Technologies & Process Highlights

• Ultrasonic Welding Technology: Dual ultrasonic units combined with synchronous floating variable-speed mechanisms extend welding time, ensuring both strong bonding and softness at the waist-.

• 3D Core Forming: Advanced 3D discrete pad formation for superior absorbency and fit.

• Positioned SAP Application: Precise SAP dosing for optimal absorbent performance and material savings-.

• Online Topsheet Embossing: In-line embossing for enhanced aesthetics and fluid distribution-.

• Quick Size Changeover: Rapid recipe-based switching between sizes (S, M, L, XL, XXL) minimises downtime.

• Modular & Custom Design: Modern lines are modular for easy maintenance and future upgrades. Manufacturers offer tailor-made solutions based on customer product and production requirements.

• CE Certification: Designed and manufactured in compliance with CE regulations and standards.