Process, equipment connection and operating requirements
Review how the complete line is arranged, which finished products it supports, how packaging is handled and what factory conditions should be confirmed.
Production process and equipment connection
3000 Semi-Automatic Toilet Paper Production Line
The 3000 Semi-Automatic Toilet Paper Production Line converts jumbo tissue rolls into embossed, perforated, cut and bagged toilet paper rolls. The standard configuration includes a 3000 mm toilet paper rewinding machine, a PE40 manual band-saw paper cutter and a re-500TS water-cooled bag sealing machine.
The production line is suitable for factories that require a wider rewinding machine and higher paper-processing capacity while retaining manual cutting and packaging operations. It provides a lower-investment alternative to a fully automatic line with an automatic log saw, roll conveyors and automatic packing equipment.
The rewinding section uses PLC and touch-screen control. Paper-log transfer, band-saw cutting, finished-roll inspection, product arrangement, bag loading and sealing require operator involvement. The line should therefore be classified as semi-automatic.
Suitable Finished Products
Standard household toilet paper rolls
Toilet paper rolls with cardboard cores
Coreless toilet paper rolls with an optional coreless device
Embossed toilet paper rolls
Perforated one-ply and multi-ply toilet paper
Manually arranged multi-roll toilet paper bags
The finished roll diameter, roll width, paper basis weight, number of plies, perforation pitch, core diameter and number of rolls per package must be confirmed before the final configuration is approved.
Production Process
Jumbo Roll Loading and Unwinding
The jumbo tissue roll is installed on the single-layer rear unwind stand. The maximum raw paper width is 3000 mm, and the maximum jumbo roll diameter is approximately 1500 mm. The listed maximum raw paper weight is approximately one ton.
The standard configuration uses manual edge alignment and manual initial paper threading. An active guide roller in the belt transmission section supports stable paper feeding during normal operation.
A raw paper break detection system monitors the web. If the paper breaks or abnormal feeding occurs, the machine can stop for inspection and adjustment.
Embossing and Perforating
The paper passes through the embossing unit before entering the perforating and rewinding section. The embossing system forms the required surface pattern and improves the appearance of the finished toilet paper.
The upper perforation blade uses an adjustable extension structure. The blade position can be adjusted according to the paper basis weight, number of plies and required tear strength.
The perforation pitch is prepared according to the confirmed finished product and target market. Proper adjustment should maintain sufficient web strength during rewinding while allowing the finished sheets to separate easily during use.
Rewinding and Tail Sealing
After embossing and perforating, the paper is rewound into long toilet paper logs. The rewinding section controls the finished log diameter, paper length, winding firmness and discharge sequence.
The reference design speed is up to 190 m/min, while the normal production speed is approximately 80 to 180 m/min. Practical speed depends on the raw paper, number of plies, embossing pressure, perforation setting and finished roll diameter.
A synchronous-belt-driven circular cutting device completes glue spraying and paper-web cutting at the end of each rewinding cycle. The finished toilet paper log is discharged through the automatic shaft-extraction and transfer mechanism.
The machine produces long toilet paper logs rather than individually cut retail rolls. Operators must transfer the logs to the manual band-saw cutting section.
Manual Band-Saw Cutting
The PE40 manual band-saw paper cutter divides long toilet paper logs into individual finished rolls.
The cutting diameter range is approximately 40 to 140 mm, while the cutting length can be adjusted from approximately 50 to 300 mm. The standard blade specification is 3740 × 40 × 0.65 mm.
The operator positions and feeds each paper log manually. Blade sharpening is also completed manually. Practical cutting capacity therefore depends on the finished roll width, log diameter, blade condition and operator experience.
The manual band saw reduces the initial investment, but it cannot normally maintain the same output as an automatic log saw. It is suitable for factories that accept operator-assisted cutting and flexible production scheduling.
Finished-Roll Inspection
After cutting, operators inspect the finished toilet paper rolls and remove irregular head and tail sections.
Normal inspection items include:
Finished roll width
Finished roll diameter
Cut-surface quality
Core position
Paper alignment
Embossing appearance
Perforation quality
Tail-sealing condition
Accepted rolls are counted and arranged manually according to the selected package format.
Bag Loading and Water-Cooled Sealing
Finished toilet paper rolls are placed into prepared packaging bags manually. The re-500TS water-cooled sealing machine then seals the bag opening.
The standard sealing length is 500 mm, and the sealing width is approximately 6 mm. The machine has a power rating of approximately 1.8 kW and uses a 220 V power supply.
The water-cooled sealing machine does not automatically count, arrange or load the toilet rolls. Operators remain responsible for preparing the bag, positioning the products and placing the bag into the sealing area.
Main Equipment Composition
3000 mm toilet paper rewinding machine
Single-layer jumbo roll unwind stand
Paper feeding and guide-roller system
Raw paper break detection system
Embossing unit
Adjustable perforating unit
Glue spraying and circular cutting device
Automatic shaft-extraction and log transfer mechanism
PE40 manual band-saw paper cutter
re-500TS water-cooled bag sealing machine
PLC and touch-screen control system
Electrical control cabinet and safety guards
Reference Technical Parameters
| Production Line Name | 3000 Semi-Automatic Toilet Paper Production Line |
|---|---|
| Automation Level | Semi-Automatic |
| Maximum Raw Paper Width | 3000 mm |
| Maximum Jumbo Roll Diameter | Approximately 1500 mm |
| Maximum Raw Paper Weight | Approximately 1 t |
| Rewinding Design Speed | Up to 190 m/min |
| Practical Rewinding Speed | Approximately 80 to 180 m/min |
| Paper Feeding System | Single-layer rear unwind stand |
| Paper Edge Alignment | Manual adjustment |
| Initial Paper Threading | Manual |
| Paper Break Detection | Included |
| Finished Log Transfer | Automatic shaft extraction and transfer |
| Band-Saw Cutter Model | PE40 |
| Cutting Diameter | Approximately 40 to 140 mm |
| Cutting Length | Approximately 50 to 300 mm |
| Band-Saw Blade | 3740 × 40 × 0.65 mm |
| Blade Sharpening | Manual |
| Sealing Machine Model | re-500TS |
| Sealing Length | 500 mm |
| Sealing Width | 6 mm |
| Reference Installed Power | Approximately 8.4 kW for the three listed machines |
| Compressed-Air Pressure | Approximately 0.45 to 0.60 MPa |
| Air Consumption | Approximately 40 m³ per shift for the rewinder configuration |
| Operators | Approximately 4 to 6 people per shift |
| Power Supply | Three-phase industrial power for the rewinder and cutter; 220 V for the sealing machine, or customized |
Equipment Dimensions and Weight
| Equipment | Reference Dimensions | Reference Weight |
|---|---|---|
| 3000 Toilet Paper Rewinding Machine | Approximately 5500 × 4500 × 1750 mm, subject to final drawing confirmation | Approximately 4000 kg |
| PE40 Manual Band-Saw Cutter | Approximately 1300 × 800 × 1800 mm | Approximately 400 kg |
| re-500TS Water-Cooled Sealing Machine | Approximately 800 × 720 × 850 mm | Approximately 30 kg |
The Chinese and English source values for the rewinder width are inconsistent. The final machine dimensions must be confirmed against the approved equipment drawing before publication or contract signing.
Automation and Manual Operations
The rewinder automatically or electronically controls the principal converting operations, while cutting and packaging remain operator-assisted.
Automatic or controlled operations include:
Paper feeding during normal production
Raw paper break detection
Embossing
Perforating
Rewinding
Glue spraying
Paper-web cutting
Tail sealing
Shaft extraction and finished-log transfer
PLC parameter control
Manual operations include:
Jumbo roll loading
Initial paper threading
Paper edge alignment
Movement of toilet paper logs
Band-saw feeding and positioning
Blade sharpening
Finished-roll inspection
Product counting and arrangement
Bag loading
Package positioning and sealing
Finished-package collection
Cleaning and routine maintenance
Operator Requirement
The recommended staffing level is approximately four to six operators per shift.
One operator for jumbo roll loading and rewinder supervision
One operator for paper threading, adjustment and product checks
One or two operators for log transfer and band-saw cutting
One or two operators for finished-roll arrangement, bag loading, sealing and product handling
The actual number of operators depends on finished roll size, cutting rhythm, package quantity and material-handling conditions.
Practical Output
The rewinder operates at approximately 80 to 180 m/min under suitable conditions. However, the finished output of the complete line cannot be calculated from the rewinding speed alone.
Manual log transfer, band-saw cutting, roll inspection, product arrangement and bag loading determine the practical output of the connected production process.
Output is affected by:
Finished roll diameter and width
Paper basis weight and number of plies
Sheet count and perforation pitch
Embossing pressure
Band-saw operator experience
Blade condition
Number of rolls per package
Bag dimensions
Material replacement and adjustment time
The final shift output should be calculated from the confirmed finished roll and verified through factory trial operation.
Workshop Requirements
The recommended equipment area is approximately 16 to 22 m long and 7 to 9 m wide. A total workshop area of approximately 180 to 280 m² provides additional space for raw paper, packaging materials, finished rolls and operator movement.
The workshop should provide:
A level and stable industrial floor
A clear height of at least 4 m
Suitable jumbo roll lifting equipment
Three-phase industrial power
A 220 V outlet for the sealing machine or a suitable transformer
Compressed air at approximately 0.45 to 0.60 MPa
Safe band-saw operating space
Maintenance and emergency passages
Raw material and finished-product storage
Possible Future Upgrades
The production line can be upgraded when the factory requires higher output or reduced operator involvement.
Additional jumbo roll unwind stands
Pneumatic or shaftless jumbo roll loading
Automatic web guiding
Automatic core feeding
Coreless rewinding device
Toilet paper log accumulator
Automatic log saw
Finished-roll separation conveyors
Automatic roll counting
Individual roll wrapping machine
Automatic multi-roll packing machine
Automatic bundling machine
Information Required for Final Configuration
Finished toilet roll width and diameter
Weight per finished roll
Number of paper plies
Raw paper basis weight
Jumbo roll width and diameter
Sheets per roll
Perforation pitch
Cardboard core diameter
Coreless production requirement
Embossing requirement
Number of rolls per package
Packaging bag dimensions
Required output per shift
Available operators
Workshop dimensions
Destination voltage and frequency
Configuration Note
The 3000 Semi-Automatic Toilet Paper Production Line provides wide-web rewinding with manual cutting and operator-assisted packaging. It is suitable for factories that require higher rewinding capacity but do not yet need a fully connected automatic cutting and packing process.
The reference installed power of approximately 8.4 kW is calculated from the listed 5.5 kW rewinder motor, 1.1 kW band-saw motor and 1.8 kW sealing machine. Unlisted auxiliary equipment is not included.
Final production capacity, machine dimensions, equipment layout and utility requirements must be confirmed according to the finished toilet roll, approved equipment drawing and destination power supply.
Primary and secondary packing options
Equipment arrangement and workshop flow
Practical output, operator quantity, installed power and workshop space depend on the final equipment combination, finished-product dimensions, packing format and operating conditions. Confirm these values in the final technical proposal.