Lesson 1Packaging and secondary lines: bagging machines, count accuracy, seal integrity, and reject handlingThis part explains packaging and secondary lines, covering types of bagging machines, counting and stacking methods, sealing conditions, and handling rejects. Focus is on keeping pack strength, accuracy, and line speed in Gambian plants.
Bagging machine types and infeed configurationsCounting, stacking, and collation strategiesSeal temperature, pressure, and dwell settingsLeak, burst, and seal integrity testing methodsReject detection logic and reject gate designLesson 2Unwinding and web handling: spool changeover, tension control, nip roll design, and web alignmentThis part addresses unwinding and handling webs for nonwovens, films, and tissue. Topics include auto splice systems, tension areas, nip roll design, and web guiding. Learners will connect web steadiness to less waste and better quality locally.
Automatic splice and turret unwind systemsTension zone layout and load cell feedbackNip roll coverings, hardness, and pressureWeb guiding sensors and actuator selectionWrinkle, bagginess, and web break preventionLesson 3Control systems and HMIs: PLC logic for speed synchronization, servo motor tuning, and interlock designThis part introduces control systems and HMIs for diaper lines, focusing on PLC logic, servo drives, and safety locks. Learners will see how speed matching, recipe control, and checks help uptime and safety in our factories.
PLC architecture and task organizationSpeed synchronization and line master logicServo tuning for registration and tensionSafety interlocks and emergency stop designHMI screens, alarms, and trend displaysLesson 4Cutting, folding, and edge trim: rotary die cutting, knife blades, cut registration, and burr controlThis part explains cutting, folding, and edge trim work, including rotary dies, shear knives, and trim removal. Learners will study cut alignment, burr control, and how tool state affects dust, noise, and safety in local operations.
Rotary die cutting cylinder designShear and crush knife selection and setupCut registration sensors and control loopsBurr, dust, and edge fray mitigationTrim conveying, chopping, and waste handlingLesson 5SAP and fluff dosing systems: gravimetric/volumetric feeders, dosing accuracy, and flow behavior of SAP mixturesThis part details SAP and fluff dosing systems, comparing weight-based and volume-based feeders. It covers flow issues, clumping, separation, and calibration to keep dosing right and core steady in Gambian production.
Gravimetric feeder design and tuningVolumetric feeder screws and pocket wheelsSAP flowability, caking, and aeration methodsFluff fiber preparation and feed consistencyDosing accuracy checks and recalibrationLesson 6Elastic application and heat/ultrasonic bonding stations: placement accuracy, tension settings, and bond energy parametersThis part covers applying elastic for waist and leg areas, including unwind and feed systems, placement control, tension levels, and heat or ultrasonic bonding. Focus is on bond strength, comfort, and avoiding product twist in local lines.
Elastic unwind, guiding, and metering systemsPlacement control relative to diaper reference marksTension profiles for waist and leg elasticsUltrasonic horn, anvil, and amplitude settingsThermal bonding temperature and dwell controlLesson 7Leg cuff and ear assembly: folding mechanisms, ultrasonic horn parameters, adhesive patterning, and positioning tolerancesThis part focuses on leg cuff and ear assembly, including folding tools, ultrasonic bonding, and adhesive patterns. It explains controlling placement limits to ensure no leaks, good fit, and reliable fastening in our context.
Cuff folding boards and plow designEar feed, preassembly, and transfer systemsUltrasonic horn profile and weld pattern designAdhesive slot die and spray pattern settingsPositioning tolerances and in-line checksLesson 8Sensors and inspection: vision systems, moisture sensors, weight sensors, and in-line measurement of core positionThis part covers sensors and inspection systems to watch diaper quality live. Topics include vision checks, moisture and weight sensing, core position, data recording, and linking alarms to reject actions for quality in Gambia.
Vision cameras, lighting, and lens selectionMoisture sensor placement and calibrationWeight sensors for product and pack controlCore position measurement and tolerancesDefect classification and reject mappingLesson 9Core forming and shaping: slot dies, compression rolls, forming belts, core density/formation metricsThis part explains core forming and shaping, from SAP and fluff spread to compression and cutting. It covers forming belts, vacuum settings, slot dies, and density measures that affect absorption and leak prevention locally.
Forming drum and forming belt configurationsVacuum profile settings for core formationSAP and fluff distribution uniformity checksCore compression roll pressure settingsCore density, basis weight, and shape metrics
