Lesson 1Packaging and secondary lines: bagging machines, count accuracy, seal integrity, and reject handlingDis section explain packaging an secondary lines, covering bagging machine types, counting an stacking logic, sealing conditions, an reject handling. Emphasis is pon maintaining pack integrity, accuracy, an line efficiency.
Bagging machine types an infeed configurationsCounting, stacking, an collation strategiesSeal temperature, pressure, an dwell settingsLeak, burst, an seal integrity testing methodsReject detection logic an reject gate designLesson 2Unwinding and web handling: spool changeover, tension control, nip roll design, and web alignmentDis section address unwinding an web handling fi nonwovens, films, an tissue. Topics include automatic splice systems, tension zones, nip roll design, an web guiding. Learners will link web stability to waste an product quality.
Automatic splice an turret unwind systemsTension zone layout an load cell feedbackNip roll coverings, hardness, an pressureWeb guiding sensors an actuator selectionWrinkle, bagginess, an web break preventionLesson 3Control systems and HMIs: PLC logic for speed synchronization, servo motor tuning, and interlock designDis section introduce control systems an HMIs fi diaper lines, focusing pon PLC logic, servo drives, an interlocks. Learners will see how speed synchronization, recipe control, an diagnostics support uptime an safety.
PLC architecture an task organizationSpeed synchronization an line master logicServo tuning fi registration an tensionSafety interlocks an emergency stop designHMI screens, alarms, an trend displaysLesson 4Cutting, folding, and edge trim: rotary die cutting, knife blades, cut registration, and burr controlDis section explain cutting, folding, an edge trim operations, including rotary dies, shear knives, an trim removal. Learners will study cut registration, burr control, an how tooling condition affects dust, noise, an safety.
Rotary die cutting cylinder designShear an crush knife selection an setupCut registration sensors an control loopsBurr, dust, an edge fray mitigationTrim conveying, chopping, an waste handlingLesson 5SAP and fluff dosing systems: gravimetric/volumetric feeders, dosing accuracy, and flow behavior of SAP mixturesDis section detail SAP an fluff dosing systems, comparing gravimetric an volumetric feeders. It cover flow behavior, bridging, segregation, an calibration so learners can maintain dosing accuracy an stable core performance.
Gravimetric feeder design an tuningVolumetric feeder screws an pocket wheelsSAP flowability, caking, an aeration methodsFluff fiber preparation an feed consistencyDosing accuracy checks an recalibrationLesson 6Elastic application and heat/ultrasonic bonding stations: placement accuracy, tension settings, and bond energy parametersDis section cover elastic application fi waist an leg areas, including unwind an feed systems, placement control, tension profiles, an heat or ultrasonic bonding. Focus is pon bond strength, comfort, an minimizing product distortion.
Elastic unwind, guiding, an metering systemsPlacement control relative to diaper reference marksTension profiles fi waist an leg elasticsUltrasonic horn, anvil, an amplitude settingsThermal bonding temperature an dwell controlLesson 7Leg cuff and ear assembly: folding mechanisms, ultrasonic horn parameters, adhesive patterning, and positioning tolerancesDis section focus pon leg cuff an ear assembly, including folding mechanisms, ultrasonic bonding, an adhesive patterns. It explain how to control placement tolerances to ensure leakage protection, fit, an fastening reliability.
Cuff folding boards an plow designEar feed, preassembly, an transfer systemsUltrasonic horn profile an weld pattern designAdhesive slot die an spray pattern settingsPositioning tolerances an in-line checksLesson 8Sensors and inspection: vision systems, moisture sensors, weight sensors, and in-line measurement of core positionDis section cover sensors an inspection systems used to monitor diaper quality in real time. Topics include vision inspection, moisture an weight sensing, core position checks, data logging, an linking alarms to reject actions.
Vision cameras, lighting, an lens selectionMoisture sensor placement an calibrationWeight sensors fi product an pack controlCore position measurement an tolerancesDefect classification an reject mappingLesson 9Core forming and shaping: slot dies, compression rolls, forming belts, core density/formation metricsDis section explain core forming an shaping, from SAP an fluff distribution to compression an cutting. It cover forming belts, vacuum settings, slot dies, an density metrics dat influence absorbency an leakage performance.
Forming drum an forming belt configurationsVacuum profile settings fi core formationSAP an fluff distribution uniformity checksCore compression roll pressure settingsCore density, basis weight, an shape metrics
