Lesson 1Packaging and secondary lines: bagging machines, count accuracy, seal integrity, and reject handlingThis section explains packaging and secondary lines, covering bagging machine types, counting and stacking logic, sealing conditions, and reject handling. Emphasis is on maintaining pack integrity, accuracy, and line efficiency.
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 section addresses unwinding and web handling for nonwovens, films, and tissue. Topics include automatic splice systems, tension zones, nip roll design, and web guiding. Learners will link web stability to waste and product quality.
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 synchronisation, servo motor tuning, and interlock designThis section introduces control systems and HMIs for nappy lines, focusing on PLC logic, servo drives, and interlocks. Learners will see how speed synchronisation, recipe control, and diagnostics support uptime and safety.
PLC architecture and task organisationSpeed synchronisation 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 section explains cutting, folding, and edge trim operations, including rotary dies, shear knives, and trim removal. Learners will study cut registration, burr control, and how tooling condition affects dust, noise, and safety.
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 behaviour of SAP mixturesThis section details SAP and fluff dosing systems, comparing gravimetric and volumetric feeders. It covers flow behaviour, bridging, segregation, and calibration so learners can maintain dosing accuracy and stable core performance.
Gravimetric feeder design and tuningVolumetric feeder screws and pocket wheelsSAP flowability, caking, and aeration methodsFluff fibre preparation and feed consistencyDosing accuracy checks and recalibrationLesson 6Elastic application and heat/ultrasonic bonding stations: placement accuracy, tension settings, and bond energy parametersThis section covers elastic application for waist and leg areas, including unwind and feed systems, placement control, tension profiles, and heat or ultrasonic bonding. Focus is on bond strength, comfort, and minimising product distortion.
Elastic unwind, guiding, and metering systemsPlacement control relative to nappy 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 section focuses on leg cuff and ear assembly, including folding mechanisms, ultrasonic bonding, and adhesive patterns. It explains how to control placement tolerances to ensure leakage protection, fit, and fastening reliability.
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 section covers sensors and inspection systems used to monitor nappy quality in real time. Topics include vision inspection, moisture and weight sensing, core position checks, data logging, and linking alarms to reject actions.
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 section explains core forming and shaping, from SAP and fluff distribution to compression and cutting. It covers forming belts, vacuum settings, slot dies, and density metrics that influence absorbency and leakage performance.
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
