The Mysterious Wet Wipes Lid: Why Are Lids Falling Off?

Have you ever experienced a situation where everything seemed perfect on the production line? The wet wipes machine was running smoothly, the raw materials were of high quality, and both the wet wipes lid and hot-melt adhesive were in top condition. Everything looked flawless before the wet wipes were packed into boxes. But then, once the products were taken out of the box, some wet wipes lids had detached from the packages. What’s going on? Is it the fault of the packaging box? Of course not!

What's Really Causing the Wet Wipes Lid to Fall Off?

After a thorough investigation, we identified the problem within the capping process on the wet wipes machine. This high-speed capping machine, equipped with a Swiss Stäubli robot and a German Beckhoff control system, uses a dual suction head design, allowing it to operate at speeds of up to 110 wet wipes lids per minute. Although the machine generally functions well at high speeds, the core issue lies in the dual suction head design itself.

What Is the Dual Suction Head Design?

In normal operation, the robotic arm picks up two wet wipes lids at the same time, applies adhesive to both, and then waits for the wet wipes packages to be transported to the capping station. The robot first attaches one wet wipes lid and then the second. The issue arises when the packaging line runs slower than expected or when the packages aren’t delivered promptly. In such cases, the second wet wipes lid, already coated with adhesive, remains idle in the air, waiting. During this wait, the adhesive cools and dries, significantly reducing its bonding strength.

This issue is particularly noticeable during colder seasons, when the adhesive cools even faster. Although the wet wipes lid might appear securely attached initially, it is more prone to falling off during transportation or when it reaches the customer.

Why Doesn't the Wet Tissue Machine with a Single Suction Head Have This Issue?

Unlike the dual suction head design, a single suction head system only picks up the wet wipes lid after the package is in place and ready for capping. The adhesive is applied immediately before the lid is attached, minimizing the time the adhesive is exposed to air. This makes the single suction head system much more suited for medium to low-speed wet wipes making machines, ensuring that the adhesive remains effective and the lid is securely attached.

How to Solve the Problem of Falling Wet Wipes Lids

After a careful evaluation, we decided to replace the dual suction head system with a single suction head design. While the dual head system is ideal for high-speed wet wipes making machines, the single suction head is much more appropriate for our medium to low-speed production line. It eliminates the issue of adhesive cooling during wait times, ensuring each wet wipes lid is firmly secured before the product leaves the factory.

However, if you’re running a high-speed production line, using a dual suction head capping machine can still be a viable option. To avoid lid detachment, we recommend keeping your production speed at 110-120 wet wipes lids per minute to ensure optimal performance. At these speeds, the dual suction head design operates efficiently without risking adhesive cooling before the wet wipes lids are applied.

Choosing the Right Wet Wipes Machine for a Stable Production Line

Our experience shows that choosing the right wet wipes machine for your production line is crucial. While the dual suction head system is highly effective for high-speed production, a single suction head design is better suited for lower speeds. It not only enhances the stability of your wet tissue machine but also ensures that the wet wipes lids are properly and securely attached.