Diaper line cutaway atlas

The large roll/unwind area is the line's raw-material throat: fluff and wrap-sheet webs are presented, guided, and tensioned before joining the absorbent-core path.

Think of it as the supply rail: wide webs enter under control, then split into liner-side and poly-side sheet paths so later stations can build the pad around a stable carrier.

Inputs

Sam + Fluff · FD roll · Liner-side wrap sheet · Poly-side wrap sheet

Moves

Unwind → Guide → Align → Feed into pad stream

Output

Stabilized wrap-sheet streams feeding pad debulking and core assembly.

Surge material and liner are cut, guided, and married into a combined stream before the pad-forming stations take over.

This is where top-sheet handling becomes a laminate problem: the acquisition/surge layer has to land on the liner in the right position before the core stack gets thicker.

Inputs

Surge · Liner · Guide points G3/G4

Moves

Cut surge → Guide liner → Merge web paths → Hold registration

Output

Combined surge-and-liner path feeding the upper assembly.

The pad train turns a thick absorbent stream into repeated, correctly spaced pad units with sealed ends, optional perfume input, and reduced bulk.

This is the density-and-repeatability section: it folds the pad into shape, spaces repeat lengths, cuts the pattern, and compresses bulk so downstream folding is predictable.

Inputs

Absorbent pad stream · Perfume input · Combined liner/surge feed

Moves

Fold → Space → Cut → Tack → Compress

Output

Repeated low-bulk pad assemblies ready for insert/body integration.

The lower Section 1 path feeds poly, flap material, and elastics so the pants product can gain stretch, fit, and leakage-control geometry.

This is the fit subsystem: thin elastic lanes and flap webs must arrive under stable tension, otherwise the final pant shape wrinkles, drifts, or loses containment performance.

Inputs

Poly roll · OC flap · Flap elastic · Leg elastic

Moves

Unwind → Tension → Guide → Place elastic into flap/body zones

Output

Prepared stretch and flap streams ready to join the body web.

The insert train cuts and transfers discrete inserts while drums rotate them, space them, and re-pitch them for the body-web cadence.

This is the clockwork heart of the line: a continuous web becomes discrete inserts, then drum surfaces change spacing and orientation without letting registration drift.

Inputs

Prepared insert web · Cutoff timing · Transfer drum vacuum surface

Moves

Tack → Cut off → Transfer → Rotate → Re-pitch

Output

Timed inserts aligned to the downstream folding and panel-bonding cadence.

Panels are added to the insert stream, tucked, folded, twisted into position, and bonded so the pant body can hold its final garment geometry.

This is where flat laminate starts behaving like a garment: panels join the insert, folding rails create symmetry, and the bonder locks the panel/body interfaces.

Inputs

Panel feed · Re-pitched insert stream · Fold conveyors

Moves

Add panel → Tuck → Bi-fold → Twist → Bond

Output

Folded and bonded pant-body assemblies moving toward final finishing.

The finishing path presses the web, cuts final products, transfers them through the product rotor, and drops rejected units before good products continue.

This section turns continuous assembly into individual products and protects the output stream: reject gates remove bad units before packing sees them.

Inputs

Folded body web · Aperture-module feed · Rotor/transfer drum timing

Moves

Press → Final cut → Rotate → Transfer → Reject bad units

Output

Accepted pant products continue left; rejected units drop out at Reject 2 or Reject 3.

Finished pants move into the pack lane and stacker, where individual products become a controlled pile for downstream packaging.

This is the line's exit discipline: speed is converted into countable stacks so packaging can take over without losing orientation or count accuracy.

Inputs

Accepted pant products · Bulk pack conveyor · Stacker infeed

Moves

Convey → Orient → Count → Stack

Output

Stacked pant products ready for final package handling.