In the fast-paced world of wet wipe manufacturing, downtime is the enemy. Every minute your wet wipe machine is stopped due to a technical glitch, you are losing money, delaying orders, and wasting raw materials.
While modern equipment, like the lines supplied by Zhenbao Trading, is designed for stability and high output, mechanical issues can arise due to wear and tear, improper settings, or raw material variations.
As a factory manager or engineer, knowing how to troubleshoot these issues quickly is a superpower. In this guide, we break down the Top 5 most common problems encountered in wet tissue production and provide actionable solutions to get your line running again.
1. Nonwoven Fabric Jamming or Off-Tracking
The Symptom: The machine stops suddenly, and you find the nonwoven fabric bunched up in the folding unit. Or, the fabric drifts to the left or right, causing uneven folding (e.g., the wipes are not centered).
The Cause: This is usually a Tension Control or Web Guide issue.
Uneven Tension: The jumbo roll of nonwoven fabric might be unwinding too loosely or too tightly.
Misaligned Rollers: If the guide rollers are not perfectly parallel, the fabric will naturally walk to one side.
Static Electricity: In dry environments, static can cause the light nonwoven fabric to stick to metal parts, causing jams.
The Solution:
Check the Web Guide System: Most modern machines from Zhenbao Trading come with an automatic Web Guiding System (Edge Position Control). Ensure the sensor is clean and calibrated to detect the fabric edge.
Adjust Tension: Use the tension controller knob. The fabric should be taut but not stretched. If it’s too loose, it will wrinkle; if too tight, it may tear or snap.
Clean the Rollers: Sometimes, glue or lint builds up on the rollers, creating friction. Clean all rollers with alcohol.
2. Inconsistent Wetting (Dry Spots or Too Soggy)
The Symptom: Your quality control team reports that some wipes are bone dry, while others are dripping wet. Or, the entire batch has an inconsistent moisture content.
The Cause: The liquid dosing system is the heart of the wet wipe machine.
Clogged Nozzles: The tiny holes in the spray pipes can get blocked by impurities in the lotion or fragrance oils.
Pump Fluctuation: The liquid pump may be sucking in air bubbles.
Speed Mismatch: If the machine speeds up, the pump flow rate must increase proportionally. If it doesn’t, the wipes will be dry.
The Solution:
Inspect Spray Pipes: Remove the spray headers and clean them. If you use a lotion with high viscosity (like specialized makeup remover), you may need larger nozzle openings.
Check for Air Leaks: Inspect the hose connections on the suction side of the pump. Even a pinhole leak can introduce air, causing the flow to “sputter.”
Flow Meter Calibration: On the PLC touch screen, check the “Liquid Ratio” setting. Ensure the flow meter reading matches the actual output.
3. Poor Sealing (Leaking Packs)
The Symptom: The flow pack looks fine, but when you squeeze it, air leaks out. This is a critical failure because airtight sealing is the only thing preventing the wipes from drying out on the shelf.
The Cause: Sealing issues usually occur at the End Seal (the cut across the pack) or the Fin Seal (the long seam down the back).
Incorrect Temperature: The heat sealing jaws are too cold (won’t seal) or too hot (melts the film).
Pressure Issues: The cutter jaws are not pressing hard enough against each other.
Product in the Seal: A piece of a wet wipe got caught in the seal area, preventing the plastic from fusing.
The Solution:
Temperature Tuning: Adjust the temperature in 5-degree increments. Thicker laminate films (like PET/PE) require higher heat compared to thinner films.
Check Cutter Alignment: Perform a “paper test.” Place a piece of carbon paper between the sealing jaws. If the impression is faint on one side, the jaws are misaligned and need mechanical leveling.
Timing Adjustment: If the wipe is getting caught in the seal, the conveyor timing is off. Adjust the phase position on the PLC to ensure the product is perfectly centered between the cuts.
4. Cutting Issues (Ragged Edges or Linked Wipes)
The Symptom: The individual wipes are not separated cleanly. When a customer pulls one wipe, three or four come out linked together, or the edges look chewed and ragged.
The Cause: The slitting unit or the cross-cutting rotary knives are the culprits.
Dull Blades: The circular slitting knives have lost their edge after millions of cuts.
Worn Anvil: The cutting blade presses against a hard roller (anvil). If the anvil has a groove worn into it, the cut won’t be clean.
The Solution:
Sharpening: Most high-speed machines have an auto-sharpening feature for the rotary cutter. Run the sharpening cycle.
Blade Replacement: If sharpening doesn’t help, replace the blades. Always keep a spare set of circular knives and rotary cutters in your inventory (Zhenbao Trading provides spare parts kits with every machine).
Gap Adjustment: The gap between the blade and the anvil is measured in microns. Consult your manual to adjust this gap properly.
5. Film Wrinkling on the Packaging
The Symptom: The finished package looks unprofessional because the plastic film has creases, wrinkles, or bubbles.
The Cause:
Bag Former Issue: The “Adjustable Bag Former” (the metal box that shapes the film) is too tight or too wide for the product size.
Film Tension: The packaging film roll is braking too hard.
The Solution:
Adjust the Bag Former: Loosen the knobs on the former. There should be a small amount of clearance around the stack of wipes. If it’s too tight, the film drags and wrinkles.
Check Film Alignment: Ensure the film roll is centered.
Cooling: If the wrinkles appear near the seal, lower the sealing temperature slightly; the film might be shrinking from excessive heat.
Prevention is Better Than Cure: A Maintenance Checklist
To avoid these top 5 problems, implement a strict maintenance schedule at your factory:
Daily: Clean the liquid spray pipes and wipe down the sealing jaws to remove melted plastic residue.
Weekly: Check the sharpness of cutting blades and lubricate moving chains.
Monthly: Inspect electrical wiring and check the PLC for error logs.
Conclusion: Partner with an Expert
Machinery is an investment, and like any car, it needs maintenance. However, starting with high-quality equipment drastically reduces the frequency of these issues.
At Zhenbao Trading, our wet wipe machines are engineered with automatic diagnostics and tool-free adjustment points to make troubleshooting easy for your operators. Plus, we offer 24/7 video support. If you have a problem you can’t solve, our engineers can guide you through it remotely.
Don’t let technical issues stall your business. Choose a machine partner that understands the “After-Sales” is just as important as the sale.
Need spare parts or a technical consultation? Contact Zhenbao Support today.