DanE’s diaper production line integrates multiple processing units, including absorbent core forming, material unwinding, lamination, elastic application, cutting, folding and quality inspection. Each production station is precisely coordinated to ensure stable material handling, accurate forming processes and consistent finished product quality.
Integrated Production Stages
Processing Stations
Raw Material to Finished Output
One connected process
Covering every stage of the process, from the forming of the absorbent core and the assembly of the various layers to folding, counting, and the output of the finished product.
forms pulp and SAP into a uniform, stable core to support consistent absorption.
Continuous feeding of upper and lower tissue layers for absorbent core wrapping.
Zero-speed material splicing, dual swing-arm tension control, automatic web guiding and an early material-shortage alarm support stable feeding.
Helps maintain continuous production, stable web tension and consistent wrapping around the core.
Converts pulp rolls into loose fibers for absorbent core formation.
Electric loading and dual crushers use servo-controlled pulp feeding, with humidification, sound insulation and bearing-temperature monitoring.
Produces evenly opened fluff fibers for consistent core forming and efficient downstream processing.
Forms the large and small absorbent core layers through independent vacuum-assisted molding.
Independently adjustable vacuum zones, rotary material leveling and timed air cleaning help keep the mold drums and forming belts clear.
Supports uniform basis weight, accurate core geometry and controlled combination of the two core layers.
Meters and distributes superabsorbent polymer into the fluff-pulp core.
Independent belt applicators use servo metering with adjustable layer distribution, plus low-material and blockage alarms.
Keeps SAP dosage and placement controlled to balance absorption performance with material use.
Synchronizes the upper and lower tissue webs around the formed absorbent core.
Matched web speed and tension maintain full coverage and help prevent loose fiber or SAP leakage during transfer.
Protects core integrity and creates a stable structure for compaction and downstream lamination.
Stabilizes core thickness, shape and internal material distribution.
Cylinder pressure and temperature are adjustable, with smooth and mesh roller sets working together for controlled compaction.
Creates a more consistent core profile for reliable conveying, positioning and lamination.
Cuts the continuous core web into individual absorbent cores for the required diaper sizes.
A carbide cutting unit supports M/L-compatible tooling, followed by vacuum transfer into the main assembly section.
Delivers consistent core length and accurate, stable transfer to the product assembly line.
Each layer and component is accurately positioned and bonded to support a secure fit and reliable leak protection.
Continuously feeds topsheet and side nonwoven materials into the standing leak-guard forming section.
Accumulator storage and dual-photoeye web guiding maintain alignment and reduce interruptions during material changes.
Provides stable material supply for consistent leak-guard formation and downstream lamination.
Slits, folds and bonds nonwoven materials with elastic strands to form raised side leak guards.
Pneumatic center slitting, two servo-stretched elastics per side and controlled glue-and-heat bonding form the folded guard structure.
Creates upright side barriers that improve fit and help reduce side leakage.
Cuts and positions the acquisition distribution layer between the topsheet and absorbent core.
Flat cutting and vacuum-assisted transfer place the ADL at the configured position on the inner topsheet.
Supports faster liquid acquisition and distribution while helping the topsheet feel drier.
Cuts and integrates elastic waistband material into the diaper structure for controlled fit.
The shown configuration supports 150 mm and 170 mm materials, with flat cutting and detection for missing waistband pieces.
Adds controlled waist elasticity for closer fit, comfort and improved back-leak protection.
Combines PE film and bottom nonwoven to form the breathable and protective backsheet structure.
Vertical material feeding, glue-and-heat lamination and three leg elastics per side are combined with elastic-break monitoring.
Creates the waterproof outer layer while the leg elastics support fit and side-leak control.
Positions the prepared absorbent core accurately between the topsheet and backsheet assemblies.
Vacuum conveying controls core transfer and placement at the center of the product web.
Keeps the absorption zone aligned with the intended body-contact area.
Uses print-mark positioning to cut front tape material to the required length.
Photoeye registration controls cutting, with an adjustable 120–130 mm cut length and a heated anti-stick bottom roller.
Improves front-tape size consistency, placement accuracy and finished-product appearance.
Applies the cut front tape to the designated backsheet area and reinforces the bond.
Controlled adhesive application and a heated pressure roller secure the tape to the product web.
Builds a stable fastening surface designed to remain attached during repeated use.
Cuts and folds the left and right fastening tapes before final positioning.
Carbide cutters provide an adjustable 25–50 mm cut length, with folding devices and manually adjustable cutter spacing.
Produces consistently sized, neatly folded side tapes that are easier for the user to handle.
Laminates folded side tapes symmetrically onto both sides of the diaper.
Adhesive bonding is combined with sensors that detect missing or skewed side tapes.
Supports balanced appearance, secure fastening and repeatable tape placement.
Applies controlled heat and pressure around the product perimeter to secure the laminated structure.
Multiple heated rollers apply adjustable temperature and pressure around the product edges.
Strengthens layer bonding and helps prevent delamination or edge leakage.
Trims side material to form the required leg-opening contour.
The shown line uses a T15 R-cutter, digital pressure display, non-stop trim removal and automatic piece counting.
Forms a clean leg contour and supports configured M/L tooling changes on the production line.
Cross-cuts the continuous assembled web into individual finished diapers.
A carbide cutting unit combines high-speed transverse cutting with controlled registration and clean edge formation.
Separates complete products consistently with neat, low-burr cut edges.
Share your needs with DanE. We’ll recommend a suitable machine configuration and line layout, and you’re always welcome to visit our factory to see the equipment and process firsthand.
Each diaper is folded and inspected before output, helping maintain consistent finished-product quality.
Folds each individual diaper longitudinally using a servo-controlled folding blade.
Servo control allows the fold position and fold length to be adjusted for the configured product.
Creates compact, consistent folded pieces for counting, stacking and packaging.
Collectively ejects products that have been marked as defective by upstream detection points.
The rejection unit can be configured for two- or three-piece batch removal using a swing arm and air-blow discharge.
Separates marked defects without disrupting the flow of accepted products.
Turns accepted folded products by 90 degrees, conveys them under vacuum and counts them automatically.
The shown configuration uses a 2 m vacuum-wheel conveyor, 10-piece counting and online phase adjustment at the discharge end.
Maintains an orderly product flow and prepares consistent groups for the next packing step.
Directs products to either an automatic stacking channel or a manual bagging channel.
One channel reserves an interface for downstream packaging equipment, while the second provides a manual bagging station.
Allows the output section to match different automation levels and packing arrangements.
At DanE, quality is managed throughout the production line, not checked only at the final output. Five key control points help maintain stable processing and consistent finished diapers.
Controlled tension, web guiding and material accumulation keep nonwovens, film, tissue and elastics feeding smoothly.
Vacuum forming, pulp distribution, SAP metering and compaction help maintain a uniform, stable absorbent core.
Photoelectric sensors, vacuum transfer and synchronized drives keep cores, ADL, tapes and other components correctly aligned.
Controlled pressure, temperature and cutting registration help maintain secure bonding and consistent diaper dimensions.
Defects are detected for rejection, while accepted diapers are turned, counted and stacked for downstream packing.
Find answers to common questions about diaper production lines. For other requirements, please contact the DanE team.
Contact us to discuss your product, capacity, and machinery requirements. Our team will help you plan the right production solution.
Tell us your requirements. We will reply with a suitable solution and quotation.