Starting a Sanitary Napkin Line: What New Companies Should Do First
Launching a sanitary napkin business is not “buy a machine and run.” The fastest way to bankable output is a closed loop: Plan → Engineer → Validate → Ramp. For first-time teams, that means:
1) Define the product matrix.
Start with 2–3 SKUs (e.g., day/night with or without wings), lock target pad lengths, basis weights, packaging counts, and retail position. This narrows raw-material options and avoids costly mid-project changes.
2) Engineer your process window.
Convert lab intent into production reality by specifying CQAs (absorbency, leakage, fit, peel/shear strength) and CPPs (glue add-on, nip pressure, web tension, rotary die phase, sealing temperature). Use small DOE trials to converge settings before scale.
3) Build digital traceability from day one.
A basic MES + SCADA/PLC stack with barcode/RFID ties raw lots to shifts and parameters. When a batch drifts, you can quarantine precisely instead of stopping the whole plant.
4) Ramp with discipline.
In week one, prioritize yield and stability; only then push speed. A realistic ramp protects cash flow and customer confidence.
Choosing the Right Platform: Why a Full-Servo Architecture Helps New Entrants
A full-servo line gives each critical station its own motion profile. That precision keeps registration stable at speed, simplifies size changeovers via recipes, and makes quality more repeatable than mechanical or mixed systems. It also shortens the learning curve for a new team—operators tune parameters at the HMI rather than the gearbox.
A Machine That Fits This Strategy
Welldone’s full-servo fast “easy-pack” sanitary napkin machine maps directly to the startup playbook:
Process & forming logic. A forming wheel combines wood pulp and SAP to create the core (strip de-moulding). Wing release paper placement is precise; side sealing is clean; a 90-degree flapping unit supports “easy-pack” presentation—all under servo control for consistency.
Throughput headroom with a realistic set point. Design speed 1,000 pcs/min; stable speed ~900 pcs/min. For a new plant, running at the stable set point is the fastest way to consistent deliveries.
Quality capability. Target passing rate ≥98% (excludes external glue applicator/auto splicing), which materially reduces material loss and complaint risk.
Open ecosystem. Glue system options (cost-effective Chinese or Nordson), web-guide options (Chinese or BST), and control options (Mitsubishi or “Simons” as listed) give you budget and service flexibility without locking you in.
Facilities ready. Machine body 28.0 × 5.5 × 3.5 m; recommended working space 39 × 9 × 5 m, compressed air 0.6–0.8 MPa, and power cabling 3×120 mm² + 1×50 mm² + 1×25 mm²—clear, practical numbers for site planning.
Service wrap. ISO/CE, one-station after-sales (installation, training, remote support), aligning with a first-plant team’s needs.
Product page: “Full servo fast & easy pack sanitary napkin machine.” (Welldone)
What Benefits Will It Bring a New Company?
1) Faster time-to-stable production.
At ~900 pcs/min, hourly output is ~54,000 pads. With ≥98% pass rate, scrap is ≤2% (~1,080 pads/hour). Compared with a 95% pass rate typical of early mechanical setups, you avoid ~1,620 wasted pads/hour—material savings that compound week after week. (Inference based on published pass-rate and stable speed.)
2) Lower cost per unit through disciplined changeovers.
Recipe-based servo control reduces size-change time and trim loss, keeping OEE higher and labour steadier during SKU rotations.
3) Cleaner downstream packaging.
Accurate wing release positioning, tidy side sealing and the 90° flapping unit produce pads that stack and bag more reliably, cutting jams and sealing defects in your bagger/sealer—fewer micro-stops, smoother takt.
4) Traceability and compliance baked in.
With a modern PLC/MES backbone and consistent forming/sealing, it’s straightforward to barcode lots and capture parameters at speed—vital for audits and retailer onboarding.
5) Scalable utilities and layout.
The documented footprint and utilities mean your building plans won’t guess. You can wire, pipe and ventilate correctly on the first pass, preventing expensive rework.
A Practical 12-Week Startup Map (You Can Hand to the Team)
Weeks 0–2 — Specification & layout. Fix SKUs and packaging counts; plan the 39×9×5 m working space; confirm power/air drops and operator stations.
Weeks 3–6 — Pre-install readiness. Train key roles (line chief, electrical, QC); agree on glue system/web guide/PLC choices; prepare incoming QA and COA templates.
Weeks 7–10 — Install & commission. Dry run → wet run; lock CPP windows (glue, tension, nip, die phase, temperature); enable SPC and defect ejection targeting ≥98% pass rate.
Weeks 11–12 — Trial & handover. Achieve stable ~900 pcs/min with daily output and downtime targets met; complete IQ/OQ/PQ and finalize SOPs.
Final Word
A startup wins not by chasing the last 5% of speed, but by making every minute sellable: consistent forming and sealing, predictable changeovers, and data you can trust. Welldone’s full-servo sanitary napkin line—designed for 1,000 pcs/min with ~900 pcs/min stable output, ≥98% pass rate, open brand options, and clear utilities—gives new companies the exact mix of headroom and control they need to scale with confidence.
If you’re exploring a sanitary napkin line or want a tailored proposal, contact us:
Email: [email protected] Website: cnwelldone.com
