Toilet Paper Production Solution

This toilet paper production solution coordinates the complete conversion of jumbo tissue rolls into perforated, rewound, cut, wrapped, and carton-packed toilet rolls. The line is built around the DB-R500 Toilet & Kitchen Non-Stop Rewinder Line and integrates roll conveying, automatic wrapping or shrink packaging, and end-of-line carton packing. The goal is to connect each process stage—from parent roll unwinding to finished pack—so that material flow, speed, and automation level are matched to your specific roll format and output target.

Production Process Overview

The solution follows a clear sequence: jumbo roll unwinding, embossing and lamination (optional), perforation, non-stop rewinding, log saw cutting, roll conveying, wrapping or shrink packing, and final carton packing. Each stage is coordinated so that material flow and automation level match the confirmed roll format and output target.

Core Converting Equipment

DB-R500 Toilet & Kitchen Non-Stop Rewinder Line

This is the primary converting stage, handling jumbo roll unwinding, embossing, lamination, printing, perforation, non-stop rewinding, and log saw cutting. It is recommended for manufacturers requiring continuous production and an automatic connection between rewinding and cutting.

Confirmed configuration includes:

Stable production speed: up to 500 m/min
Parent roll width: 2,000–3,650 mm
Parent roll diameter: 2,000–3,000 mm
One to five independently driven unwind stands
Four independent feeding channels
Full-servo Siemens motion control
Automatic web-break detection
Optional embossing, lamination, and printing

Output from this stage: finished toilet tissue logs ready for automatic cutting.

Roll Conveying and Packaging Selection

Toilet Roll Conveying System

After cutting, the conveying system separates, arranges, and transfers the rolls to the selected packaging machine. Available functions may include roll separation, orientation, product accumulation, inspection and rejection, and automatic wrapping-machine feeding. The conveyor layout is matched to the selected packaging method and factory space.

You must select one primary packaging method based on your target retail format:

Selection Criteria	Option A: DB-TR-120P Wrapping Machine	Option B: DB-S-5525 Shrink Packing Machine
Recommended for	Individually paper-wrapped toilet rolls	Individual or grouped rolls in shrink film
Main function	Automatic roll feeding, wrapping-paper cutting, suction, clamping, pressing, and discharge	Automatic film sealing, cutting, and heat shrinking
Confirmed speed	60–120 rolls/min	60–100 packs/min
Key size limits	Roll width 90–130 mm; diameter 95–130 mm	Max pack width + height: 550 mm; center-folded POF film
Changeover	Quick size changeover	Automatic production-line connection

Both options support automatic production-line connection. The final choice depends on whether your finished product is a single wrapped roll or a multi-roll shrink pack.

End-of-Line Carton Packing

DB-C-8P Semi-Automatic Tissue Case Packing Machine

This optional stage stacks the packaged toilet rolls and assists the operator in loading them into cartons.

Maximum design speed: 8 cartons/min
Applicable carton length: 220–550 mm
Applicable carton width: 130–400 mm
Applicable carton height: 150–500 mm

Output from this stage: carton-packed toilet tissue products ready for storage and shipment.

Optional end-of-line additions include carton sealing equipment, coding and labeling systems, and inspection and rejection systems.

Configuration Decisions and Product Range

The line can be configured for cored or coreless toilet rolls, single-ply or multi-ply products, and embossed or laminated rolls. The final product range depends on the confirmed roll specifications and selected equipment configuration.

Before engineering review, you must confirm the following parameters:

Parent roll width, diameter, and tissue basis weight
Number of plies and embossing/lamination requirements
Finished roll width, diameter, and sheets per roll
Core diameter or coreless requirement
Target production output (rolls/min or tons/day)
Packaging method: single-roll wrap or multi-roll shrink pack
Rolls per package and carton dimensions
Factory floor space and power supply standard

Final machine configuration should be matched to tissue grade, finished size, target output, available floor space, and the required level of automation. The values listed above are design parameters, not guaranteed acceptance values.

Project Input Checklist

To prepare a complete line configuration, please provide the following information:

Parent roll width and diameter
Tissue basis weight and number of plies
Finished roll width and diameter
Core diameter or coreless requirement
Sheets per roll
Target production output
Required packaging method
Rolls per package
Carton dimensions
Factory dimensions
Power supply

Request a Line Configuration Review

Send us your product specifications, packaging requirements, and factory layout. We will prepare a DB-R500-based toilet paper production-line configuration matched to your roll format and output target. For a closer look at the rewinding stage, you can review the DB-R500 non-stop rewinder line details or check the toilet paper machine FAQ for common configuration questions.

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