Tissue Paper Break Causes and Fixes in Converting Lines

Why Does Tissue Paper Break During Converting?

Paper breaks are a frequent cause of downtime and waste in tissue converting. The issue usually stems from a few controllable areas: the parent roll, web tension, the paper path, machine settings, or running speed. Instead of making random adjustments, a systematic check helps you find the root cause faster and stabilize your production output.

1. Inspect the Parent Roll Condition First

Before changing any machine settings, verify the quality of the parent roll. Tissue is lightweight and sensitive to variations in the base paper. Small defects in the roll can easily translate into web breaks during high-speed converting.

• Uneven moisture profile across the web
• Weak or damaged edges
• Wrinkles or creases on the surface
• Loose or inconsistent winding
• Visible holes or thin spots
• Inconsistent paper strength within the same roll

If breaks consistently occur with a specific parent roll, the root cause is likely the raw paper quality rather than the converting machine itself.

2. Verify Web Tension Settings

Incorrect web tension is a common trigger for paper breaks. If the tension is too high, the web can be stretched beyond its tensile limit and snap. If it is too low, the paper may wrinkle, drift, or contact machine parts unexpectedly.

Operators should check the following points:

• Is the web visibly too tight or too loose?
• Does the dancer roll move smoothly without sticking?
• Are there sudden tension spikes during operation?
• Does the break happen mainly during acceleration or deceleration?

When troubleshooting tension, change only one parameter at a time. Observe the effect before making further adjustments.

3. Examine the Paper Path for Obstructions

The web travels through rollers, guide bars, embossing units, and folding sections. Any irregularity along this path can cause the paper to drift, wrinkle, or tear.

• Is the paper feeding straight into each unit?
• Are all rollers clean and free of damage?
• Is there a buildup of paper dust or adhesive on the rollers?
• Are the guide rolls properly aligned?
• Is the web touching any sharp edge or rough surface?

If the paper consistently breaks at the same location, focus your inspection on that specific section of the machine.

4. Review Machine Adjustments

Machine settings directly affect web stability. Excessive pressure, incorrect timing, or poor alignment can pull or tear the delicate tissue web.

• Embossing pressure is too high or uneven across the width
• Cutting or perforating knives are not synchronized
• Folding position is unstable
• Feeding alignment is off
• Machine speed is not matched to the current paper grade

If the issue started after a product change, a paper grade switch, or a speed increase, re-verify all related settings for the new conditions.

5. Evaluate Running Speed and Acceleration

Some tissue grades run fine at low speeds but break more frequently as speed increases. This often indicates that the tension control or machine settings are not optimized for the current material at higher speeds.

If breaks occur mainly during ramp-up, reduce the speed and see if the problem resolves. This test helps determine whether the issue is related to speed response, tension control, or the material's stability.

6. Record Key Information for Technical Support

When breaks are frequent, gather the following details before contacting your machine supplier. This data helps engineers diagnose the issue remotely and reduces downtime.

• Exact break location on the machine
• When the break occurs (startup, steady run, speed change)
• Parent roll number and condition
• Actual running speed at the time of the break
• Product type and format being produced
• Photos or short videos of the break point
• Any recent changes to settings, materials, or operators

Need Help Solving Tissue Paper Breaks?

If you are experiencing repeated web breaks, contact DOUBLE Machinery with the details above. Our technical team can help you determine whether the issue is related to raw material, tension control, machine settings, or your specific production setup.