KANSAN is an engineering, technology, and machinery group that creates essential manufacturing solutions for all aspects of wet wipe production from converting and packaging to lid application, and even further integration to case packers and palletizers. TBD at conversation with Mr Anil Kirhalli, Sales & Business Development Director of KANSAN MAKINA KAGIT SAN VE TIC A.S. regarding innovation in wipe mannufacturing machinery.

From design parameters to component selection, from final assembly to machine testing Kansan has been ensuring the best performance and quality to meet and exceed not only today’s but also tomorrow’s expectations. Innovation and experience being the center of Kansan’s corporate identity, today Kansan is considered to be the leading machinery supplier of complete wet wipe manufacturing solutions. Kansan has been constantly monitoring the dynamics, requirements, and trends of the global trade to redesign our machines and services to reach more flexible and tailor-made solutions.

Can you provide a brief overview of your wipes machine and its primary functions?

KANSAN, a leader in the wet wipe machinery industry, specializes in fully automated and synchronized production lines for wet wipes. Our machines primarily focus on wet wipe flat packing and cross fold converting, which includes key processes such as bobbin unwinding, folding, substrate impregnation, cutting, stacking, and transferring. Additionally, our flow wrapping process involves film unwinding, labeling, die-cutting, pack forming, gusseting, and final sealing, along with the application of plastic lids, which encompasses dispensing, gluing, and on-lid labeling. Each of these stages incorporates several quality control measures to ensure precision, such as monitoring lid and label positioning, die-cut integrity, and the accuracy of QR code and batch code printing. For clients seeking further downstream integration, we also provide fully automated robotic solutions for end-of-line case packing, palletizing, and depalletizing. Moreover, we offer grouping and multipack solutions tailored for wet wipe packages, including multi-bag flow wrappers, multi-pack labelers, and loop handle labelers.

KANSAN’s flat pack and cross-fold wet wipes converting machines are engineered for optimal efficiency, adept at processing various materials, including biodegradable and flushable wipes. These highly flexible and versatile machines can produce an extensive range of commercial wipes, from baby and disinfectant wipes to general cleaning and personal care wipes, all while maintaining a quality standard with an overall equipment effectiveness (OEE) of over 95%.

What are the key features and innovations in your latest model of wipes machines?

The landscape of the wipes industry is evolving, driven by shifting customer demands influenced by emerging trends and global events, including pandemics and growing environmental consciousness. A significant trend in recent years has been the development of more environmentally friendly wipe products. Traditional wipes, primarily composed of polyester and entangled viscose or cotton fibers, pose recycling challenges due to the difficulty in separating these materials. As a result, the primary method of disposal remains landfilling, which is far from ideal. To address these challenges, a new generation of packing films and substrates has emerged, including recyclable f ilms and biodegradable materials made from pulp, Tencel, and rayon fibers. While conventional machines handle traditional materials effortlessly, adapting to process these innovative materials requires more advanced technology.

KANSAN’s QUICKSTACK converting machines and ACURAPACK flow wrapping machines are specifically designed to efficiently process these new-generation materials without compromising performance or increasing waste and discard rates. The core design of these machines prioritizes non-stop operation and high efficiency.

Moreover, KANSAN is recognized as one of the pioneering machine manufacturers in the industry, having produced ATEX-certified wet wipe production lines since 2014. This initiative began well before the pandemic, specifically to manufacture 100% alcohol wipes for disinfection and disease control. Throughout the pandemic, KANSAN’s ATEX-fitted wipe lines played a critical role in the global effort to combat the virus, supporting frontline response initiatives worldwide.

How does your machine differ from other wipe machines on the market?

KANSAN wet wipe machines are highly adaptable and can be tailored to meet the specific needs of our customers. They operate efficiently with a variety of substrates, enabling the production of a wide range of wipes, from baby wipes to disinfectants and general cleaning wipes. This level of versatility is rare in the market.

KANSAN brings a wealth of experience, supported by a global network and successful machine projects in over 60 countries. We recognize that market requirements and customer preferences vary across different cultures and regions. As such, KANSAN is adept at gathering data and feedback to develop wet wipe machine concepts that address these diverse needs effectively.

Our continuous commitment to research and development allows KANSAN machines to accommodate both new-generation materials and traditional materials with equal proficiency.

What types of wipes can your machines produce (e.g., Cross Fold, Flat Pack or Single Pack)?

• Flatpack converting machines

• Cross-fold converting machine

• Flatpack machines

• Lid applicator robots

• End-of-line secondary multi-bag machines, multipack labeling machines

• Robotic case packers • Robotic palletizers and depalletizes

Are there different machine models or configurations for different types of wipes?

KANSAN’s wet wipe machine models are designed for the production of various types of wet wipes, including f lat packs and cross-folded wipes. Both formats can be manufactured on compatible converting machine platforms without sacrificing quality or efficiency.

Additionally, these machines can be equipped with ATEX certification, enabling the production of 100% alcohol wipes. KANSAN machines are highly versatile, capable of producing a diverse array of wipes in both large and small dimensions, as well as accommodating various folding styles.

How does your machine handle different types of material types?

The key to our success lies in our extensive experience and dedicated research and development activities over the years. In our R&D laboratories, our engineers employ the latest innovative techniques to design machine parts and modules. Our technical team rigorously tests nearly every type of challenging packaging film and nonwoven substrate. We meticulously adhere to market conditions, regulatory requirements, governmental restrictions, and environmental standards when designing and constructing new machine modules or platforms. This commitment to excellence is at the heart of KANSAN’s global success.

What is the typical production capacity of your wipes machines in terms of wipes per minute or hour?

Our flat-fold converting lines can achieve a maximum production rate of 25,000 wipe sheets per minute and up to 240 packs per minute. Meanwhile, our cross fold lines are capable of producing up to 2,800 wipes per minute, also reaching up to 240 packs per minute. KANSAN also offers lower-capacity production lines designed for less demanding operations or markets. Additionally, our robotic lid applicator machines, case packers, and palletizers are engineered to match these maximum output numbers, ensuring efficiency and productivity throughout the production process.

How do you ensure consistent productivity and minimize downtime during operation?

Our machines are fully automated and integrated, streamlining the entire production process from converting to packaging and palletizing. This automation minimizes manual intervention, reducing the risk of human error and allowing for continuous operation and increased throughput. Each machine is equipped with self-diagnostic and error correction systems in critical areas to ensure operational continuity. Additionally, a variety of in-line quality control and discard systems are implemented to manage unfit products at nearly every stage of the production process.

All machines in the production line operate in full synchronization. In the event of momentary stoppages or necessary slowdowns, all machine units maintain alignment with the line speed, effectively minimizing or even eliminating the potential for production waste during ramp-up and ramp-down phases.

Can your machines be scaled up or down based on production needs?

Certainly, KANSAN machines are highly configurable to meet the diverse production needs of our customers. We can easily implement tailored machine solutions to ensure optimal performance and efficiency according to specific requirements.

What quality control measures are incorporated into your wipes machines?

KANSAN machines are equipped with numerous in-line quality control and machine process control systems to ensure optimal performance and product quality. Some of the key features include:

• Impregnation Control: Monitors and rejects stacks that do not meet preset values at startup.

 • Nonwoven Bobbin Splice Control: Identifies and rejects spliced clips.

• Cutting Control System: Stops the machine and/or activates an audible alarm if cutting is not performed correctly, prompting the operator to check the issue.

• Folding Control: Detects misalignment of nonwoven materials, allowing the machine to reject improperly folded products and/or activate an audible alert for the operator.

• Stack Formation Control: Manages stack transfer jamming to ensure smooth operation.

• Overload and Torque Control Systems: Monitors servo and AC motors to prevent damage.

• Die-Cut Over-Cut Control: Identifies and rejects unfit packs resulting from die-cutting errors.

• Label Position and Availability Control: Ensures proper labeling and rejects unfit packs.

• QR Code Control System: Verifies QR codes and rejects non-compliant products.

• Batch Code Control System: Checks batch codes and rejects unfit products.

• Film Splice Control: Monitors and rejects spliced packs to maintain quality.

• On-Lid Label Control System: Confirms the presence of labels on the lids and rejects unfit packs.

• Lid Position and Availability Control System: Ensures lids are correctly positioned and rejects unfit packs.

These systems work collaboratively to maintain high standards of quality and efficiency throughout the production process.

How does your machine maintain consistent wipe quality throughout a production run?

Above mentioned quality control systems ensure consistent quality at and above end users’ and market expectations.

Can you provide examples of how your machines have addressed common quality issues in the wipes industry? Yes, KANSAN machines are equipped with numerous advanced in-line quality systems designed to significantly reduce quality issues during production. While these state-of-the-art systems are invaluable, it is essential to recognize that high-quality production cannot be solely attributed to machine features or in-line quality control systems. Achieving consistent, trouble free production begins with careful selection of the machine, materials, and manpower.

Effective project planning and execution are crucial to this process. Many errors stem from inadequate planning and insufficient coordination among sales, marketing, production, and product design teams. KANSAN’s experienced project managers offer expertise in factory planning, product design, raw material selection, and execution to ensure the most efficient wet wipe production. This comprehensive approach facilitates the establishment and maintenance of stringent quality standards throughout the entire production journey.

What is the typical rejection rate for wipes produced by your machines?

The process rejection rate is maintained at less than 1% of the overall production process. Specifically, the reject rate for lid application is even lower, consistently remaining under 1%. With a well-selected and effectively executed production process, these numbers can be further minimized, achieving even lower rejection rates.

How does your machine detect and handle defective or off-spec wipes?

This was explained in one of the above questions. The same information can be used here.

How flexible is your machine in accommodating different wipe sizes and formats?

KANSAN machines are highly versatile, capable of producing flat pack wipes ranging from a minimum length of 100 mm to a maximum of 350 mm, and a minimum width of 150 mm to a maximum of 300 mm.

For cross-fold wipes, they can produce lengths ranging from 100 mm to 220 mm, with widths from 120 mm to 300 mm.

Additionally, KANSAN machines support all commercially available folding types and formats, with the ability to stack from 5 to 300 wipes in a single stack.

What adjustments or modifications are needed to switch between different product sizes?

Most adjustments on KANSAN machines are primarily made electronically, with some adjustments being mechanical. Each machine is equipped with 300 recipe slots to store both electronic and mechanical parameters. In the event of format changes, these recipes can be quickly recalled and uploaded to the machine within seconds. Furthermore, mechanical settings do not require any tools, allowing operators to easily set up the machines using hand wheels and knobs without any difficulties.

Can your machine handle custom or non-standard wipe sizes?

Yes, thanks to our extensive experience and broad network of customers, we have encountered a variety of unique requests over the years. We have successfully designed non-standard wipe machines and tailored solutions on numerous occasions to meet these specific needs.

What sustainability features are integrated into your wipes machines?

In wet wipe manufacturing, sustainability initiatives can cover a range of practices that minimize environmental impact, from raw material selection to packaging and energy usage. In KANSAN we apply the following techniques to reduce the environmental impact of our machine and over all wet wipe production

Biodegradable Materials: KANSAN machines are optimized to handle nonwoven fabrics made from biodegradable or compostable fibers, such as bamboo, cotton, or wood pulp. This shift reduces reliance on synthetic fibers like polyester, which contribute to long term environmental waste.

Water-Efficient Production: Some of our machines can incorporate water recycling systems, ensuring that water used in the wipe solution is reused and purified multiple times, minimizing overall water consumption.

Energy-Efficient Machinery: KANSAN is increasingly designing wet wipe machines that consume less energy through efficient motors and advanced automation, which reduces the overall carbon footprint of production.

Waste Reduction Technologies: As explained in previous questions. Our machines are equipped with precision cutting, folding and impregnation, technologies that minimize material waste during the production process. Some systems also anticipate and reduce the waste materials, reducing the volume sent to landfills. The in-line QC systems also contribute to reducing rework of packed products and helping efficient use of manpower and other resources.

Eco-Friendly Packaging: KANSAN machines can be integrated with systems that support sustainable packaging options, such as recyclable, biodegradable, or reusable packaging materials. This includes using less plastic in packaging or shifting to paper-based or compostable films.

Reduction of Harmful Chemicals: Wet wipe solutions can be manufactured using fewer harmful chemicals, with a greater focus on natural ingredients like plant extracts and essential oils. KANSAN machines can easily be configured to support the formulation and application of these eco-friendly solutions.

Closed-Loop Manufacturing: Some wet-wipe production facilities are moving toward closed-loop systems where waste materials (including scrap fabric, water, and chemicals) are reprocessed and reused within the same production cycle. In KANSAN, we are specifically encouraging our customers to shape their shop floors accordingly. With our latest non-woven technology, we can help our customers to set-up this type of highly efficient production facility. By adopting these sustainable practices, the users of KANSAN machines can significantly reduce their environmental impact while responding to growing consumer demand for eco-friendly products.

How do your machines contribute to reducing waste and improving resource efficiency?

This was already explained above

Are there options for using eco-friendly materials or reducing the environmental impact of the wipes produced?

Yes, there are. As explained above KANSAN machines can be integrated with systems that support sustainable packaging options, such as recyclable, biodegradable, or reusable packaging materials. This includes using less plastic in packaging or shifting to paper-based or compostable films.