Production line and factory setup overview
A small converting project using purchased jumbo tissue reels to make one selected folded product through reel release, controlled unwinding, embossing or ply lamination, slitting, V-fold interfolding or napkin folding, counting, log or stack cutting, inspection and soft-pack, carton or manual bag packing. Facial tissue and table napkins use different folders and should not be promised from one machine unless supplier trials prove the changeover.
Recommended lowest-entry line configuration Choose one route at launch: a four- to six-lane V-fold facial-tissue interfolder for one 2-ply soft-pack size, or a dedicated quarter-fold napkin machine. For facial tissue, include jumbo stands, emboss/lamination, slitting and interfolding, counting, manual or semi-auto log cutting and soft-pack sealing. Add a separate napkin folder, colour print or automatic case packing only after confirmed demand.
Production process and implementation sequence
- Jumbo-reel receiving and hygiene release
- Unwinding, tension and edge control
- Embossing or ply lamination
- Slitting and V-fold interfolding or napkin folding
- Automatic counting and stack/log separation
- Manual or semi-auto final cutting
- Soft-pack or napkin-bag sealing
- Sheet, fold, lint, count and pack inspection
Products, capacity and market fit
- Facial tissue and napkins serve homes, offices, hotels, restaurants and healthcare buyers.
- Jumbo-reel converting avoids tissue-mill capital while building a local brand.
- One fold, sheet size and pack count reduce changeover waste.
- Product softness, lint, count and hygiene matter more than advertised machine speed.
- Two-ply V-fold facial tissue - One approved open/folded size, sheet count, softness, lint, tensile and soft-pack seal - Homes, offices, hotels, clinics and retail
- Quarter-fold table napkin expansion - Separate folder, sheet/fold dimensions, emboss or print and pack count - Restaurants and events after dedicated-machine validation
Core production machinery and line specifications
| Machine / stage | Function / value | Production note |
|---|---|---|
| Jumbo-reel stands and tension system | Feeds tissue webs without wrinkles | Specified reel width/diameter |
| Embossing or ply-lamination unit | Creates pattern and ply bond | One 2-ply recipe |
| Four- to six-lane V-fold interfolder | Slits, folds and counts facial tissues | One launch sheet size |
| Log/stack cutter | Separates counted facial-tissue stacks | Manual or semi-auto entry |
| Soft-pack sealer | Protects one retail pack | Printed film or plain bag |
| Separate napkin folder option | Makes quarter-fold table napkins | Not included unless contracted |
| Tissue laboratory and inspection table | Checks count, strength, lint and folds | Buyer test plan |
Raw materials, utilities and factory requirements
- Qualified jumbo tissue reels by gsm, ply, softness, strength and moisture
- Approved ply adhesive where lamination is used
- Printed soft-pack film or napkin bags
- Cartons, labels, blades, emboss rolls and critical spares
- Stable three-phase power and clean compressed air
- Clean dry reel, converting and finished-goods zones
- Dust extraction, fire protection and hygienic housekeeping
- Safe reel handling and guarded cutting equipment
- Pest control and worker changing facilities
Indicative low-entry investment and implementation plan
These planning ranges prioritize economical machinery, local labor and local civil works. Final pricing follows confirmed capacity, product specification, delivery terms and site conditions.
| Scope | Indicative range | Entry-plan note |
|---|---|---|
| V-fold interfolder with emboss/slitting | US$18k-48k | Four- to six-lane entry |
| Stack cutting and soft-pack sealing | US$7k-22k | Manual/semi-auto route |
| Laboratory, extraction and handling | US$4k-12k | Hygiene and product release |
| Freight, installation, tooling and spares | US$7k-20k | One facial-tissue format |
| Indicative installed low-entry total | US$36k-102k | Napkin folder, auto case packing and reel stock excluded |
Detailed proposal and next step
The proposal contains the complete line flow, machinery scope, raw-material and utility requirements, implementation stages and indicative entry planning. Final configuration follows confirmed products, capacity, site and budget.