Double Packaging Efficiency? How Bottom Pull Tissue Packaging Machines Eliminate Empty Packs and Continuous Packs

Double Packaging Efficiency? How Bottom Pull Tissue Packaging Machines Eliminate Empty Packs and Continuous Packs

In the household paper industry, the tissue packaging link has always been a major bottleneck in production capacity. Problems such as empty packs, continuous packs, loose seals, and skewed tissues not only reduce production efficiency but also directly consume film materials, labor, and after-sales costs. Dongguan Ailixing Machinery Co., Ltd. has been deeply engaged in tissue packaging equipment for many years. Aiming at the pain points of the mainstream bottom extraction type tissue packaging in the market, we optimize the equipment structure and control system, and use core technologies to double packaging efficiency and eliminate production problems such as empty packs and continuous packs from the source. Today, we will take you to deeply analyze the core principle, technical advantages and selection points of the bottom extraction type tissue packaging machine.

I. What is Bottom Extraction Packaging?

Simply put, bottom extraction tissue is tissue extracted from the opening at the bottom of the packaging bag, which is different from the traditional top extraction packaging form and is currently the mainstream style for soft tissues in supermarkets, catering and household use.

Ailixing's bottom extraction tissue packaging machine adopts an integrated automatic process: automatic unwinding and conveying of film materials → automatic forming of the bottom of the packaging bag → accurate filling of tissues into the bag → bottom sealing, side sealing → cutting and discharging of finished products. The whole process realizes integrated automatic operation of bag forming, tissue filling, bottom opening and sealing without manual intervention, which not only ensures the regular bag shape but also avoids the basic hidden dangers of empty packs and continuous packs structurally.
 

II. Core Structure Disassembly | The Core Design Logic of Ailixing Equipment

A stable and efficient bottom extraction tissue packaging machine is supported by five core structures, which are also the key to eliminating empty packs and continuous packs.

1. Film Feeding System: Stable Tension to Eliminate Film Wrinkles

The film feeding system is the foundation of packaging. Ailixing equipment is equipped with a constant tension servo film unwinding mechanism, combined with multiple groups of adjustable film guide wheels and deviation correction devices, to real-time control the uniform and stable tension of the bottom film conveying. It avoids uneven stretching, deviation and wrinkling of the film material during high-speed operation, and prevents loose seals and empty pack leaks caused by film material problems from the source.

2. Forming Machine: U-shaped/L-shaped Forming to Adapt to Tissue Shape

The forming machine adopts a customized U-shaped or L-shaped bottom forming angle design, optimizing the arc and opening size according to the length, width and thickness of the tissue. It can not only ensure the regular and upright bottom of the packaging bag but also accurately match the tissue specifications. During filling, the tissue will not get stuck or deviate, effectively avoiding empty packs caused by inadequate tissue filling.

3. Sealing and Cutting System: Double Precision of Temperature and Pressure Control, Adapting to All Types of Film Materials

The sealing and cutting system is divided into bottom transverse sealing and side longitudinal sealing. It optimizes temperature control and pressure parameters for heat-sealing films and cold-sealing films respectively: the heat-sealing mode controls the temperature accurately to avoid film damage due to high temperature and loose sealing due to low temperature; the cold-sealing mode is suitable for low-temperature film materials with uniform pressure output. Ailixing equipment adopts an independent temperature control module, and the temperature and pressure of transverse and longitudinal sealing can be adjusted independently to eliminate false sealing and continuous pack adhesion.

4. Tissue Pushing Mechanism: Servo Crank Drive, No Tissue Damage or Skewing

Abandoning the impact feeding of traditional pure pneumatic pushers, Ailixing is equipped with a servo crank type tissue pushing mechanism, which can push tissues at a constant speed and flexibly. Compared with pneumatic pushers, it has smaller impact force, avoiding extrusion and damage of tissues during high-speed feeding; at the same time, it accurately controls the pushing stroke to prevent excessive or insufficient tissue pushing, eliminating continuous packs and empty packs.

5. Bottom Opening and Sealing Unit: Suction Cup Opening, Upright Finished Products Without Collapse

The equipment adopts a high-precision vacuum suction cup bag opening mechanism instead of manipulator bag opening. The bag opening force is soft and the positioning is accurate, which can stably open the bottom opening of the packaging bag to ensure the smooth entry of tissues; the bottom sealing unit completes the bottom sealing synchronously, with flat and firm sealing edges, strong uprightness of the bag shape, regular finished products and reduced output of defective products.
 

III. Key Technical Difficulties and Ailixing's Exclusive Solutions

In high-speed tissue packaging, problems such as tissue deviation, opening failure and poor sealing are likely to occur. Ailixing has specially solved the industry pain points:

1. Tissue being blown away or skewed at high speed
Adopt servo constant speed feeding + forming machine limit guidance, combined with air flow guidance structure to reduce the impact of air flow on tissues during high-speed operation, and accurately control the pushing stroke to ensure the centered filling of tissues and eliminate skewing.

2. Film electrostatic adsorption leading to bottom opening failure
The equipment is equipped with an electrostatic elimination device, combined with adjustable vacuum suction cups, to optimize the bag opening delay parameters. For composite films and PE films that are prone to static electricity, it eliminates static interference and stabilizes the bag opening effect.

3. Quick switching of tissues with different grammages
For 30g thin tissues and 50g thick tissues, the equipment supports one-key parameter adjustment. The pushing force, speed, bag opening force and sealing and cutting temperature can be adjusted independently, without complex debugging, adapting to the production of multi-specification tissues.

4. Online rejection of defective products to prevent defective products from flowing out
Equipped with an online sealing detection + automatic rejection system, it real-time detects the bottom sealing firmness and tissue filling status, identifies empty packs, leaking seals and continuous packs, automatically rejects defective products, does not mix into finished products, and reduces rework costs.

IV. Must-See for Purchasing! Key Parameters for Equipment Selection

Many manufacturers only look at the peak speed when purchasing equipment and ignore the actual production capacity. Ailixing reminds purchasers to focus on these 5 key parameters:

1. Packaging Speed: Distinguish between Peak Speed and Stable Speed
The peak speed of equipment on the market is often marked as 80 packs per minute, but the actual continuous stable operation is mostly 60 packs per minute. Ailixing equipment's stable speed can reach 65–75 packs per minute, with a peak of 85 packs per minute, and no jamming in high-speed production.

2. Tissue Size Range
It is suitable for conventional soft tissue sizes, focusing on the adaptability of tissue thickness, supporting free switching of multi-specification tissues to meet the needs of multi-category production.

3. Film Material Applicability
Compatible with PE film, CPP film and composite film, supporting single-sided heat-sealing and double-sided heat-sealing film materials, adapting to catering, household and commercial tissue packaging scenarios.

4. Convenience of Production Change
Tool-free quick changeover, equipped with accurate scale + recipe memory function, saving parameters of different tissue specifications, one-key call, and greatly shortening the changeover time.

5. Brand of Core Components
Standard configuration of Yaskawa/Delta servo motors, SMC/Festo pneumatic components and well-known brand PLC. The core accessories are stable and durable, with low failure rate and longer service life.

V. Common On-Site Production Failures and Quick Troubleshooting Table

For high-frequency production failures, a simple troubleshooting plan is sorted out to reduce downtime:

VI. Cost and Return on Investment | Must-See for Bosses, Cost Reduction and Efficiency Improvement Are Visible

1. Equipment Investment

The reasonable investment range of Ailixing's bottom extraction tissue packaging machine in the industry is $26000-32000, which is priced according to speed, automatic configuration and specification adaptability, suitable for large, medium and small tissue processing plants.

2. Significant Savings in Labor Costs

One automatic packaging machine can replace 3–4 manual bagging workers. According to the labor cost calculation, the equipment cost can be recovered in 1–2 years.

3. Reduction in Film Material Consumption

Compared with traditional top film wrapping, bottom extraction packaging has a smaller overlapping area of sealing edges, saving 5%–8% of film materials, and the cost of film material loss is significantly reduced in long-term production.

4. Significant Improvement in Pass Rate

The pass rate of traditional manual/simple equipment is about 96%. Using Ailixing's automatic packaging machine, the pass rate is stably increased to more than 99.5%. Problems such as empty packs, continuous packs and poor sealing are almost eliminated, reducing defective product loss and after-sales problems.

Dongguan Ailixing Machinery Co., Ltd. focuses on the R&D and production of household paper packaging equipment. Aiming at the industry pain points of bottom extraction tissue packaging, we continuously optimize the equipment structure, control system and adaptability, providing stable, high-speed, low-fault and high-pass rate packaging solutions for tissue manufacturers, helping enterprises reduce costs, improve efficiency and seize market opportunities.