Application Background:

The wet wipes folding step rack is a dedicated unit in a wet wipes production line, responsible for continuous folding, length control and alignment of nonwoven material according to predefined patterns. It prepares a stable semi-finished web for subsequent moistening, cutting and packaging. With the growing demand for disposable wet wipes in markets such as Italy, Thailand, Malaysia, Korea, Russia, Mexico, the United States, Brazil, Switzerland, Singapore, Portugal, Vietnam, Taiwan, India, Peru and South Africa, local converters are looking for folding equipment that is fast, stable and easy to maintain. This case describes a control solution designed to meet common requirements across these export markets and to adapt to different local power and safety standards.

Solution Overview:

• Main controller: Mitsubishi PLC

• Process segment: Wet wipes folding step rack control

• Project I/O configuration: 32DI + 32DO per step rack

• Annual I/O usage: Approx. 100k points

Project Description:

The system uses RS-series remote I/O modules together with a Mitsubishi PLC to build an efficient control platform for various wet wipes folding modules. The I/O modules collect digital signals from photoelectric sensors, limit switches, tension detectors and speed feedback devices, enabling real-time monitoring of web position, folding rhythm and material shortage. Based on process recipes, the PLC precisely controls servo drives, inverters and cutting actuators to achieve stable folding for different web widths and folding formats. During design, power supply and safety requirements of both European markets (e.g. Italy, Switzerland, Portugal) and emerging markets (e.g. Thailand, India, Vietnam, Brazil, South Africa) were taken into account, so that the complete machine can be commissioned quickly after export.

Application Advantages:

• Compact I/O modules with integrated sensor power supply, reducing wiring and control cabinet space;

• Supports multiple folding formats and speed recipes, ideal for frequent order changes across Europe and Asia;

• High-speed folding with precise registration, reducing wrinkles and scrap and improving the visual quality of wet wipes;

• Remote diagnostics interface reserved, enabling software updates and troubleshooting for overseas lines in Italy, Mexico, India, South Africa and other markets.