Wet Wipe Automation: Ensuring Scalable Robotic Solutions

Major wet wipe manufacturers produce millions of products every year for multiple brands. One week, a manufacturer might send wet wipes down the production line for a big box retailer, and the next they’re pouching products for a smaller niche brand — all with different sizes, SKUs, packaging, and lid configurations.

This variability has led some manufacturers to believe that automation isn’t feasible. They’re hesitant to even think about purchasing a robotic solution because they believe they’ll be locked into a single SKU.

Not so. 

Here, we’ll explore wet wipe automation and how modern robotics adapt to varying wet-wipe product designs.

The Wet Wipe Automation Challenge

Common wet wipe applications include cosmetic, disinfectant, and baby wipe products. Arguably, the most complex step in the production process is applying the rigid flip-top lid onto the flexible pouch. Pouches can vary in size and thickness, containing as few as 10 or more than 100 sheets. Likewise, flip-top lid designs may also vary.

Lid application automation has been a major challenge due to the variances in package sizes and the configurations of the lids. Having an operator pick each lid, apply adhesive, and position the lid on each package is laborious and not feasible for mass production.

A robust robotic solution will spray glue to the bottom side of a lid and apply it to the package. To recap, challenges include:

• Picking lids that may be randomly placed in a bulk bin
• Dispensing and applying the proper amount of adhesive
• Accurately positioning the lid onto pouches that may not be positioned uniformly on the production line
• Adapting the robotic solution to accommodate varying pouch sizes, lid designs, and configurations
• Ensuring accuracy and repeatability from one package to the next
• Production speed

RELATED: Addressing the Challenges of Nonwoven Wet Wipe Automation

What to Look for in Scalable Wet Wipe Automation

Accuracy, repeatability, and speed are top priorities for wet wipe automation, and a robotic integrator needs to work closely with customers to refine solutions that address these concerns. However, adjusting processes and tooling to accommodate different SKUs can disrupt production.

A key innovation is a unique lid feed system designed by the engineers at QComp Technologies. It enhances precision and consistency while also improving cycle times. The system is built to handle various package heights and widths with minimal manual adjustments. 

Most changeovers are managed through simple recipe changes on the system’s human-machine interface (HMI) — the user interface or control dashboard that allows operators to interact with and control machinery, systems, or processes. If different lids are required, a quick-change module allows for fast swaps — typically in under 10 minutes. If a new lid design emerges later, QComp can provide a tailored change-out module, ensuring long-term flexibility.

Vision technology enables the robot to identify pouch locations and track them on the conveyor, automatically adjusting for height variations up to 10 inches, and tool sensors confirm product movements. Depending on the size of the system, we recommend having duplicate end-of-arm tooling to facilitate maintenance offline without downtime. 

QComp’s solution automates the production process from the lidder and downstream to the bundling of stacks of pouches, labeling, case packing, and palletizing and wrapping for shipment. Our team has also added bundlers to existing lines and helped manufacturers forecast for growth as needs arise. Whether upgrading an existing line or proactively planning for future growth, this type of scalable solution allows manufacturers to start with a core system and expand as production demands increase. 

What to Look for in a Robotics Partner

Just as important as the solution is the solution partner. Looking for a provider with experience is a given, but selecting a robotic integrator who has the experience and knowledge to ask the right questions — those you might not think of — is just as important. 

QComp has learned through many years of developing system solutions in the wet wipes industry, and our experience and knowledge of the challenges manufacturers face allow us to install a solution that will exceed expectations. In fact, we often address issues that our customers didn’t realize existed until they were fixed by one of our integrations.

Our systems and expert support team have been proven among the top wet wipe producers. We deliver 24/7 service with engineers on call to address any issues promptly, even during overnight shifts. 

Explore how QComp’s innovators can help you conquer the complexity of wet wipe automation and how they’re able to deliver scalable solutions. Contact our team today.