1. Raw Material Preparation
Nonwoven Fabric:
Spunlace (hydroentangled) fabric is most common (e.g., viscose, cotton, or PLA blends).
Rolls of fabric are fed into production lines (width: 1.6–3.2m).
Lotion Formulation:
Water (purified to USP standards) + active ingredients (aloe, preservatives, disinfectants).
Mixed in stainless steel reactors, then stored in IBC totes.
2. Fabric Unwinding & Folding
Process:
Fabric rolls are mounted on unwinders and fed through tension control systems.
Folded into "C-fold" or "Z-fold" patterns for pop-up dispensing.
Key Tech:
Ultrasonic or heat sealing creates perforations between wipes.
3. Impregnation (Moistening)
Methods:
Spray System: Lotion sprayed evenly onto fabric (for light saturation).
Dip & Squeeze Rolls: Fabric immersed in lotion, then excess squeezed out (controlled moisture levels).
Moisture Control:
Typically 250–500% saturation (e.g., 4x fabric weight in lotion).
4. Cutting & Stacking
Cutting:
Rotary die-cutters slice fabric into squares/rectangles (e.g., 180mm x 180mm).
Stacking:
Wipes stacked into piles (e.g., 60–100 wipes for canisters, 10–20 for sachets).
5. Packaging
Primary Packaging:
Flow Wrapping: Wipes sealed in foil-lined pouches (prevents drying).
Canister Filling: Stacks loaded into plastic tubs with flip-top lids.
Aseptic Options:
Gamma irradiation or UV treatment for sterile medical wipes.
6. Quality Control
Critical Checks:
Lotion pH (5.0–5.5 for skin safety).
Moisture Uniformity (IR sensors detect dry spots).
Seal Integrity (pressure decay tests).
Microbiological Safety (ISO 11737 for sterility).
7. Automation & Speeds
Production Lines:
Operate at 400–600 wipes/minute.
Robotic arms handle case packing/palletizing.
Output:
1 million+ wipes/day per line.
Key Manufacturing Technologies
| Component | Technology | Purpose |
|---|---|---|
| Nonwoven Fabric | Spunlace (hydroentanglement) | Softness + strength |
| Preservation | Natural agents (radish root ferment, benzoate) | Extend shelf life (18–24 months) |
| Packaging | Tri-layer foil (PET/AL/PE) | Block oxygen + moisture |
| Dispensing | Ultrasonic perforation | One-handed pop-up |
Eco-Friendly Innovations
Biodegradable Fabrics:
PLA (corn starch) or FSC bamboo decompose in 90 days.
Water-Saving Systems:
Closed-loop purification (98% water recycled).
Sustainable Packaging:
Compostable PLA pouches or recycled PCR plastic.
Industry Challenges & Solutions
Problem: Lotion migration → Solution: Controlled viscosity + precision spraying.
Problem: Bacterial growth → Solution: ISO 11930 challenge testing + natural preservatives.
Problem: Environmental impact → Solution: OK Compost certification + carbon-neutral logistics.
Global Leaders in Wet Wipe Manufacturing:
Asia: Quanzhou Zhiyue (China), Unicharm (Japan)
Europe: SCA (Sweden), Lenzing (Austria)
Americas: Kimberly-Clark (USA), Rockline (USA)
For customized production (e.g., biodegradable formulas or private labeling), manufacturers like Quanzhou Zhiyue offer end-to-end solutions from R&D to global compliance support.
⚙️ *Example: A 1-ton MOQ lotion order can yield ~500,000 wipes.*
