1. Proven Global Quality: Worry-Free Production for Your Business
Our underpad manufacturing machines have served thousands of production enterprises across 52 countries and regions worldwide. With over a decade of market iteration and validation across all operating scenarios, our equipment ranks among the industry's top tier for stability and durability.
Core Performance & Reliability Metrics
When our standard maintenance protocol is strictly followed:
· Average equipment service life extends from the industry norm of 5–6 years to 10–12 years, boosting overall return on investment by 40%.
· Annual unplanned downtime is reduced by over 80% compared to the industry average.
· Overall production yield remains consistently above 97.8%, with the vision inspection system achieving a 99.5% defect detection rate.
Statistics show that 70% of production shutdown incidents can be detected and prevented through routine daily inspections. Of all anomalies that occur,fewer than 10% are core hardware failures, while over 90% are routine issues caused by parameter mismatches, consumable wear, or insufficient cleaning. These can be quickly resolved by on-site operators after standardized training, without causing prolonged production interruptions.
We firmly believe that excellent equipment is defined not only by high output capacity, but also by minimal downtime and easy troubleshooting. Below is a complete overview of common anomalies, troubleshooting methods, solutions, and our comprehensive support system across all production scenarios - giving you full transparency before purchase and complete confidence after commissioning.
2. Full-Scenario Anomaly Resolution: Standardized Troubleshooting for Rapid On-Site Fixes
We categorize all potential production anomalies into three classes based on occurrence frequency and resolution difficulty. Each category follows a complete workflow of symptom description → step-by-step troubleshooting → standard solutions → data-backed prevention, allowing operators to quickly locate and resolve issues.
2.1 Product Quality Anomalies (Most Frequent: 80% of Daily Issues, Resolvable in 10–30 Minutes)
These anomalies do not involve hardware damage. They are mostly caused by raw material incompatibility, parameter drift, or insufficient cleaning - common, routine issues in hygiene product manufacturing.
2.1.1 Material Misalignment & Web Deviation
Typical Symptoms: Raw materials such as non-woven fabric and PE film deviate from their running path during operation, resulting in dimensional inaccuracies and uneven edges in finished products. In severe cases, material breakage causes production shutdowns.
Step-by-Step Troubleshooting:
1. Verify tension parameters for the current production formula. Confirm that tension values at the unwinding section, intermediate transition section, and rewinding section match the grammage and width of the current material. Check for accidental parameter modifications.
2. Inspect guide rollers along the material path. Check for looseness or misalignment, and look for foreign matter such as hot melt adhesive residue or scrap material on roller surfaces.
3. Examine the sensing surface of the web guide sensor. Check for coverage by fluff pulp dust, SAP powder, or other foreign objects blocking the sensing area.
Standard Solutions:
· Parameter issues: Reapply the standard tension parameters for the corresponding product specification, and fine-tune until the material runs smoothly.
· Guide roller issues: Recalibrate the levelness and parallelism of guide rollers, and clean adhesive residue and scrap material from roller surfaces.
· Sensor issues: Gently wipe the sensor sensing surface with a lint-free cloth dipped in anhydrous ethanol. Reset the web guide system after cleaning to restore normal operation.
Preventive Benefits: Inspecting tension before each shift and cleaning web guide sensors weekly can reduce the occurrence of such anomalies by over 90%, virtually eliminating batch defects.
2.1.2 Hot Melt Adhesive Stringing, Interruption & Uneven Spraying
Typical Symptoms: Adhesive spraying exhibits trailing stringing, localized interruption, or inconsistent glue line thickness, causing product delamination, debonding, and leakage - directly impacting production yield.
Step-by-Step Troubleshooting:
1. Check the temperature control panel of the hot melt adhesive applicator. Confirm that temperatures of the glue tank, delivery hose, and glue gun are within the standard range of 150–170°C. Check for over-temperature carbonization or excessive viscosity due to low temperature.
2. Inspect air pressure readings at the air treatment unit (FRL unit). Confirm that spraying air pressure is stable at 0.6–0.8 MPa. Check for pressure fluctuations.
3. Observe the glue discharge pattern from the nozzle. Check for nozzle clogging from carbonized adhesive particles, or insufficient adhesive supply due to carbon buildup in the filter.
Standard Solutions:
· Temperature anomalies: Adjust glue temperature back to the standard range, and perform test sprays after temperature stabilizes.
· Unstable air pressure: Regulate the pressure valve to standard pressure, and drain condensed water from the pneumatic FRL unit.
· Clogging issues: Clear minor clogs with a dedicated nozzle cleaning needle; replace with a spare nozzle for severe clogs. Simultaneously remove the filter screen and clean out carbonized adhesive blocks and impurities.
Preventive Benefits: Using factory-certified medical-grade hot melt adhesive, strictly controlling glue temperature, and performing weekly deep cleaning of glue guns and filters can reduce downtime from such failures by 85%. Using low-quality hot melt adhesive adds an average of 8–12 hours of cleaning downtime per month, reduces yield by 5%–10%, and over time scratches glue rollers and scrapers - with replacement costs exceeding $5,000 per set.
2.1.3 Uneven SAP Distribution, Clumping & Material Interruption
Typical Symptoms: Super Absorbent Polymer (SAP) in the absorbent core exhibits uneven thickness distribution, clumping, or blank areas, resulting in substandard product absorption performance and localized leakage.
Step-by-Step Troubleshooting:
1. Check the condition of SAP raw material. Look for moisture-induced clumping or uneven particle size. Verify that raw material storage meets dry storage requirements.
2. Stop production and inspect the gaps of the distribution roller. Check for clogging by fluff pulp fibers or SAP clumps causing uneven material discharge.
3. Examine the mixing device and feeding mechanism inside the hopper. Check for material bridging or jamming.
Standard Solutions:
· Moisture-damaged raw material: Replace with properly dried SAP raw material, and simultaneously check if workshop humidity exceeds standards.
· Clogged distribution roller: Thoroughly clean gaps in the distribution roller and dust/clumps inside the hopper to clear the material discharge channel.
· Poor material flow: Adjust the hopper mixing speed and feeding roller rotation speed to match the material volume required for the current production speed.
Preventive Benefits: Maintaining workshop relative humidity at 40%–60% and cleaning the distribution device weekly can reduce the occurrence of such anomalies by over 80%, avoiding batch core scrappage.
2.1.4 Vision Inspection System False Rejections & Missed Defects
Typical Symptoms: Qualified products are falsely rejected as defective, or defects such as missing sheets, missing adhesive, stains, and dimensional deviations go undetected, allowing defective products to pass through.
Step-by-Step Troubleshooting:
1. Check camera lenses and light source surfaces. Confirm that no dust or adhesive residue is obstructing imaging clarity.
2. Examine workshop ambient lighting. Check for direct strong light or significant brightness variations that interfere with detection accuracy.
3. Verify detection programs and parameters. Confirm they match the current product specifications, and check for parameter drift.
Standard Solutions:
· Dirty lenses: Gently wipe lenses and light source reflectors with a lint-free lens cloth to remove surface dust and stains.
· Light interference: Turn off direct workshop light sources and adjust light shields to maintain uniform and stable lighting in the detection area.
· Parameter drift: Recalibrate the vision system with a standard calibration template; adjust brightness, contrast, and exposure time parameters; switch to the detection formula for the corresponding product.
Preventive Benefits: Weekly cleaning of lenses and light sources, plus monthly full-precision calibration, maintains the system's defect detection rate above 99.5% and controls the false rejection rate within 0.5%.
2.2 Equipment Operation Anomalies (Occasional: ~15% of Issues, Resolvable via Self-Inspection + Remote Support)
These anomalies are mostly caused by mechanical wear, improper parameter settings, or power supply environment issues. Most can be resolved through on-site inspection; complex issues can be diagnosed via our remote technical support.
2.2.1 Servo Motor Alarm Shutdown
Typical Symptoms: The equipment shuts down suddenly, and the control system displays a servo alarm code. Common alarms include overload, over-temperature, and encoder anomalies.
Step-by-Step Troubleshooting:
1. Record the alarm code displayed by the system and review the alarm prompt. Prioritize checking for overload alarms.
2. Verify the current production speed. Confirm whether it exceeds the equipment's designed maximum speed, or if over-specification heavy-grammage raw materials are being used, causing excessive load.
3. Check workshop power supply voltage. Confirm for significant voltage fluctuations or phase loss.
4. Touch the servo motor housing. Check for excessive surface temperature, and verify that the cooling fan is operating normally.
Standard Solutions:
· Overload/overspeed: Reset the alarm, adjust production speed back to the equipment's designed rated range, replace with specification-compliant raw materials, then restart operation.
· Voltage issues: Restart after voltage stabilizes. Install a voltage stabilizer if fluctuations are frequent.
· Recurring alarms: If alarms trigger repeatedly after resetting, do not disassemble the equipment independently. Contact our technical support directly to read operation logs via the remote diagnostic system and locate the root cause of the failure.
Preventive Benefits: Strictly adhering to rated production parameters and prohibiting long-term operation at more than 20% overspeed extends the service life of the servo system and transmission components by over 50%. Data shows that long-term operation at 20% overspeed reduces overall equipment lifespan by 30%–40% and lowers yield by 3%–5%.
2.2.2 Abnormal Noise & Vibration During Operation
Typical Symptoms: Abnormal metal friction or impact sounds occur during equipment operation, or localized vibration increases significantly. Long-term operation in this condition accelerates component wear.
Step-by-Step Troubleshooting:
1. Immediately press the emergency stop button. Preliminarily identify the location of the anomaly by sound (transmission chain section, roller section, reducer section).
2. Inspect fasteners at the corresponding location: bolts, nuts, pins, retaining rings, etc. Check for looseness or detachment.
3. Examine the tension and wear condition of the transmission chain and timing belt. Check for chain rust or timing belt tooth loss/cracking.
4. Inspect moving components such as bearings and guide rails. Check for oil shortage or dry friction.
Standard Solutions:
· Loose fasteners: Use a torque wrench to tighten all loose bolts to the specified torque. Mark easily loosened positions for focused inspection during the next maintenance.
· Abnormal transmission component tension: Adjust the tension of the chain and timing belt. Standard: 10–15 mm sag when pressing the center vertically with a finger. Apply dedicated chain grease for full lubrication. Replace with spare parts directly for severe wear.
· Oil shortage/dry friction: Apply the corresponding model of lubricating oil/grease to guide rails and bearings. Confirm that the automatic lubrication system is supplying oil normally.
Preventive Benefits: Conducting operation sound and temperature inspections every 2 hours during shifts, plus weekly transmission system inspection and lubrication, extends the service life of core transmission components by 42% and improves equipment precision retention by 60%.
2.3 Auxiliary System Anomalies (~5% of Issues, Avoidable via Routine Maintenance, Simple to Resolve)
These anomalies are concentrated in auxiliary systems such as pneumatic, vacuum, and electrical cooling systems. They are mostly caused by expired consumables or insufficient cleaning - issues that can be completely avoided through preventive maintenance.
2.3.1 Pneumatic System Leaks & Cylinder Action Sticking
Troubleshooting & Solutions: Apply soapy water to all air pipe joints, solenoid valves, and cylinder seals. Bubbling indicates a leak point. For minor leaks, simply tighten the joint. For aged seals, replace the corresponding sealing rings and air pipes. For cylinder sticking, clean the piston rod and apply dedicated pneumatic grease. Test the action sensitivity of the solenoid valve, and replace faulty valve bodies directly.
Preventive Benefits: Comprehensive monthly inspection of pneumatic system sealing, plus regular cleaning of the pneumatic FRL unit water cup and replenishment of lubricating oil, reduces pneumatic system failure rate by over 90%.
2.3.2 Reduced Vacuum Pump Suction & Insufficient Air Compressor Supply
Troubleshooting & Solutions: Prioritize checking the air filter - replace directly if clogged. Drain condensed water from the gas-water separator and pipelines. Check oil level and quality: top up with the corresponding model of dedicated oil for low levels; completely replace with new oil for blackened or emulsified oil. Clean dust from heat sinks to ensure proper heat dissipation.
Preventive Benefits: Monthly inspection of filters and oil levels, plus air filter replacement every 3 months, avoids a 20%–30% increase in energy consumption caused by clogged filters while significantly extending pump service life.
2.3.3 Electrical Cabinet Overheating & Poor Heat Dissipation
Troubleshooting & Solutions: Open the cabinet door to check if cooling fans are operating normally. Clean dust buildup on fans and heat sinks. Check ventilation openings for obstruction by debris to ensure air circulation. If workshop ambient temperature is excessively high, install a dedicated small air conditioner for cabinet cooling.
Preventive Benefits: Maintaining electrical cabinet operating temperature within a reasonable range doubles the service life of electrical components. Data shows that for every 10°C increase in electrical component temperature, service life is reduced by 50%.
3. Three-Tier Fault Support Mechanism: From On-Site Self-Inspection to Global On-Site Service
We have established a comprehensive three-tier fault handling closed loop: on-site self-inspection → remote support → on-site service, covering all anomaly scenarios. This ensures any issue is resolved in the shortest time, minimizing your production losses.
3.1 Tier 1 Anomalies: On-Site Independent Resolution (Over 80% of Issues, Production Resumed Within 30 Minutes)
All the aforementioned product quality, simple mechanical, and auxiliary system routine anomalies fall under Tier 1 issues. During equipment installation and commissioning, we provide your operation and maintenance team with 7–10 days of free systematic training covering five modules: equipment structure principles, daily operation procedures, maintenance methods, common fault troubleshooting, and safety operation regulations. We adopt a training model of theoretical explanation + practical demonstration + hands-on practice + assessment acceptance to ensure every trainee achieves proficiency.
3.2 Tier 2 Anomalies: 7×24 Hour Remote Technical Support (~15% of Issues, Average Resolution Within 2 Hours)
For highly professional issues such as servo parameter debugging, system program anomalies, complex alarm codes, and electrical system troubleshooting, you do not need to disassemble the equipment independently - simply contact our technical support team directly.
· 24/7 Response: We provide uninterrupted 7×24 technical support, responding to your requests within 15 minutes, regardless of holidays or working hours.
· Multi-Channel Support: Service is available via telephone guidance, video conferencing, and remote diagnostic system. The standard-equipped remote diagnostic system reads real-time equipment operation data, alarm logs, and parameter settings - allowing our engineers to accurately locate issues without being on-site.
· Resolution Efficiency: Statistics show that over 90% of Tier 2 anomalies are resolved within 2 hours via remote guidance, with no on-site service required.
3.3 Tier 3 Anomalies: Global On-Site Service Coverage (Less Than 5% of Issues, Rapid On-Site Complete Resolution)
For complex failures requiring core component replacement, complete equipment disassembly and overhaul, or precision calibration, we provide global on-site service to completely eliminate your concerns:
· On-Site Response Time: For domestic customers, engineers arrive on-site within 24–48 hours. For major global markets, engineers arrive on-site within 3–7 days.
· Warranty Policy: We provide a 12–24 month complete machine warranty. All non-human-damaged parts are replaced free of charge during the warranty period, with no labor or travel fees for on-site repairs.
· Annual Maintenance Service: Outside the warranty period, we also offer annual deep maintenance service. Professional engineers conduct on-site complete equipment disassembly inspection, worn component replacement, system upgrades, and precision calibration. Upon completion, a detailed
Equipment Annual Health Report is issued, including status assessment, issue descriptions, next-year maintenance recommendations, and spare parts planning - helping restore equipment to factory-level performance.
· Used Parts Recovery & Repair: For repairable core components that have been replaced, we provide used parts recovery and repair services at only 30%–50% of the cost of new parts, significantly reducing your long-term operation and maintenance costs.
4. Comprehensive Spare Parts Supply System: Scientific Inventory + Express Delivery
Many customers worry about long spare parts procurement cycles leading to prolonged shutdowns. We have established a global spare parts supply network paired with scientific inventory guidance to completely eliminate spare parts waiting issues.
4.1 ABC Classification Inventory Guidance: Scientific Stocking Without Waste
Based on spare part consumption frequency, importance, and procurement cycle, we adopt the industry-standard ABC classification method to provide precise inventory recommendations - neither occupying excessive capital nor leaving you unprepared for emergencies:
· Class A Spare Parts (Wear Parts: Keep 3–6 Months Supply on Hand): Low cost, fast consumption, frequent replacement - essential for daily maintenance. Includes various blades, scrapers, timing belts, chains, bearings, sealing rings, nozzles, filter elements, proximity switches, etc. We recommend keeping a 3–6 month supply on hand for direct replacement when worn, with no procurement waiting required.
· Class B Spare Parts (Critical Parts: Keep 1–2 Sets as Emergency Reserve): Higher cost, long service life, but damage causes immediate complete shutdown with long procurement cycles. Includes servo motors, servo drives, PLC modules, touch screens, tension sensors, vision inspection cameras, solenoid valves, vacuum pumps, etc. We recommend reserving 1 set of core electrical spare parts and 1 set of key pneumatic spare parts per machine. Multiple machines of the same model can share spare parts to further reduce reserve costs.
· Class C Spare Parts (Specialized Parts: Consignment as Needed): High cost, extremely low damage probability, long procurement cycles. Includes hot melt adhesive applicator main units, rollers, molds, reducers, frame structural components, etc. We do not recommend customers purchase and stock these independently. We provide spare parts consignment service for long-term cooperative customers: spare parts are stored at your factory, with no advance payment required - settlement only occurs after actual use. Unused spare parts remain our property, and we conduct regular on-site inspections and updates. This guarantees emergency response capability without occupying your working capital.
4.2 Global Supply Network with Express Delivery
· Regional Spare Parts Warehouses: We maintain regional spare parts warehouses in core cities across the globe, stocking all Class A common spare parts and partial Class B critical spare parts. Delivery to your factory is available within 24–48 hours after ordering.
· Emergency Air Freight Service: For specialized spare parts not available at regional warehouses, we arrange urgent air freight from our Chinese headquarters via international express, with delivery to major global cities within 3–5 days.
· Online Traceability System: We establish complete spare parts files for each machine. You can query spare part models, prices, inventory, and delivery times online through the customer service system, place one-click orders, and enjoy full transparency and efficiency throughout the process.
5. Root-Cause Failure Reduction: Full-Process Quality Control + Preventive Maintenance
The best fault handling is reducing fault occurrence at the source. Our equipment controls reliability throughout the entire process - from design, material selection, factory testing, to post-delivery maintenance systems - fundamentally reducing failure probability.
5.1 Premium Core Components: Stability Guaranteed From Design
All core components of the equipment adopt international first-tier brands, including servo drive systems, pneumatic components, high-precision sensors, vision inspection cameras, etc. Rigorous operating life testing under working conditions ensures mean time between failures far exceeds industry levels.
The complete machine adopts a modular design, with each system operating independently yet collaboratively. This facilitates maintenance and inspection while preventing a single failure from affecting overall equipment operation. Additionally, the equipment is equipped with multiple safety protection mechanisms, including emergency stop protection, safety door interlock protection, photoelectric protection, overload protection, over-temperature protection, insufficient air pressure protection, electric leakage protection, etc. Millisecond-level shutdown response occurs when anomalies are detected, preventing minor issues from escalating into major failures and causing greater losses.
5.2 Strict Factory Testing: Zero Hidden Defects Upon Delivery
Every machine undergoes rigorous full-performance testing before leaving the factory:
· Continuous 72-hour full-load operation test, simulating real production scenarios with different raw materials and production speeds.
· Over 100 performance indicators tested item by item, including production speed, dimensional accuracy, adhesive spraying precision, yield rate, noise, vibration, temperature rise, etc.
· All safety protection functions verified one by one to ensure full sensitivity and reliability.
Only when all indicators meet standards can the equipment be shipped. This ensures that what is delivered to you is mature equipment with zero hidden defects, ready for immediate production.
5.3 Full-Cycle Preventive Maintenance System: Significantly Extending Equipment Lifespan
We provide a complete five-level preventive maintenance system: daily → weekly → monthly → seasonal → annual. Strict implementation extends the service life of core components by 42%, improves equipment precision retention by 60%, and reduces annual yield loss due to performance degradation by 75%.
· Daily Maintenance: 10-minute pre-shift inspection, 2-hourly inspections during shifts, 5-minute post-shift cleaning. Just over ten minutes per day prevents 70% of shutdown incidents.
· Weekly Maintenance: 1-hour shutdown per week to complete five major tasks: sensor cleaning, transmission system inspection, lubrication, hot melt system cleaning, and fastener tightening.
· Monthly Maintenance: 4-hour shutdown per month to complete servo system performance testing, vision system calibration, power auxiliary system maintenance, electrical cabinet dust removal, and comprehensive pneumatic system inspection.
· Seasonal Maintenance: Conducted once each March–April and September–October, with an 8-hour shutdown each time. Includes oil changes for temperature and humidity changes, calibration of tension and temperature control systems, comprehensive testing of safety devices, and adjustment of workshop environmental parameters.
· Annual Maintenance: Recommended to be performed on-site by our engineers, with a 2–3 day shutdown. Includes complete equipment disassembly inspection, worn component replacement, system upgrades, full instrument calibration, and complete machine performance testing and acceptance.
5.4 Production Environment Optimization Guidance: Creating Optimal Operating Conditions
Many customers easily overlook the impact of production environment on equipment. In reality, harsh environments are an important hidden factor causing premature equipment aging. Data shows that equipment operating in standard-compliant environments averages over 40% longer service life and over 60% lower failure rate than those in harsh environments.
When delivering equipment, we provide a complete production workshop environment optimization solution, including standards and implementation plans for temperature and humidity control, dust management, power stabilization, and foundation construction. We guide you in creating the most suitable production environment for equipment operation, further reducing failure rates and extending equipment lifespan from the environmental level.
Conclusion
Choosing our underpad manufacturing machine means you are purchasing not just production equipment with a capacity of 400–700 pieces per minute, but a complete full-lifecycle solution for stable operation and profitable production.
From pre-commissioning personnel training and workshop planning, to daily maintenance guidance and rapid anomaly response during production, to long-term technology upgrades, spare parts supply, and annual maintenance - we provide full end-to-end support as your long-term reliable partner. We have the confidence and capability to guarantee long-term stable operation of your production line, helping you achieve sustained profitability in the hygiene products market.
