Add a KNK Line
Increase capacity while keeping selected existing equipment in service. The assessment focuses on floor layout, material supply, staffing and downstream packing balance.
Capacity Expansion & Replacement Planning
Upgrade Cotton Pad Output With a Measured Engineering Plan
Compare your current accepted output, labor scope, material use and downtime with a product-specific KNK-310 proposal—before deciding whether to add, replace or reconfigure capacity.
Expected results are confirmed from your product dimensions, lane layout, raw material, shift pattern and acceptance conditions—not from a universal percentage.
Add CapacityInstall a new line alongside current production
Replace BottlenecksRetire unstable or labor-intensive equipment
Expand FormatsAdd product specifications through tooling plans
Define the Project First
“Upgrade” Can Mean Three Different Investments
The correct proposal depends on whether your priority is more accepted output, more stable production or a broader product range.
Replace an Existing Line
Compare current accepted output, stoppages, maintenance burden, product quality and labor allocation against a defined new-line acceptance plan.
Add Shapes and Sizes
Evaluate new molds and lane arrangements for products that fit within the KNK-310's 310 mm total material web width.
Scope boundary: this page primarily covers adding or replacing production equipment. Retrofitting controls or mechanisms on third-party machines requires a separate technical review and is not automatically included.
Baseline → Proposal → Acceptance
Compare Production Evidence, Not Headline Numbers
A useful upgrade comparison connects every claimed improvement to your current record, the proposed configuration and a measurable acceptance method.
| Decision Metric | Your Current Baseline | Proposed KNK Configuration | Acceptance Evidence |
|---|---|---|---|
| Product & layout | Shape, dimensions, layers, material and lanes currently produced. | Drawing, mold scope and lane arrangement for each required SKU. | Approved sample and signed technical specification. |
| Accepted output | Good pieces per hour or shift after rejects and stoppages. | Target output stated for the approved product and operating condition. | Timed FAT or agreed production trial. |
| Downtime | Jam, adjustment, cleaning, maintenance and changeover records. | Planned controls, access and operating procedure. | Defined trial duration and logged interruptions. |
| Labor scope | Operators by feeding, collection, inspection, packing and material handling. | Automated and manual tasks shown separately. | Observed staffing during the agreed trial. |
| Material use | Input weight versus accepted product and recoverable skeleton waste. | Product-specific nesting and cutting layout. | Material reconciliation using the same SKU and material. |
| Changeover | Current mold, material and parameter change procedure. | Required tools, settings, training and validation steps. | Timed change under the agreed scope. |
Nameplate speed alone does not represent sellable output. Product configuration, efficiency, rejects, upstream supply and downstream packing all affect actual daily production.
Reference platform shown. Final machine layout, guarding, tooling and options follow the confirmed order specification.
Reference Platform
KNK-310 Flexible Cutting & Stacking
The platform is designed around a 310 mm total material web width. Product size, shape and transverse arrangement determine the mold layout and the number of pieces produced across the web.
- Process scopeMaterial feeding, forming / embossing, cutting and organized stacking.
- ControlSeven-axis independent servo architecture.
- Rated referenceUp to 2,000 pcs/min under the specified product configuration.
- Layout referenceApprox. 4,950 × 1,210 mm equipment footprint; verify final GA drawing.
- Utility referenceAC 380 V, 50 Hz and 0.6–0.8 MPa compressed air; final electrical configuration must be confirmed.
- Final packingManual in the standard scope unless separate packaging automation is specified.
Reference values are not a site-specific performance guarantee. The signed technical agreement and accepted product sample govern the final project.
Production Controls
Review operating access, recipes, counting logic and alarm handling during technical confirmation.
Product-Specific Tooling
Cutting layout is developed from product geometry, 310 mm web width and material behavior.
Organized Stacking Output
Confirm stack count, discharge arrangement and the manual or automated downstream handoff.
Project Economics
Build ROI From Your Own Operating Data
Payback should be calculated from achievable accepted output and documented cost inputs—not a fixed promise that applies to every factory.
Open the ROI CalculatorContribution From Added OutputAccepted pieces × realized contribution per piece, constrained by actual demand.
Labor ReallocationCompare tasks removed, retained and added—including final packing and material handling.
Material DifferenceMeasure input-to-good-output yield using the same product, material and test basis.
Total Project CostInclude machine, tooling, freight, duties, installation, utilities, training and working capital.
Site Integration Checklist
Plan the Factory Around the Whole Material Flow
The machine footprint is only one part of the installation. Raw material, operators, waste, product discharge and packing also need space and access.
Product & Tooling
Confirm every launch SKU, sample standard, mold scope and future-product priority.
Raw Material
Review roll width, diameter, weight, splice method, storage and material variation.
Floor & Access
Check machine route, working clearance, maintenance access, floor condition and waste removal.
Power & Air
Confirm local voltage, frequency, grounding, compressed-air capacity and connection points.
Output & Packing
Balance stack discharge with inspection, manual packing or a separately engineered interface.
Safety & Documentation
Define site rules, operator language, training, guarding review and required project documents.
Execution Path
A Controlled Upgrade From Assessment to Ramp-Up
Each stage closes a specific technical or commercial risk before the next investment step.
01Current-State Review
Collect products, operating records, bottleneck videos, staffing and site information.
02Technical Proposal
Define scope, tooling, layout, utilities, target conditions and responsibility split.
03Sample & FAT Plan
Agree test material, product sample, trial duration, measurements and acceptance criteria.
04Delivery & Commissioning
Prepare the site, install the line and verify controls, tooling, product and operator readiness.
05Ramp & Review
Track accepted output, stops, quality and actions during the agreed production ramp period.
Engineering Input
Send a Useful Upgrade Brief
The more clearly your current state is documented, the faster the engineering team can identify whether an additional line, replacement or product-expansion plan is appropriate.
- Current ProductsShape, size, layers, material, weight and pack format.
- Operating BaselineGood output per shift, hours, shifts, rejects and frequent stops.
- Labor by TaskFeeding, machine operation, collection, inspection, packing and handling.
- Target CapacityRequired accepted output by SKU and desired launch timing.
- Current EquipmentModel, age, photos, video, main bottlenecks and mold information.
- Material DetailsRoll width, diameter, composition, supplier sheet and sample roll access.
- Site InformationFloor plan, available area, access route, voltage and compressed air.
- Project BoundaryNew equipment, replacement, third-party retrofit inquiry or packaging interface.
Upgrade FAQ
Questions to Resolve Before Investment
These answers keep the project scope realistic until product samples, layout and technical terms are confirmed.
Can KNK retrofit our existing machine?
Third-party retrofit feasibility depends on the machine structure, controls, documentation, condition and required change. Send the model, drawings, photos and operating video for review. A new line or replacement may be more practical in some cases.
How much will our output increase?
The result depends on product size, lane count, material, operating time, efficiency, reject rate and downstream capacity. KNK should state the applicable target and test condition in the project specification.
How many operators will the upgraded line require?
Staffing depends on material handling, inspection, stack collection, final packing, shift practices and local safety rules. The proposal should separate automated machine functions from the remaining manual tasks.
Can our existing molds be reused?
Mold compatibility cannot be assumed across machines. KNK must review dimensions, interfaces, cutting structure, product specification and condition before confirming whether reuse or new tooling is appropriate.
Will installation stop our current production?
The impact depends on whether the project is an additional line or a replacement and whether utilities or floor work are shared. A site-readiness and cutover plan should be agreed before shipment.
Does the standard line include automatic final packing?
No. The standard scope described here ends with organized stacking; final packing is manual. A future or separate packaging interface requires its own product, stack-transfer and packaging-machine assessment.
Start With the Bottleneck
Show Us What Limits Your Production Today
Send your product specification, current output record, equipment photos or video, floor plan and target capacity. KNK will use them to define the next technical review.
Email: support@knkautomation.com · WhatsApp: +86 198 6866 6397