KNK-310 Production Process

From Material Web to Counted Cotton Pad Stacks

See how the KNK-310 platform coordinates feeding, layer forming, embossing, lock-edge processing, die-cutting and stacking—and where operator handling remains part of the workflow.

Discuss Your Product Design View KNK-310 Details
Material Platform310 mm total web width
Motion Control7-axis independent servo system
Flexible OutputShape and size defined by tooling
Process BoundaryFinal packing is completed manually
Five Coordinated Stages

How the production flow works

The exact roller set, mold layout and operating parameters are configured around the customer’s material and finished-pad design. The sequence below shows the standard process logic.

  1. 01
    Web Preparation

    Roll Loading and Controlled Feeding

    Operators load the specified material rolls and prepare the web path. The feeding system guides the layers into the line under controlled operating parameters so downstream forming remains stable.

    Control focusWeb alignment and feeding stability
    Operator taskLoad rolls and confirm the material path
  2. 02
    Layer Forming

    Layer Alignment and Thermal Bonding

    Multiple material layers are aligned and processed with controlled heat and pressure. For applicable product structures, this creates layer cohesion without adding chemical adhesive. Final settings are established through material trials.

    Control focusLayer registration, temperature and pressure
    Process resultA stable multilayer web for further forming
  3. 03
    Surface and Edge Forming

    Custom Embossing and Lock-Edge Processing

    Configured rollers create the approved surface pattern and edge structure. Pattern depth, edge appearance and bonding performance depend on the material combination, roller design and validated process window.

    Tooling choiceCustom embossing and lock-edge rollers
    Quality checkPattern, edge integrity and layer cohesion
  4. 04
    Product Shaping

    Rotary Die-Cutting and Trim Layout

    The selected cutting mold forms round, square, oval or custom pads. Product dimensions and the number produced across the web are determined by the drawing, mold design and layout within the 310 mm total material width.

    Flexible elementReplaceable product-specific cutting mold
    Yield focusPractical nesting and minimized cutting gaps
  5. 05
    Finished-Pad Handling

    Counting, Stacking and Staggered Output

    Finished pads are counted and organized into stacks before staggered discharge. Operators then transfer the stacks into the agreed final packaging format; packaging automation can be evaluated as a separate integration project.

    Automated resultCounted stacks delivered for packing
    Current boundaryFinal bagging and sealing remain manual
Flexible Production Logic

What changes when your SKU changes?

The main platform remains the same. KNK engineers define the tooling and process setup around the new product instead of treating every shape or size as a completely separate production line.

1
Product drawing

Shape, dimensions and edge geometry establish the design target.

2
Mold and roller set

Cutting, embossing and lock-edge tooling are matched to the approved product.

3
Web layout

The number of pads across the 310 mm width is calculated from size, shape and spacing.

4
Validated parameters

Speed, temperature, pressure and synchronization are set through material trials.

Clear Automation Scope

What the line automates—and what it does not

A clear scope makes staffing, layout and investment planning more accurate before quotation.

Automated in the main line

Functions coordinated by the configured KNK-310 production platform.

  • Continuous material feeding
  • Layer forming and thermal processing
  • Embossing and lock-edge processing
  • Rotary die-cutting
  • Counting, stacking and staggered output

Operator or project-dependent work

Tasks that remain manual or must be defined for the specific project.

  • Raw-material roll loading and web setup
  • Tooling changeover and setup confirmation
  • Routine sampling and quality inspection
  • Transfer into final bags or containers
  • Final packaging, sealing and case packing

Machine configuration and customer-side automation can vary. The final quotation and technical agreement should define the exact included functions, interfaces and acceptance criteria.

Engineering Input

What we need to design your process

Send these inputs so our engineers can evaluate tooling, web layout and operating feasibility before preparing a proposal.

01

Product size and shape

Dimensioned drawing, sample or clear target specification.

02

Material structure

Material type, basis weight, layer count and roll information.

03

Surface and edge design

Embossing pattern, lock-edge appearance and reference samples.

04

Required output

Target production rate, shift plan and expected product mix.

05

Stack and pack format

Pieces per stack, bag dimensions and downstream handling plan.

06

Factory conditions

Destination, utilities, available space and installation constraints.

Turn your product design into a workable production flow

Send your pad dimensions, material structure and target packaging format. KNK will review the web layout, tooling concept and recommended process configuration.

Send Product Requirements Email the Engineering Team