Difference Between Demolding and Traditional Core Forming Process in Hygiene Product Manufacturing
1. Process Flow Comparison
The demolding process refers to a technology where the absorbent core is formed inside the forming drum and then transferred from the mold cavity to the next production process through a dedicated demolding mechanism and precise control.
For certain product designs, the demolding process can reduce or even eliminate the need for traditional tissue paper wrapping around the absorbent core, helping manufacturers optimize product structure and reduce material costs.
Taking a sanitary napkin machine as an example, during the demolding process, fluff pulp, SAP, and other absorbent materials are first crushed and mixed, then transferred into the mold cavities on the forming drum under vacuum suction.
The vacuum system inside the forming drum creates suction force, allowing the materials to distribute evenly according to the mold design and form a complete absorbent core structure.
When the forming drum reaches the demolding section, the core is smoothly released from the mold cavity and transferred to the next production station through the demolding mechanism.
The traditional core forming process is different. The absorbent core is continuously formed into a strip shape and then wrapped with upper and lower tissue paper layers. After that, the wrapped core is transferred to the vacuum channel, where an internal cutting knife separates individual cores.
The difference between the two processes can be clearly seen from the production flow:
Demolding Process:
Absorbent materials → Core forming inside mold cavity → Precise demolding transfer → Further lamination → Finished product
Traditional Core Forming Process:
Absorbent materials → Tissue paper wrapping → Core forming → Further lamination → Finished product
2. Main Difference Between the Two Processes
For hygiene product manufacturers, the biggest difference is that the demolding process does not require tissue paper as an additional raw material.
For machine manufacturers, the key consideration is whether the production line is equipped with:
- Only a tissue paper wrapping system;
- Only a demolding system;
- Or a combination of both systems.
The machine must ensure that the absorbent core can be separated from the forming mold accurately and stably during high-speed production, while maintaining smooth connection with the following processes.
Why Traditional Core Forming Requires Tissue Paper?
For most hygiene product manufacturers, tissue paper has long been an essential raw material in traditional sanitary napkin production. It mainly serves the following functions:
1. Supporting Absorbent Materials
After fluff pulp is crushed and mixed with SAP, the absorbent materials can easily become loose. Tissue paper provides support for these materials by sandwiching the absorbent core between two layers of tissue paper, helping maintain structural stability.
2. Improving Product Appearance
Hygiene products require a consistent absorbent core shape. During high-speed production, tissue paper helps maintain the core structure, improve flatness, and reduce material dust.
3. Improving Core Transfer Stability
In high-speed production lines, tissue paper acts as a supporting layer, helping the absorbent core transfer smoothly to the next production station.
4. Reducing Material Loss During Production
During high-speed operation, tissue paper helps prevent absorbent materials from scattering during transfer, improving production stability.
Therefore, it has become an important auxiliary material in traditional absorbent core structures.
What Are the Advantages of the Demolding Process?
1. Lower Raw Material Cost
The biggest advantage of the demolding process is reducing material costs.
Although it only eliminates one material — tissue paper — the savings can become significant when calculated based on high-speed production output.
According to actual production feedback from SQM customers, for 280mm sanitary napkins with a daily output of approximately 600,000 pieces, the demolding process can save around USD 315 per day compared with the traditional tissue paper wrapping process.
Many Indian customers, especially those producing products for government supply projects, prefer the demolding process because of its lower long-term production cost.
2. Improving Absorbent Core Forming Stability
The stability of absorbent cores in sanitary napkins, underpads, adult diapers, and other hygiene products is one of the key factors affecting product quality.
SQM equipment uses a precise demolding system to control core weight and ensure stable separation from the forming mold.
The finished product qualification rate can reach 99.99% under stable production conditions.
3. Ability to Produce Thicker Products
Since the demolding process does not require tissue paper, the absorbent core needs sufficient basis weight to be transferred smoothly through the demolding system and directly laminated with the top sheet nonwoven.
According to feedback from overseas customers, consumers in some Islamic countries prefer thicker sanitary napkins because thicker products provide a more visible feeling of quality and reliability.
4. Greater Flexibility for Product Development
By adding a demolding process, the machine provides greater flexibility in product transfer and structure adjustment.
Manufacturers can optimize raw material combinations and develop more product types, helping them respond better to different market demands.
Why Traditional Non-Demolding Process Is Still Widely Used?
Although demolding technology provides many advantages, most manufacturers still choose the traditional tissue paper wrapping process.
Some customers are not familiar with demolding technology, while others are entering the hygiene product industry for the first time and prefer a simpler machine structure with lower investment costs.
1. Tissue Paper Wrapping Provides High Equipment Stability
The traditional non-demolding structure has been developed and widely used for many years.
Compared with demolding technology, it removes the additional core transfer step, making the machine structure simpler and the production speed easier to increase.
Most markets still accept tissue paper wrapped cores, and many high-speed production lines continue to use this structure, especially manufacturers focusing on maximum output.
2. Lower Equipment Manufacturing and Maintenance Costs
The demolding process requires a more complicated machine structure, which increases equipment manufacturing costs and requires higher operator training levels.
Traditional machines are relatively easier to operate and maintain.
Challenges of Demolding Technology
Demolding technology is a comprehensive technical challenge for equipment manufacturers.
1. Higher Precision Control Requirements
The key challenge of demolding is ensuring that the absorbent core separates from the mold at the correct timing and position.
This requires more precise machine control.
2. Higher System Integration Capability
A demolding system is not a single component. It requires coordination between multiple systems, including:
- Forming mold design;
- Vacuum system control;
- Servo synchronization control;
- Product transfer system.
It requires the machine manufacturer to have a deep understanding of the entire production process.
SQM machines have been tested through actual production by multiple customers and can maintain stable product structures during continuous high-speed operation.
3. Understanding Absorbent Material Characteristics
Fluff pulp and SAP both have characteristics that make them easy to disperse after processing.
Demolding is not only a mechanical action but also requires precise control of absorbent material forming characteristics.
Different fluff pulp ratios, SAP content, and product structures will influence demolding performance.
Which Hygiene Product Manufacturers Are More Suitable for Demolding Technology?
1. Manufacturers with Stable Production Capacity Looking to Reduce Long-Term Costs
For factories producing hundreds of thousands of pieces per day or more, material savings can create significant cost advantages.
2. Manufacturers Developing Differentiated Products
Demolding is suitable for manufacturers focusing on:
- Ultra-thin sanitary napkins;
- High-absorption core products;
- Differentiated hygiene products.
Is Demolding Technology the Future Trend in Hygiene Product Manufacturing?
As the global hygiene product market continues moving toward higher quality, higher efficiency, and more diversified products, demolding technology is becoming an increasingly important equipment upgrade option for manufacturers seeking product differentiation, production efficiency improvement, and long-term cost optimization.
As a professional hygiene machinery manufacturer, SQM continues to optimize demolding technology through continuous improvement and real customer production experience.
We help customers achieve more stable absorbent core production and provide reliable support for future product upgrades and capacity expansion.
Conclusion
Demolding technology and traditional tissue paper wrapping technology are not absolute replacements for each other.
For manufacturers focusing on stable high-speed production and lower initial investment, traditional technology still has clear advantages.
For manufacturers looking to reduce long-term material costs, develop differentiated products, and improve market competitiveness, demolding technology provides a more advanced production option.
The final choice should depend on product positioning, production capacity requirements, market strategy, and long-term development plans.
FAQ
1. Is the demolding process always better than traditional tissue paper wrapping?
No.
Both technologies have their own suitable applications.
Traditional technology is mature and stable, making it suitable for manufacturers focusing on high-speed mass production.
Demolding technology is more suitable for manufacturers looking to optimize material costs and develop differentiated products.
2. Which hygiene products can use demolding technology?
Demolding technology can be applied to:
- Sanitary napkin production lines;
- Underpad production lines;
- Adult diaper production lines;
- Other absorbent hygiene product equipment.
3. Why do not all manufacturers choose demolding technology?
The main reasons are that demolding equipment requires more complicated machine structures, higher technical capabilities from equipment manufacturers, more production experience, and relatively higher investment costs.
4. What are the advantages of SQM demolding equipment?
Through independent development and customer production verification, SQM continuously optimizes:
- Core forming system;
- Demolding mechanism;
- Vacuum control system;
- Servo synchronization system.
These improvements help customers achieve stable and efficient absorbent core production during high-speed operation.
