Toilet Paper Making Machine Common Faults, Causes & Troubleshooting

1.  Paper Breakage During Rewinding

Main Causes

1. Unstable tension parameter set on PLC touch screen; too tight paper web pulling force
2. Perforating knife burrs, sharp edges scratch tissue paper
3. Uneven unwinding resistance of parent tissue jumbo roll
4. Paper threading shaft rusted or deformed, causing paper friction scratch
5. Low gram weight thin tissue paper with excessive embossing depth

Giải pháp

• Adjust PLC tension control to “tight first, loose later” mode
• Polish perforating cutting blades, replace worn knife sets
• Refuel unwinding stand bearing, check cylinder air pressure
• Grind or replace rusted seamless steel paper threading shaft
• Reduce embossing pressure for lightweight base paper

2. Loose Paper Core & Roll Delamination after Storage

Main Causes

1. Single constant tension without segmented PLC tension control
2. Insufficient tail glue spraying volume
3. Paper tube inner diameter mismatch with winding mandrel
4. Electronic brake failure, unstable rewinding speed

Giải pháp

• Activate the segmented tension program on CNC PLC controller
• Calibrate glue spray nozzle to ensure uniform adhesive coating
• Customize paper tube mandrel according to your paper core size
• Inspect variable frequency drive and electronic brake sensor

3. Uneven Edge Trimming, Ragged Roll Sides

Main Causes

1. Trimming cutter dull or tilted installation
2. Parent jumbo roll offset loading on unwinding rack
3. Solid cast iron bearing base loose, perforating knife shaking
4. Synchronization error between trimming and rewinding PLC program

Giải pháp

• Sharpen or replace trimming blades, calibrate cutter horizontal position
• Re-position jumbo rolls, fix separable unwinding rack lock
• Tighten all cast iron bearing base fixing bolts
• Reset PLC synchronous parameter for edge trimming & gluing

4. Failed Tail Sealing, Missing 10–20mm Paper Tail

Main Causes

1. Glue pump blocked, nozzle clogging
2. PLC synchronous timing disorder of trimming-gluing-sealing
3. Air cylinder pressure insufficient for tail pressing
4. Worn glue spray solenoid valve

Giải pháp

• Clean glue pipeline and spray nozzles daily to prevent solidified glue blockage
• Recalibrate HMI synchronous operation parameters
• Adjust air compressor output pressure to standard 0.6–0.8MPa
• Replace aging glue control solenoid valve

5. Automatic Paper Tube Dropping Malfunction

Main Causes

1. Paper tube storage bin jammed by deformed cardboard tubes
2. Tube feeding cylinder air pressure shortage
3. PLC sensor fault for tube position detection
4. Tube slide rail deformed by long-term vibration

Giải pháp

• Remove irregular deformed paper tubes from storage bin
• Boost cylinder air pressure and check air pipeline leakage
• Clean photoelectric sensor lens or replace damaged sensor
• Straighten deformed slide rail, reinforce square steel rack support

6. Embossing Pattern Fuzzy, Uneven Texture

Main Causes

1. Embossing roller surface wear or dirt accumulation
2. Embossing cylinder pressure inconsistent on left and right sides
3. Rewinding speed fluctuating due to unstable frequency converter
4. Paper web deviation leads to partial embossing missing

Giải pháp

• Clean embossing roller surface regularly, repair worn roller surface
• Balance left-right cylinder pressure of embossing unit
• Debug VFD frequency converter to stabilize running speed
• Calibrate paper deviation correction sensor

7. CNC PLC & Touch Screen Control Failure

Main Causes

1. Dust, paper scraps entering PLC control cabinet, short circuit
2. Touch screen wiring loose or damaged
3. Overload voltage impact on controller without voltage stabilizer
4. Program parameter lost after power failure

Giải pháp

• Clean control cabinet weekly, equip dustproof cabinet door
• Reconnect loose wiring, replace broken touch screen cables
• Install industrial voltage stabilizer for the whole production line
• Save parameter program backup file on computer for quick recovery

8. Abnormal Vibration & Loud Running Noise

Main Causes

1. Solid cast iron bearing base fixing bolts loose
2. Bearing lack lubricating oil or bearing wear
3. Square steel machine head deformed by heavy load
4. Unbalanced jumbo parent roll rotation

Giải pháp

• Tighten all fixed frame bolts of perforating knife bearing base
• Fill food-grade lubricant to all rolling bearings monthly
• Reinforce deformed square steel machine head structure
• Balance jumbo roll before installing on unwinding rack

9. Daily Maintenance Tips to Reduce Rewinder Fault Rate

1. Lubricate all bearings, shafts and cylinder moving parts every 8 working hours
2. Clean glue spray system, trimming knife and embossing roller before machine shutdown daily
3. Clear paper scraps inside PLC electric cabinet to avoid circuit failure
4. Check air compressor pressure and air pipeline leakage every morning
5. Back up all PLC production parameters monthly to avoid data loss
6. Inspect channel steel rack and square steel head for loose bolts weekly

10. FAQs About Máy sản xuất giấy vệ sinh Malfunctions

Q1: Why finished toilet rolls loosen several days after production?

A: The core reason is single tension rewinding without PLC segmented tight-loose tension program. Upgrade or activate the segmented tension function on touch screen to solve core separation.

Q2: Paper breaks frequently during high-speed rewinding, how to fix quickly?

A: First check perforating knife burrs and paper threading shaft friction; then lower the rewinding tension value on HMI, reduce embossing pressure for thin tissue paper.

Q3: The machine cannot automatically feed paper tubes, what parts need inspection?

A: Check three core parts: tube feeding air cylinder pressure, tube position photoelectric sensor, and paper tube slide rail deformation.

Q4: The touch screen fails to respond after power cut, is the PLC broken?

A: Mostly parameter loss or wiring loose. Reload backup PLC program first, then check touch screen power wiring, rarely controller hardware damage.

11. Professional After-Sales Support from MÁY NRC

If you encounter complex toilet paper rewinder failures that cannot be fixed by daily maintenance, contact NRC MACHINE technical team anytime:
Mobile/WhatsApp: +86 15254213289
Email: james@nrcmachine.com
Trang web chính thức: https://nrcmachine.com
We provide 24-hour online remote PLC debugging, spare parts supply and overseas on-site maintenance service for all toilet paper manufacturing production line buyers.