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How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process

Wet wipes have become a daily necessity in personal hygiene, particularly with the spread of COVID-19 and the desire for greater protection against bacteria and disease. This rising popularity has caused an unprecedented increase in demand for personal care wipes, antibacterial wipes, and even moist toilet paper.

But what ingredients are involved, how are baby wipes manufactured, and what procedures are followed during production? This informative guide from DROID Group covers the full wet wipe manufacturing process from beginning to end. Discover everything you need to understand about wet wipes production by reading on!

How are wet wipes made?

Wet wipes are usually manufactured from a mixture of synthetic fibers and a solution including water and additional substances for moisturizing, cleansing, and disinfection. The fibers are first woven into a sheet, which is then divided into smaller pieces and immersed in the solution. The sheets are then kept in airtight containers to maintain their moisture until they are utilized.

What is the complete wet wipes manufacturing process?

A wet wipes production line typically consists of several key pieces of the process, including a RO water purification process, a lotion preparation process, a wet wipes converting and packaging process, a wet wipes lid application process, a wet wipes secondary packaging process, and an end-of-line packaging process.

Step 1: RO Water Purification Process

Generally, wet wipes contain up to 99% water. Wet wipes should be made using water that is either highly purified or reverse osmosis standard. Reverse osmosis (RO) is a water purification process that involves forcing water through a semi-permeable membrane to eliminate impurities and contaminants. In the context of wet wipes production, RO water purification may be used to purify the water that is used in the liquid solution that is used to saturate the wipes.

The RO process usually consists of the following steps:

  1. Pre-treatment: Chemicals are used to clean the water of any big pollutants or particles that can affect the RO membrane.
  2. Filtration: Water is filtered through several filters to get rid of any pollutants or leftover particles.
  3. RO: Water is forced across a membrane that is semi-permeable and enables water molecules to flow over but stops big impurities and contaminants.
  1. Post-treatment: Chemicals are used to regulate the pH and get rid of any contaminants still present in the purified water.

By using RO water purification, wet wipes producers can ensure that the water used in their liquid solution is free of impurities and contaminants, which can improve the quality and effectiveness of their wipes. Thus, the first stage in producing a good wipe is to set up purified water.

RO Water Treatment Equipment UT WT - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process

Step 2: Lotion Preparation Process

Wet wipes are a kind of pre-moistened cloth that may be applied to the skin to clean, refresh, or moisturize it. The following stages are usually included in the process of producing wet wipes with lotion:

  1. In a large mixing tank, combine the ingredients for the lotion or cleaning solution. Water, glycerin, or other moisturizing ingredients are often included in this, along with any additional required ingredients like fragrances or preservatives.
  2. Dip the wipes into the lotion or cleansing solution, making sure they are completely saturated.
  3. Squeeze out any excess liquid from the wipes and spread them out on a flat surface to dry.
  4. The wipes may be divided into individual wipes and packed for usage after they have dried.

When making wet wipes lotion, it’s crucial to choose the best ingredients and adhere to proper production techniques to guarantee the finished product is secure and beneficial for skin application.

Lotion Preparation System UT 2000L1500L1000L - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process

Step 3: Wet Wipes Converting & Packaging Process

Non-woven Roll Unwinding → Tissue Folding → Tissue Cutting → Wetting → Tissue Stacking → Die Cutting → Re-sealable Sticker Labeling → Bag Forming→ Bag sealing → Output Product (Without Plastic Lid)

The following steps are commonly included in the wet wipes converting and packaging process:

  1. On a rolling conveyor belt, the wet wipes are loaded and fed through a machine that divides them into individual wipes and shapes them as required (e.g., rectangular, square, or round).
  2. Once inside a packaging machine, the folded wipes are sealed within a package or container using heat sealing or another technique.
  3. After quality-checking, the wipes are packaged and placed into bigger boxes or cases for delivery.

This method is used to produce all kinds of wet wipes for a wide range of purposes in the market. For example, Facial Wipes, Flushable Wipes, Biodegradable Wipes, Pet Wipes, Alcohol Wipes, Kitchen Wipes, etc. The machine speed, convertible formats such as tissue counts in the bag, tissue dimensions, and bag dimensions are the main differences between each model of wet wipes manufacturing line applied in this process.

The converting and packaging of wet wipes is typically carried out using specific machinery that is intended to manage the delicate nature of the wipes and guarantee that they are properly packaged for usage. Depending on the wipes’ intended purpose and the manufacturers’ choices, a pouch, container, or another packaging style may be chosen.

Wet Wipes Converting Packaging Process DH 250 - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process
Wet Wipes Converting Packaging Process UT FL22 Lanes - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process
Wet Wipes Converting Packaging Process UT FL4 4 Lanes - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process
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Wet Wipes Converting Packaging Process UT BH20 - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process

Step 4: Wet Wipes Lid Application Process

labeling on lid →gluing →lid pasting

The wet wipes lid application process is a process in wet wipes production that involves attaching a lid or cover to the wipes container or pouch. This typically involves the following steps:

  1. Wet wipes in the package are placed into a machine that attaches the lid or cover while being positioned on a moving conveyor belt.
  2. Depending on the type of packaging being applied, either heat sealing or another technique is employed to attach the lid or cover to the container or pouch.
  3. After being quality-checked, the wipes with lids are then placed in bigger boxes or cases and ready for shipment.

The operation of applying the lids to wet wipes is normally carried out with the aid of specialized machinery that is intended to manage the delicate nature of the wipes and guarantee the lids are attached correctly. The intended application of the wipes and the preferences of the manufacturer will determine the kind of lid to be used (e.g., flip-top, peel-off, etc.).

Wet wipes are not often glued or attached to a lid via adhesive. The conventional packaging for wet wipes consists of a pouch or container with a lid that is attached by heat sealing or another technique, such as ultrasonic welding. This makes it simple to use the wipes and keeps them from drying out. It would be challenging to dispense the wipes if they were attached to a lid with adhesive, and there is a chance that the glue would come in touch with the skin, which might be dangerous. It is more typical to use heat sealing or another technique to attach the lid to the container or pouch.

Wet Wipes Lid Application Process DH L300 - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process
Wet Wipes Lid Application Process UT LM70 - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process

Step 5: Wet Wipes Secondary Packaging Process (Optional)

Wet wipes are often supplied in individual packages on the market.

But maybe you’ve seen the bargain pack, which has 3 to 6 packets of wipes in a PE bag.

Multi-pack wet wipes bagging machines or hand packaging are employed to achieve it.

This step may be ignored if making and selling value packs is not your intention.

Wet Wipes Secondary Packaging Process DH MP80 - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process

Step 6: End-Of-Line Packaging Process

Case packing→ palletizing

Case packing and palletizing are the end-of-line packaging processes in the production of wet wipes.

Wipes packets are usually packed into each carton during the case packaging process, typically in a less efficient method.

A fully automated end-of-line packaging system eliminates manpower shortages and rising labor costs.

Once the wet wipes are palletized, they are ready for storage or transportation to warehouses, distribution centers, or retail outlets.

A wet wipes production line might include other processes for quality assurance, inspection, and other tasks in addition to these essential processes.

End of line Packaging Process UT C300 - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process

What different types of wet wipe manufacturing lines are there?

There are four different types of wet wipes production lines:

Facial Wipes 6 scaled - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process

Example: airline wipes, restaurant wipes, alcohol swabs

Facial Wipes 7 300x150 - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process

Example: 10 counts of facial wipes, 25 counts of makeup removal wipes

Facial Wipes 8 scaled - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process

Example: 80 counts of baby wipes, 100 counts of kitchen wipes

Button Design 300x150 - How Are Wet Wipes Made? – A Complete Wet Wipes Manufacturing Process

Example: car wipes, household cleaning wipes

At DROID, we provide wet wipes industry professionals with the end-to-end solutions and machinery they need to manage every phase of their manufacturing process.

Our experts are ready to advise you through every step of the wet wipe manufacturing process from beginning to end.

Contact us now!

DROID is committed to providing high-quality products and excellent service to customers. We follow strict quality management standards to ensure that each wet wipes manufacturing machine is fully tested before delivery. We aim to be a leader in the global wet wipes production field through continuous technological innovation and outstanding customer service, growing together with our customers.

Wet wipes are generally manufactured from nonwoven fabrics (comprising synthetic, natural, or blended fibers) and a liquid solution containing purified water and functional constituents.

Since wet wipes contain up to 99% water, reverse osmosis (RO) purification ensures the water is free of pathogens, impurities, and contaminants, thereby enhancing product safety and stability.

A comprehensive process encompasses RO water treatment, lotion formulation, wipe conversion and packaging, closure application, optional secondary packaging, and end-of-line case packing and palletizing.

The lotion is manufactured in mixing containers where purified water is combined with moisturizers, preservatives, fragrances, or disinfectants, and then accurately dispensed onto the wipes.

Specialized wet wipe converting machines manage roll unwinding, folding, cutting, wetting, layering, bag formation, sealing, and labeling within a continuous automated process.

Yes. Contemporary wet wipe manufacturing lines can produce infant wipes, facial wipes, flushable wipes, biodegradable wipes, pet wipes, alcohol wipes, and kitchen wipes, in various formats.

Lids are affixed using automated lid applicators, with exact positioning and heat sealing or ultrasonic welding, to maintain the moisture of the wipes and facilitate simple dispensing.

Secondary packaging consolidates several wipe packs (e.g., 3–6 packs) into a single polyethylene bag utilizing multipack bundling machinery, typically employed for value packs.

Automated case packing and palletizing reduce labor costs, improve operational efficiency, and ensure uniform, damage-free packaging for storage and transportation.

There are various production lines tailored for single sachets, small-count facial wipes, medium-sized packs, large baby wipe packs, and domestic or automotive wipes.

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