Tissue Converting Line Troubleshooting: Causes & Fixes

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Problems on this page:

Web breaks at the unwind or rewinder Log diameter or firmness varying Perforation not tearing cleanly Embossing or ply bonding faults Log saw cutting badly Tail sealing failures Dust levels too high Long grade or size changes

Web breaks at the unwind or rewinder

Hits OEE: Availability

Symptoms: The tissue web breaks during unwinding or rewinding, and the line stops to rethread.

Parent reel defects such as holes, wrinkles or wet streaks

Record the reel number at each break and feed the defects back to the paper machine.

Web tension too high for the grade

Check the unwind brake or drive and the dancer settings for that grade.

Parent reel out of round or with soft spots

Check reel hardness and roundness before loading.

Dust build-up on rollers and idlers

Clean rollers on the set interval and check the dust extraction.

Prevention: Breaks recorded per parent reel and per position on the line.

Log diameter or firmness varying

Hits OEE: Quality

Symptoms: Finished logs vary in diameter or feel soft, and rolls fail the specification.

Rewinder winding profile changed

Compare the winding profile settings with the approved recipe for the product.

Sheet count wrong for the diameter

Check the sheet count setting and the perforation pitch.

Bulk of the parent reel changed

Check parent reel bulk and caliper against the specification.

Core diameter or quality varying

Check the cores from the core winder.

Prevention: Log diameter and firmness measured on samples each hour.

Perforation not tearing cleanly

Hits OEE: Quality

Symptoms: Sheets tear across the perforation badly, or the roll separates by itself.

Perforating blades worn or chipped

Inspect the perforating blades and replace damaged ones.

Anvil and blade setting wrong

Set the blade engagement as the maker specifies for the grade.

Perforation pitch changed

Check the pitch setting for the product.

Paper strength changed

Check the strength of the parent reel against the specification.

Prevention: Perforation tear checked on samples each hour.

Embossing or ply bonding faults

Hits OEE: Quality

Symptoms: Plies separate, or the embossed pattern is weak or uneven.

Glue application uneven or the glue viscosity wrong

Check the glue level, the applicator roll and the glue viscosity.

Embossing roll pressure wrong

Check the embossing pressure on both sides of the roll.

Rubber roll worn

Check the rubber roll hardness and surface.

Plies not registered

Check the ply alignment before embossing.

Prevention: Ply bond and embossing checked on samples each hour.

Log saw cutting badly

Hits OEE: Quality

Symptoms: Roll ends are torn, fuzzy or not square after the log saw.

Saw blade dull

Sharpen the blade on the set interval, or check the automatic grinder works.

Log clamping loose

Check the clamps so the log does not move during the cut.

Blade speed or log feed wrong

Check the blade speed and feed settings.

Blade not cooled or lubricated

Check the lubrication system on the saw.

Prevention: Roll ends checked on samples each hour; blade changes are done only with the saw isolated and locked off.

Tail sealing failures

Hits OEE: Quality

Symptoms: Roll tails are not sealed, unroll in the pack or stick too hard.

Tail glue amount wrong

Check the tail sealer glue application.

Tail position wrong when sealed

Check the tail finding and the roll rotation.

Glue too thick or too thin

Check the glue viscosity.

Logs arriving too fast

Check the transfer speed to the tail sealer.

Prevention: Tail seal checked on samples each hour.

Dust levels too high

Hits OEE: Availability

Symptoms: Paper dust builds up on the line and in the room, raising cleaning time and fire risk.

Dust extraction not working at the source points

Check the extraction at the rewinder, log saw and perforator.

Filter of the dust collector blocked

Clean or change the filters and check the pressure drop.

Cleaning schedule not kept

Clean the line on the set interval; paper dust build-up is a known fire risk.

Paper grade creating more dust

Report dusty reels to the paper machine.

Prevention: Dust build-up checked and cleaned at set times each shift.

Long grade or size changes

Hits OEE: Performance

Symptoms: Changing product takes long, and the first logs are waste.

Change parts and cores not ready

Stage the cores, glue and change parts before the change starts.

Settings not stored per product

Store the winding, perforation and embossing settings per product.

Parent reels for the next product not staged

Stage the next parent reels at the unwind.

No written changeover sequence

Write the changeover sequence and train each crew on it.

Prevention: Changeover time recorded per product change.

Guidance only. Always follow lockout/tagout and your site's safe-work procedures, and verify against OEM manuals before acting.

Related equipment guides: paper machine · slitter rewinder · shrink wrapper · case packer · dust collector

Stop the same fault coming back

Recurring tissue converting line stops usually trace to a cause you cannot see by hand. The partner we recommend is Fabrico: it tracks OEE and downtime live from PLCs, IoT sensors or AI cameras; where cameras are fitted, the video of a stop sits next to its machine data so the cause can be reviewed; and a technician opens the work order from the stop in the same system. Data is hosted in the AWS EU region, and Fabrico and the company behind it hold ISO/IEC 27001, ISO/IEC 20000-1 and ISO 9001.

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Methods that cut recurring stops: the six big losses · root cause analysis · preventive vs predictive maintenance · TPM · SMED & changeover