High-Speed Sanitary Napkin Counting & Stacking Solution
2025-12-05 20:00High-Speed Sanitary Napkin Counting & Stacking Solution
Client Background
A leading feminine hygiene products manufacturer in Southeast Asia faced increasing production demands driven by rapid market expansion and rising private-label orders. Their existing semi-automatic process for counting and stacking sanitary napkins caused frequent bottlenecks, low accuracy, and unstable packaging output.
Challenges
Before upgrading, the client encountered several issues:
Inaccurate counting leading to packaging inconsistencies
Manual stacking inefficiency, limiting overall production speed
High labor cost due to multiple operators required per line
Frequent line stoppages caused by misalignment and product jams
Inability to meet large-volume OEM orders during peak seasons
The client needed a fully automated, stable, and high-speed solution to support continuous production.
Solution: High-Speed Sanitary Napkin Counting & Stacking Machine
We recommended and installed our High-Speed Sanitary Napkin Counting & Stacker (Model: HS-CS600), designed for high-output hygiene product production lines.
Key Features Implemented
Up to 600 pcs/min counting speed with ≥99.9% accuracy
Servo-controlled stacking system for precise alignment
Automatic rejection system to remove miscounted or defective pads
Support for multiple pad sizes, including ultra-thin, day-use, and night-use
Modular structure for easy connection to packing machines
Touchscreen HMI with recipe saving and real-time fault diagnosis
Full stainless-steel design, meeting hygiene and GMP requirements
Deployment Process
Production line audit and output analysis
Custom adjustment for pad size, softness, and folding type
Factory installation & operator training
Pilot run validation (48-hour continuous test)
Full production launch
Within 7 days, the client’s new automated line was fully operational.
Results
Before & After Comparison
| Indicator | Before (Semi-automatic) | After (HS-CS600) |
|---|---|---|
| Counting accuracy | 94%–96% | 99.9% |
| Output capacity | 180 pcs/min | 600 pcs/min |
| Labor requirement | 3–4 operators | 1 operator |
| Downtime | High | Reduced by 70% |
| Packaging consistency | Low | Highly stable |
Overall Impact
Production efficiency increased by 220%
Labor cost reduced by 60%
OEM orders increased by 35% due to improved production stability
Enhanced brand competitiveness and product consistency
Client Feedback
“After upgrading to the high-speed counting and stacking machine, our line stability and product quality improved significantly. We can now take more orders and guarantee delivery time. The machine has exceeded our expectations.
This project demonstrates how automated counting and stacking technology can dramatically improve productivity, accuracy, and long-term competitiveness in the sanitary napkin manufacturing sector.