Curt G. Joa, Inc. has been inventing automation solutions for the hygiene industry since 1932. Regardless of economic cycle, automation provides an investment return as measured by increased production through-put, reduction of labor, increased uptime and reduced maintenance expenses, and improved quality with positive market response.
JOA approaches every project with the same engineering discipline rooted in the TRIZ methodology, or the theory of inventive problem solving. Technology does not substitute knowledge, and therefore every project relies on the logic, data and research for problem formulation, system analysis, failure analysis, and patterns of system evolution. The approach gives customers the optimal solution they need for their specific goals.
The JOA® machine platforms support the production of hygiene, medical PPE and other disposable products. Specifically, the adult platform comprises pant, brief and light incontinence products; and the baby platform provides options for both pant and diaper/nappie. The many feminine care production machine options reflect the extensive variety of the market.
1. The baby diaper platform, the J8T-B, has the production speed of 1200 ppm and features the patented No Scrap Ear (NoSE™) System. The unique NoSE™ process utilizes ergonomically or symmetrically shaped ears from a continuous web with no waste. The JOA® NoSE™ System allows for different leading and trailing angles and shaped cuts. As the smaller version of the adult, the baby platform also includes the patented Gentle Touch™ Folder, which maintains the visual appeal and absorbent functionality of the diaper core.
2. The baby pant platform, the J7I-BP, has production speeds of 1000 ppm and features proprietary technologies, including turret unwinds that automatically splice raw materials at-speed during production. In addition, our insert attachment process applies adhesive up to the cut edge, eliminating the need for a cover strip. Also available is the patented Single Transfer Insert Placement Process (STIPP™), allowing for multiple pitch lengths without changing the entire unit. In addition, cross directional placement control is offered as well, which reduces downtime during size change by easily shifting the unit’s centerline.
3. The adult pant platform is comprised of the J8T-AP and J7I-AP, with production speeds of 500 ppm and 300 ppm, respectively. Both machine options can include stretch film lamination, with the flexibility to switch between stretch film and strands in minutes. The unique Auto Re-feed Feature maximizes material efficiency and reduces machine stops due to material damage. Finally, the Single Transfer Insert Placement Process (STIPP™) is available with the same benefits of multiple pitch lengths and cross directional placement control.
4. The adult brief platform, the J8T-AB, has a production speed of 450 ppm and the inventive Gentle Touch™ Folder which prevents cores from cracking while increasing the maximum machine speed. The tandem folding process results in bi-fold, tri-fold and quad-folded brief products.
5. The light incontinence platform includes the J20S-LI and DEDE330, with production speeds of 1500 ppm and 800 ppm, respectively. A variety of production capabilities are available for cores, materials, and ADLs. In addition, the platform includes multiple processes for different fold and wrap options, including overwrap or pouch. Also available is the Flexographic Printing Unit with three-color printing of specific patterns in the ADL or topsheet.
6. The variety of feminine care production is reflected by the variety of JOA® production solutions offered from the platform. Both the J20S-PL and J20S-FN, with production speeds of 3000 ppm and 2600 ppm, respectively, have the Turn and Pitch (TAP) Unit for rotating individual inserts in the machine process. As the unit rotates, individual inserts are picked up and turned 90 degrees for transfer and repitch. For higher production speeds, two product streams can feed into two separate packaging machines with the Double Pad Turner. Two identical rotator units pick-up the product from the main process flow and rotate 90 degrees, diverting to the proper packaging machine. In addition, the platform includes the DEDE300 with production speeds of 1500 ppm for panty liners and 1000 ppm for sanitary napkins. The Universal Foam Applicator eliminates size changes, stretching foam strips and applying them at specific distances. The Flexographic Printing Unit can be included as well for each production solution.
7. Finally, the DEDE400 is included with its unique cross machine production process. Products are manufactured at 90 degrees to production direction, providing production speeds of 1500 ppm for both panty liners and sanitary napkins, and 500 ppm for winged napkins.
8. Plus, JOA continues providing face mask machines, building on its nearly 25-year history by introducing its patent-pending design for the efficient production of quality face masks and expanding into isolation gowns.
The market continues to demand higher premium features with greater production efficiency, and JOA responded with several new innovations.
1. The patented design of an expandable absorbent core structure improves the performance of high-SAP core products. The unique product feature and process design ensure the absorbent core and core wrap expand in unison, maintaining the overall integrity of the product, giving the manufacturer all the benefits of SAP and the user the confidence in the disposable hygiene product.
2. In addition, the recently announced Single Anvil In-Line (SAIL™) Bonder technology leverages a patented design that provides better bond strength with unique designs, reduces overall costs for maintenance and material consumption, plus allows simple adjustments for size changes. The most significant aspect for efficiency, however, is that these benefits are provided at top production speeds, 1000-1200 ppm.
Until now, the traditional ultrasonic process was limited by the dwell time required to form bonds of sufficient quality, limiting machine speeds. JOA’s invention breaks through barriers and provides consistent quality at the highest production speeds. Furthermore, with the precision of the process, seams require less material which creates a more aesthetic product.
3. Specific technologies benefitting absorbent cores include forming processes that create highly defined yet soft edges with less waste, with the cost advantages of the discreet forming process. Solutions for strand products make high density features practical, and the overall strand maintenance easy and cost-effective. As an alternative to strands, JOA’s patented lamination process provides OEM elastic film with fewer materials. These efficient technologies, and many more sustainable solutions, are included in JOA converting machines and available for other makes.
4. Furthermore, JOA maintains its focus on reducing material waste in three major categories: start-up/shutdown, material splicing and automated correction. Combined, these innovations minimize material use by delaying the initiation of high-cost material features and intelligently correcting process errors, reducing rejects while improving product quality. Additionally, new inventions, such as the SAIL™ Bonder, minimize material use which prevents concerns about waste. These efforts reduce the environmental impact and operating expenses.
JOA’s Single Anvil In-Line (SAILTM)
JOA J8T baby diaper machine and the SAILTM ultrasonic bonder
JOA® solutions are also found in related industries such as filtration, food pads, homecare, medical, packaging, and other specialty production needs.
For more information, visit www.joa.com.
Curt G. Joa, Inc. is known globally for engineering and technical inventiveness. Located in USA, Germany, and Japan, professional engineers, technician crews and assembly staff are building thriving partnerships with customers to create the innovative and sustainable solutions that convert challenges into successes. Since 1932, JOA has been the standard in quality and efficiency.www.joa.com.
