How to Make Tissue Paper Packaging Bags

From Design to Finished Product: An Analysis of the Professional Manufacturing Process of Tissue Paper Packaging Bags

Abstract: As the direct carrier connecting the production end with the consumption end, the function of toilet paper packaging bags goes far beyond merely wrapping the product. A high-quality packaging bag must combine multiple missions including protection, convenience, information transmission, and brand marketing. This article systematically analyzes the complete process flow of toilet paper packaging bags, from material selection and structural design to printing technology and finished product manufacturing, aiming to provide a professional and rigorous technical reference for industry practitioners and interested parties.

Chapter 1: Preliminary Planning and Design – Laying the Cornerstone of Success

Before entering actual production, meticulous planning and design are crucial to ensuring the quality and market acceptance of the packaging bag.

1.1 Define Functional Positioning

First, it is necessary to clarify the core functional requirements of the packaging bag:

Basic Protection: Prevent toilet paper from moisture, dust contamination, and crushing deformation.

Convenience Features: Easy to carry, open, and reseal (if applicable).

Information Display: Clearly mark brand, product type, roll count, specifications, raw materials (e.g., 100% virgin wood pulp), executive standards, environmental labels, etc.

Brand Communication: Establish brand recognition through visual design to attract consumer attention.

Environmental Considerations: Whether the materials are recyclable, biodegradable, and comply with increasingly stringent environmental regulations.

1.2 Structural Design and Dimension Planning

Carry out structural design based on the specifications of the packaged toilet paper (e.g., 10-roll pack, 12-roll pack, family large pack, etc.).

Bag Type Selection: The most common are back-seal bags (three-side seal bags) and stand-up bags.

Back-seal bag: Mature technology, lower cost, wide applicability, the mainstream choice for toilet paper packaging.

Stand-up bag: Has a support structure at the bottom, allowing for upright display on shelves, enhancing display effect, but with slightly higher cost and process complexity.

Dimension Calculation: Determine the final dimensions of the packaging bag by accurately calculating the length, width, and height of the stacked toilet paper and reserving appropriate margin (usually 2-5mm). Too little margin makes filling difficult; too much appears bulky and wastes material.

1.3 Visual and Layout Design

This is the core reflection of brand value and requires completion by professional designers.

Main Visual Area: Typically places the brand logo, product series name, high-quality product renderings, or warm usage scenario images.

Information Description Area: Lists all necessary information in a clear, standardized font to ensure compliance.

Color Management: Establish standard PANTONE or CMYK color values to ensure color consistency in printing.

Material Texture: Consider the tactile feel of the final product during the design stage, such as whether lamination is needed to increase gloss and wear resistance, or using matte materials to create a premium feel.

Chapter 2: Material Science and Selection – Building the Body of the Packaging

The performance of packaging materials directly determines the product's protective capability and user experience.

2.1 Base Layer: Printing and Support

Art Paper: Smooth surface, excellent printability, high color reproduction, a common choice for high-quality toilet paper packaging. Often laminated with plastic film.

White Cardboard: Higher thickness and stiffness, providing better physical protection, often used for packs with more rolls and heavier weight.

Kraft Paper: High strength and an environmentally friendly, rustic visual style, suitable for products emphasizing "natural" or "eco-friendly" concepts. Can be divided into natural kraft paper and bleached kraft paper.

2.2 Functional Layer: Barrier and Protection

Single paper often cannot meet all requirements, so composite technology is commonly used.

Plastic Film: The most commonly used are Polyethylene (PE) or Polypropylene (PP) films. They are combined with paper through dry lamination or solvent-free lamination processes, providing excellent moisture barrier and certain anti-tear strength. PE film is also commonly used to make the heat-seal layer of the packaging bag.

Aluminum Foil (AL): For high-end products with extremely high requirements for moisture, light, and oxygen barrier, aluminum foil-containing composite materials are used. However, due to high cost and difficulty in recycling, its application in toilet paper packaging is relatively limited.

2.3 Eco-friendly Material Trends

With the deepening of sustainable development concepts, the application of the following materials is becoming increasingly widespread:

Recyclable Polyethylene (PE): Using single-material PE film facilitates post-consumer sorting and recycling.

Biodegradable Plastics: Such as Polylactic Acid (PLA), derived from renewable plant resources, can completely degrade under specific conditions.

Water-based Inks and Eco-friendly Adhesives: Reduce the emission of Volatile Organic Compounds (VOCs) during the production process.

Chapter 3: Core Manufacturing Process Flow – From Roll Material to Finished Product

This is the core link that transforms the design blueprint into a physical product.

3.1 Printing

Select the appropriate printing method based on order quantity and quality requirements:

Gravure Printing: High printing precision, saturated and bright colors, strong sense of depth, especially suitable for large-scale, long-run printing. It is the mainstream printing method for toilet paper packaging bags. High plate-making cost, but low unit cost for large print runs.

Flexographic Printing: Often uses water-based inks, more environmentally friendly, printing quality has greatly improved in recent years, increasing application in the mid-to-high-end market.

Digital Printing: No need for plates, low minimum order quantity, enables variable data printing, very suitable for small-batch customization and proofing.

3.2 Lamination

Firmly combine the printed base layer with the functional layer (e.g., PE film) using adhesive. Modern processes mostly use solvent-free lamination due to its environmental friendliness, safety, and the good softness of the laminated product.

3.3 Curing

Place the laminated material into a curing room where, under specific temperature and time, the adhesive fully cross-links and cures, achieving the final laminate strength.

3.4 Bag Making

This is the final forming step, completed by a fully automatic bag-making machine.

Unwinding: Mount the laminated roll material onto the machine.

Web Guiding: Ensure the roll material does not deviate during travel.

Folding: Fold the roll material to the predetermined width.

Bottom Heat Sealing: Fuse the PE heat-seal layer through heat and pressure to form the bag bottom.

Back Sealing: Form the center seam of the bag.

Punching: Create hand holes (if needed).

Cutting: Cut into individual packaging bags according to the set length.

Counting and Stacking: Finished bags are automatically counted and stacked neatly, ready for shipment.

Chapter 4: Quality Control and Testing – The Lifeline of Quality

Strict quality control must be implemented throughout the entire production process.

Raw Material Inspection: Test incoming paper, film, etc., for grammage, thickness, tensile strength, etc.

Printing Quality Inspection: Use densitometers, colorimeters, and other tools to check if colors match the standard, and for issues like misregistration or spots.

Laminate Strength Test: Use a peel strength tester to check the bonding force between layers.

Heat Seal Strength Test: Ensure the seal edges are strong and will not split during transportation and handling.

Sealing Performance Test: Perform pressure or vacuum tests on finished bags to ensure no leakage points.

Drop Test: Simulate drops during transportation and handling to test the protective performance of the packaging bag.

Chapter 5: Future Prospects and Innovation

The development of toilet paper packaging bags is evolving towards smarter and more sustainable directions.

Intelligentization: Introduce QR codes to connect online content, enabling product traceability, promotional interaction, or providing usage tips.

Lightweighting: Reduce material usage while ensuring performance, achieving plastic and paper reduction at the source.

Circular Economy: Establish more comprehensive packaging recycling systems and actively explore "refillable" packaging models.

Conclusion

Creating a seemingly simple toilet paper packaging bag is actually a systematic engineering project that integrates materials science, mechanical engineering, visual communication, and market insight. From precise preliminary design to the rigorous control of each production process, and the quality monitoring throughout, the continuous improvement in every link collectively forges the final packaging artifact that is both practical and aesthetically pleasing, presented in the hands of consumers. In an increasingly competitive market environment, a deep understanding and continuous innovation in packaging manufacturing processes have become an important part of building a brand's core competitiveness.