Industrial Implementation of Digital Twin in the Tissue Paper Converting System

The tissue paper converting system involves critical stages, including unwinding, embossing, folding, stacking, cutting, and packaging. Despite its maturity, challenges such as production interruptions during roll changes, equipment coordination issues, and unstable packaging speeds persist, affecting overall efficiency. While existing methods like fast roll change mechanisms and automated speed regulation systems have improved individual equipment performance, they fall short in achieving system-wide optimization. This paper proposes a digital-twin-based framework for the tissue paper converting system. High-precision simulation models are developed for key equipment, including the base paper roll stand, folding machine, paper stacker, and packaging machine, enabling real-time system monitoring and prediction. Key performance indicators such as base paper availability, folding speed, stacking status, and packaging progress are effectively predicted, preventing interruptions and reducing downtime. The proposed framework was validated in a real-world application at a Chinese paper manufacturing company. Results show that it increases machine runtime by 3 h per day, improving production efficiency by 15%. This leads to an additional daily output of 35,000 packs, contributing approximately CNY 85,000 in revenue growth. Additionally, the system helps prevent 300 kg of base paper waste daily, saving CNY 600 in manufacturing costs per day.