Manufacturers entering the wipes industry often compare dry wipes machines and wet wipes machines during the early stages of a project. At first glance, the two products seem very similar. Both are made from nonwoven fabric, both are folded into stacks, and both are packaged into convenient consumer products. Because of these similarities, many people assume that the same production line can be used to produce both dry wipes and wet wipes.
However, once we look beyond the finished product and examine the manufacturing process itself, the differences become much more significant. From folding technology and counting methods to packaging requirements and machine construction, dry wipes and wet wipes are produced in very different ways. Understanding these differences is essential when selecting equipment or planning a new production project.
Different Production Processes
The biggest difference between dry wipes and wet wipes machines begins with the production process itself.
A typical dry wipes production line follows the process below:
Nonwoven Unwinding → Cross Cutting → Folding → Counting & Stacking → Stack Separation & Output → Slitting → Packaging
In a dry wipes machine, the nonwoven fabric is first unwound and cut to the required folding length. The material then enters the folding section, where sheets are continuously folded and stacked. After the required sheet count is reached, the stacks are separated, slit if necessary, and transferred to the packaging system.
A wet wipes production line follows a completely different process:
Nonwoven Unwinding → Lane Folding → Fabric Conveying → Lane Combining → Liquid Application → Length Cutting → Stacking & Counting → Packaging → Lid Applying
Unlike dry wipes production, wet wipes manufacturing introduces liquid application as a key process step. This addition affects not only the machine configuration but also the entire production logic. Once moisture is introduced, manufacturers must consider liquid dosing accuracy, moisture consistency, hygiene requirements, sealing performance, and product shelf life.
Although both production lines begin with nonwoven fabric and end with packaged wipes, the journey in between is very different.
Machine Configuration Differences
Because of the different production processes, the equipment required for each type of product is also different.
Both dry wipes and wet wipes machines require core functions such as folding, cutting, counting, stacking, and packaging. However, wet wipes production requires several additional systems that are not needed for dry wipes manufacturing.
These typically include:
- Liquid application system
- Liquid storage and mixing tanks
- Pumps and pipelines
- Moisture control system
- Airtight packaging system
- Lid applying system
The addition of these systems increases both machine complexity and project investment.
Another important difference is machine construction. Since wet wipes production involves continuous contact with liquids, many machine components are manufactured from stainless steel to improve hygiene, simplify cleaning, and prevent corrosion. Dry wipes production does not face the same requirements, allowing a simpler machine structure in many areas.
For many investors, this is the first major difference they notice when comparing the two types of equipment.
Folding Technology: Similar Results, Different Methods
Although both products appear folded inside the final package, the folding methods used by the machines are fundamentally different.
Traditional wet wipes machines usually rely on folding plates or forming devices. As the nonwoven material travels through the machine, it is gradually folded into the desired shape. Depending on the product design, the machine may produce V-fold, Z-fold, W-fold, or other folding formats. Multiple narrow lanes are folded separately before being combined later in the production process.
Dry wipes machines use a completely different approach.
Instead of folding plates, dry wipes folding is typically achieved through a combination of vacuum adsorption technology and rotating folding rollers. The coordinated movement of the rollers continuously folds the material while maintaining stable production speed and accurate sheet positioning. More significantly, dry wipes folding machine can achieve interfolded or somebody called interlock in this way, which is what wet wipe machines cannot do.
Therefore, the final folded products may look similar to consumers, but the mechanical principles behind them are entirely different.
Different Counting and Stacking Logic
Another important difference can be found in the counting and stacking process.
For wet wipes production, the sheet count is largely determined by the number of folded lanes entering the machine simultaneously. For example, a 20-lane wet wipes machine produces 20 sheets during each cutting cycle. If the final product requires 100 wipes per pack, the machine must accumulate five cutting cycles before the stack is complete and ready for packaging.
In other words, the sheet count is closely related to the number of lanes and the stacking cycles.
Dry wipes production uses a different logic. The machine controls stack quantity through servo systems, PLC programs, and the operating timing of the folding rollers. By accurately controlling the separation point between stacks, the machine can automatically produce the required sheet count without relying on multiple folded lanes.
Both systems can achieve accurate counting, but the way they reach that result is very different.
Packaging Requirements
Packaging is often where the differences become most visible.
Dry wipes packaging is relatively straightforward. Manufacturers commonly use tubular film bags or pre-made bags. The packaging process usually consists of bag opening, product insertion, and sealing. Since the product does not contain liquid, airtight sealing is not a critical requirement. In many cases, a simple tear line is sufficient for consumer convenience.
Wet wipes packaging is considerably more demanding.
Most wet wipes products use flow wrap packaging made from roll film. During packaging, the film may require punching, labeling, and precise sealing operations. Because the product contains moisture, maintaining package integrity is essential. Poor sealing can lead to moisture loss, reduced product quality, and shorter shelf life.
After packaging, many wet wipes products also require an automatic lid applying process. The lid helps preserve moisture after opening and improves the consumer experience.
As a result, wet wipes packaging systems are generally more complex than dry wipes packaging systems and often operate under stricter quality requirements.
Can One Machine Produce Both Dry and Wet Wipes?
So now, going back to our initial question, for traditional wet wipes machines, the answer is generally no.
However, market demands are changing. More manufacturers are looking for flexible equipment that can reduce investment risk and expand product offerings without purchasing multiple production lines.
Conclusion
Dry wipes and wet wipes may start with the same nonwoven material, but they are produced using very different manufacturing processes.
Understanding these differences is important not only when selecting equipment, but also when evaluating project costs, production requirements, and future product plans.
The good news is that technology continues to evolve. While traditional wet wipes machines cannot normally produce dry wipes products, new equipment concepts are beginning to challenge this limitation. In our next articles, we will introduce a newly developed production line capable of producing both dry wipes and wet wipes on a single platform, offering manufacturers greater flexibility and investment efficiency. Please stay tuned.
