Efficiency and Flexibility in Underpad Production: Fresh Insights from the AURA-UP Quick Check
AURA-UP, a next-generation machine for the production of disposable underpads, is increasingly being recognized for its efficiency, versatility, and ability to handle demanding production environments. A recent Quick Check survey provided insights into common industry practices and highlighted where AURA-UP is a benchmark for technology leadership.
Drum Change: From Half an Hour to Minutes
The survey revealed that > 80% of producers need longer time than AURA-UP. Almost 60% even need 30+ minutes for a drum changeover. Such downtimes translate into significant productivity losses. By contrast, the AURA-UP enables changeovers in under 15 minutes, with streamlined processes that reduce operator strain and free up valuable capacity.
Energy Efficiency at High Speeds
Energy use is more critical than ever. While almost 60% of production lines report vacuum-system demands of 51-150 kW at full speed, AURA-UP achieves high-speed performance at consumption levels below 50 kW. This balance between productivity and efficiency offers manufacturers a tangible way to control rising energy costs without compromising on output.
Speed and Stability
Production speeds varied widely among respondents, with many systems plateauing between 200-350 products per minute. Only about 20% reported exceeding 500 products per minute. AURA-UP is engineered to run well 500 products per minute for standard 600×600 mm underpads—delivering consistent quality even at high volumes.
Flexibility Without Compromise
In terms of product versatility without need of changing parts, most manufacturers remain limited: half can only manage 1-2 lengthfold types without part changes, and over 40% are restricted to only 1 embossing pattern. The AURA-UP platform extends this significantly, supporting multiple lengthfolds and embossing options without any part change. This flexibility allows producers to diversify their portfolios and respond more quickly to customer needs.
Material Handling Across Weight Ranges
When it comes to fluff-core weights, 1/3 of survey participants reported a limitation of 41-60+ gsm, whereas 50% are able to run lighter cores down to 20 gsm at full speed. AURA-UP, however, is especially designed for low-weight cores even below 20 gsm and with unmatched homogeneity of the core —opening opportunities for material savings paired with premium quality.
Industry Outlook
The Quick Check results underscore a simple truth: many existing lines still struggle with energy consumption, long changeovers, high core weights and limited flexibility. AURA-UP directly addresses these pain points, offering underpad manufacturers a pathway to higher productivity, lower costs, better products and faster response to shifting market demands.
Learn more about the AURA-UP system on our product page.
Under the banner of our industry-leading Winkler+Dünnebier (W+D) brand, BW Converting engineers and manufacturers machinery for the envelope and direct mail converting, printing and inserting, as well as e-commerce mailing bag markets. We also manufacture machinery for converting and precise processing of thin and sensitive materials at high production speeds, such as folded tissue handkerchiefs, facial tissues, baby diapers and pants, feminine hygiene, light incontinence products, adult diapers and pants and underpads.
Auszubildende (Germany only)
BW Converting designs and manufactures precision machinery for Tissue, Hygiene, Print, Packaging, Mailing, Textiles and other high-performance Industrial applications. We unify our product brands Paper Converting Machine Company (PCMC), Winkler+Dünnebier (W+D), Baldwin Technology Co., Hudson-Sharp, STAX Technologies, and Northern Engraving and Machine under one global organization.