WIPE ROLL LEADER

Abstract

A wipe roll includes a length of connected wipes, wherein each wipe is separated from adjacent wipes by a perforation, wherein the length of connected wipes can be torn at a given perforation to separate one or more wipes from the length of wipes, wherein the length of wipes is wrapped concentrically into a roll having an innermost wipe positioned at a center of the roll and an outermost wipe positioned at an exterior of the roll, wherein the innermost wipe comprises a leader distinguishing the innermost wipe from other wipes of the length of connected wipes, wherein the leader is configured to indicative of a location of the innermost wipe to a user.

Claims

1. A wipe roll comprising: a length of connected wipes, wherein each wipe is separated from adjacent wipes by a perforation, wherein the length of connected wipes can be torn at a given perforation to separate one or more wipes from the length of wipes, wherein the length of wipes is wrapped concentrically into a roll having an innermost wipe positioned at a center of the roll and an outermost wipe positioned at an exterior of the roll; wherein the innermost wipe comprises a leader distinguishing the innermost wipe from other wipes of the length of connected wipes, wherein the leader is configured to indicative of a location of the innermost wipe to a user.

2. The wipe roll of claim 1, wherein the wipes comprise one or more of polyester, polypropylene, cotton, wood pulp, bamboo, seaweed substrate, hemp, or rayon.

3. The wipe roll of claim 1, wherein the leader comprises a material different from a material of the wipes.

4. The wipe roll of claim 3, wherein the leader comprises a material configured to provide a grip for the user.

5. The wipe roll of claim 3, wherein the leader comprises a wax that is stamped onto a portion of the innermost wipe.

6. The wipe roll of claim 5, wherein the stamped portion of the innermost wipe comprises a corner of the innermost wipe.

7. The wipe roll of claim 5, wherein the stamped portion is more rigid than the innermost wipe.

8. The wipe roll of claim 1, wherein the leader comprises an elongated spindle configured to be grabbed by the user, wherein at least a portion of the elongated spindle is disposed in a central cavity defined by the wipe roll.

9. The wipe roll of claim 1, wherein the leader extends outwardly from a corner of the innermost wipe.

10. The wipe roll of claim 1, wherein the leader is flush with an edge of the innermost wipe.

11. The wipe roll of claim 1, wherein the leader is more rigid than the wipes.

12. The wipe roll of claim 1, wherein the leader is attached to the innermost wipe by an adhesive.

13. The wipe roll of claim 1, wherein the leader is attached to the innermost wipe by stitching.

14. The wipe roll of claim 1, wherein the spindle is attached to the innermost wipe by a mechanical connection.

15. The wipe roll of claim 1, wherein at least a portion of the leader is a different color than the innermost wipe.

16. The wipe roll of claim 1, wherein the leader comprises a colored indicia on a portion of the innermost wipe.

17. The wipe roll of claim 1, wherein the leader comprises a cut on a portion of the innermost wipe.

18. A system comprising: a wipe roll comprising: a length of connected disposable cleaning wipes, wherein each wipe is separated from adjacent wipes by a perforation, wherein the length of connected wipes can be torn at a given perforation to separate one or more wipes from the length of wipes, wherein the length of wipes is wrapped concentrically into a roll having an innermost wipe positioned at a center of the roll and an outermost wipe positioned at an exterior of the roll; wherein the innermost wipe comprises a leader distinguishing the innermost wipe from other wipes of the length of connected wipes, wherein the leader is configured to indicative of a location of the innermost wipe to a user; and a reusable container housing the wipe roll, wherein the wipe roll is positioned in the reusable container such that the leader of the innermost wipe is accessible via a spout of the reusable container.

19. The system of claim 18, wherein the wipes comprise one or more of polyester, polypropylene, cotton, wood pulp, bamboo, seaweed substrate, hemp, or rayon.

20. The system of claim 18, wherein the leader comprises a material different from a material of the wipes.

Description

DESCRIPTION OF DRAWINGS

[0059] FIGS. 1A-E are views of a roll of wipes with an example leader.

[0060] FIG. 2A and B are views of a wipes with an example leader.

[0061] FIG. 3 is a view of a wipe with an example leader.

[0062] FIG. 4 is a view of a production line for rolls of wet wipes sealed in a film packaging.

[0063] FIG. 5 is a view of another production line for rolls of wet wipes sealed in a film packaging.

[0064] FIG. 6 is a view of another production line for rolls of wet wipes sealed in a film packaging.

[0065] FIGS. 7 and 8 are flow charts.

DETAILED DESCRIPTION

[0066] The present disclosure provides systems, devices, and methods for easily identifying a wipe at the center of a roll of disposable, perforated wipes, such as cleaning wipes or personal hygiene wipes. A leader provided on the wipe at the center of the roll of wipes (referred to as the innermost wipe) indicates the innermost wipe to a user, and in some cases can provide easy accessibility to the user to grip the innermost wipe. This configuration allows the user to easily identify the innermost wipe, facilitating use of the wipe roll.

[0067] In more detail, the wipe rolls described here are designed for use with reusable wipe containers. A wipe roll is placed in the reusable wipe container, and when the wipe roll is used up, a user restocks the container with a new wipe roll. Such wipe containers have a spout in their lid, e.g., towards the center of the lid, through which wipes are dispensed. When a wipe roll is disposed in a reusable container, the innermost wipe of the wipe roll is substantially aligned with the position of the spout. For smooth operation, wipes are dispensed from the roll and through the spout starting from the innermost wipe of the roll. If wipes instead were to be dispensed starting from the exterior of the roll, the misalignment between the wipe and the spout would cause difficulties in dispensing the wipes, e.g., the wipe may tear or get stuck, frustrating the user and potentially wasting wipes.

[0068] In a tightly wrapped wipe roll, it may be challenging to identify the innermost wipe, thus making it difficult for a user to thread that innermost wipe through the spout of the reusable wipe container. To assist the user in identifying the innermost wipe, a leader is provided on the innermost wipe. The leader is an easily visible element that indicates the location of the innermost wipe to the user, allowing the user to readily identify the innermost wipe when filling/refilling a reusable container with a fresh wipe roll. That is, the presence of the leader streamlines the refill process, enhancing user experience and thereby encouraging continued use of environmentally friendly refillable wipe containers. In some examples, the leader also provides a grippable surface (e.g., a surface that is less slippery than the wipes themselves) that facilitates threading that innermost wipe through the spout.

[0069] FIGS. 1A-E illustrate a process of refilling a reusable wipe container 100 with a roll of wipes 102. The roll of wipes 102 includes a length of connected disposable wipes, such as cleaning wipes or personal hygiene wipes, that are connected to one another by perforations (e.g., as in a roll of paper towels).

[0070] The length of wipes is wrapped concentrically to form the roll 102, such that an innermost wipe of the length is positioned at the center of the roll and an outermost wipe is positioned at an exterior of the roll. A leader 104 is attached to the innermost wipe at the center of the roll 102 to clearly indicate the identity and location of the innermost wipe and to provide a grip that allows the user to easily grab to pull the innermost wipe.

[0071] The wipes can be formed of, e.g., cotton, polyester, polypropylene, wood pulp, rayon fibers, cellulosic materials, bamboo, hemp, seaweed based substrates, and/or other suitable disposable materials. In some implementations, the wipes can be treated with softeners, lotions, perfumes, water, alcohol (e.g., isopropyl alcohol), preservatives (e.g., methylisothiazolinone), and/or other liquids depending on the desired use of the wipes.

[0072] The wipe container 100 is a generally cylindrical container that is sized to receive the roll of wipes 102. The size of the roll of wipes 102 depends on a target use case for the wipes a roll of industrial cleaning wipes is generally larger than a roll of wipes for household cleaning or personal hygiene use. For instance, a roll of wipes can include, e.g., 25 wipes, 50 wipes, 100 wipes, 250 wipes, 500 wipes, or another suitable number. The wipe container has a diameter sufficient to receive a corresponding roll of wipes, e.g., a diameter of about 3 inches, 4 inches, 6 inches, 10 inches, 12 inches, 18 inches, 24 inches, 50 inches, or another suitable diameter. The wipe container 100 is reusable, meaning that when one roll of wipes is used up, the container itself need not be discarded, but instead can be refilled with a new roll of disposable wipes. For instance, wipe container can be formed of, e.g., plastics, ceramics, metals, and/or other reusable materials.

[0073] Referring to FIGS. 1B and 1C, a lid 106 of the container has a spout 108 at the center of the lid 106. Also illustrated is the roll of wipes 102 being stored within the wipe container 100. When the roll 102 is placed into the wipe container 100 and the lid 106 is closed onto the container 100, the center of the roll of wipes 102 is substantially aligned with the spout 108. The leader 104 provides a way for the user to quickly identify the innermost wipe of the roll 102 so that he or she can easily thread that innermost wipe through the spout 108. Specifically, the user can grasp the leader, which is attached to or otherwise formed on the innermost wipe of the roll. Grasping and pulling on the leader, e.g., pulling the leader through the spout 108, thus also threads the innermost wipe through the spout such that the roll is fully loaded in the container. Pulling the innermost wipe through the spout is advantageous because in some implementations, pulling a different wipe (e.g., the outer wipe) through the spout jams the container. In a reusable container, the nature of the packaging of the wipes provides the user an options to grab the outermost wipe or the innermost wipe. In this case, a leader can cause a user to grab the innermost wipe rather than an outermost wipe.

[0074] In the example illustrated in FIGS. 1A-1C, the leader 104 is a rigid element that protrudes beyond the top of the roll 102 even before the user has grasped the leader. With this configuration, when the roll 102 is inserted into the wipe container 100 and the container lid 106 is closed onto the container 100, the leader 104 already extends through the opening 108 in the container lid 106. The user simply grasps and pulls the leader, which pulls the innermost wipe 100 (see FIG. 1D) through the spout 108. The presence of the leader makes the innermost wipe immediately visible and accessible, helping the user to avoid pulling a different wipe (e.g., a wipe at the edge of the roll or an intermediate wipe) through the spout as the first wipe of the roll. In some implementations, the leader 104 extends through the opening 108 because the leader is taller than the container 100. The base of the container 100 pushes the leader 104 through the opening 108 of the container lid 106. In addition to identifying the innermost wipe, this removes the need of the user to try and thread the innermost wipe through the spout, which can be difficult and frustrating. The leader 104 also allows the user to easily pull only the innermost wipe (e.g., rather than multiple wipes) through the opening 108 of the container lid 106.

[0075] Referring to FIG. 1E, once the innermost wipe 110 is threaded through the spout 108, the user can pull the innermost wipe 110 out and tear it at the perforation linking it to the remainder of the wipes in the roll. This then threads the next wipe 112 through the spout 108 so that the user can continue to grab wipes easily until the roll of wipes 102 is depleted. At that point, the user can place a new roll of wipes into the reusable container 100.

[0076] In some embodiments, the roll of wipes can be packaged in a flexible film (e.g., formed of aluminum, plastic, etc.) that is lighter and cheaper than typical plastic tubing. In some implementations, the packaging can be environmentally sustainable, e.g., by including recyclable materials. The packaging can protect the roll of wipes 102 from damage and degradation, along with holding the absorbed liquid within the wipes (e.g., by preventing the liquid from evaporating). In some implementations, the roll of wipes can be packaged in a pouch. For example, the pouch can have a flexible gusset on the bottom, flexible sides, and a seal on top. The pouch can be formed of a flexible material, e.g., aluminum, plastic, etc., that is lighter and cheaper than typical plastic tubing. In some implementations, the top of the pouch can be resealable (e.g., through adhesives, snap-fit connections, or a zipper closure).

[0077] FIG. 1E illustrates an example implementation of the leader 104. In this example, the leader 104 is a rigid spindle, e.g., a wooden or plastic spindle, having a length that is similar to the height of the roll of wipes 102. For instance, the spindle has a length that is between 50% and 120% of the height of the roll of wipes. When assembled (see, e.g., FIG. 1A), an end portion 120 of the spindle protrudes beyond the top of the roll of wipes 102, and an elongated body portion 122 of the spindle is disposed in a central cavity of the roll of wipes. The leader 104 is attached to a corner of the innermost wipe 110, e.g., by an adhesive, stitching, a mechanical connection such as a snap or rivet, or another suitable connection. In some implementations, the spindle 104 may be attached to other portions of the innermost wipe (e.g., a center of the innermost wipe, a length along the innermost wipe, etc.). In the illustrated example, the spindle is colored differently than the wipes to draw the user's attention. The rigidity of the spindle provides a gripping surface that helps the user to grasp the spindle to draw the innermost wipe 110 through the spout 108.

[0078] FIGS. 2A-2B illustrate another implementation of a leader 204 identifying an innermost wipe 210 at the center of a roll of wipes 200. The leader 204 is a flexible tag that is attached to the innermost wipe 210, e.g., by adhesive, stitching, or another flexible attachment mechanism. For instance, the tag is formed of fabric, e.g., the same fabric as the wipes or a different fabric. For example, the wipes 200 can be formed of, e.g., cotton, polyester, polypropylene, wood pulp, rayon fibers, cellulosic materials, bamboo, hemp, seaweed based substrates, and/or other disposable materials. The tag 202 can also be formed of, e.g., cotton, polyester, polypropylene, wood pulp, rayon fibers, cellulosic materials, bamboo, hemp, seaweed based substrates, and/or other disposable materials, but may be a different material than the roll of wipes 200. In some examples, the tag is string, yarn, or another elongated, substantially 2-dimensional material.

[0079] In the illustrated example, the tag 204 is attached to a corner of the innermost wipe 210. In some examples, the tag 204 is attached elsewhere on the innermost wipe 210, such as along an edge. The tag extends beyond the edge of the innermost wipe 210 such that it protrudes beyond the top of the roll of wipes 202. For instance, As also illustrated, the tag is brightly colored (e.g., a different color than the innermost wipe 210) to attract the attention of the user.

[0080] FIG. 3 illustrates another implementation of a leader 304 identifying an innermost wipe 310 at the center of a roll of wipes 300. In this example, the leader 304 is an element that is flush with the edges of the innermost wipe 310, e.g., such that the leader 304 substantially does not extend beyond the edges of the wipe. When the leader 304 is an element that is flush with the edges of the innermost wipe 310, the leader does not immediately extend through the spout of the container lid (e.g., as it does in the implementation of FIGS. 1A-1E). Instead, the user grasps the leader and pulls to extend the corner of the innermost wipe 310, and manually threads the corner through the spout.

[0081] In some instances, the leader 304 is a corner of the innermost wipe 310 that is dyed a color different from the color of the rest of the wipe.

[0082] In some instances, the leader 304 is an additional piece of material (e.g., fabric or a rigid material such as wax, wood, plastic, or another suitable material) that is attached to the corner of the innermost wipe 310 and that can be of a different color than the rest of the wipe. The rigid additional piece of material can be attached to the innermost wipe, e.g., by an adhesive, stitching, a mechanical connection such as a snap or rivet, or another suitable connection. In one example, the rigid material can include a wax that is stamped into place on the corner of the innermost wipe 300.

[0083] In another implementation, the leader 304 is a portion of the innermost wipe 310 that is starched or otherwise made more rigid via hardening. For example, starching a portion of the innermost wipe 310 makes the starched portion (i.e., the leader 304) more rigid than the unstarched portions of the innermost wipe 310.

[0084] Other examples of leaders are also possible. For instance, a leader can be a cut in the innermost wipe (e.g., in the corner of the wipe) to distinguish the corner. Implementations without additional materials (e.g., a colored corner or a cut corner) can be efficient and simple to implement while producing the roll of wipes.

[0085] FIG. 4 illustrates a production line 400 for wetting and packaging a roll of wipes 402.

[0086] The roll of wipes 402 is formed into a roll prior to entering the production line 400. For instance, the roll of wipes 402 is formed from a length of material that is perforated into individual wipes. The wipes can be formed of, e.g., cotton, polyester, polypropylene, wood pulp, rayon fibers, cellulosic materials, bamboo, hemp, seaweed based substrates, and/or other suitable disposable materials. A roll of wipes can include, e.g., 25 wipes, 50 wipes, 100 wipes, 250 wipes, 500 wipes, or another suitable number, e.g., depending on its intended use. For instance, the size of a roll of industrial cleaning wipes is generally larger than a roll of wipes for household cleaning or personal hygiene use.

[0087] The roll of wipes 402, in a dry state, are placed into the production line 400 by workers or automatically (e.g., via production machinery). The roll of wipes 402 is moved through the production line 400 on a conveyor, where the roll of wipes 402 is wetted with a liquid formulation 404 in a wetting station 410 and packaged in a packaging station 420.

[0088] The liquid formulation 404 is produced and/or stored within a formulation container 406. The liquid can include, e.g., softeners, lotions, perfumes, water, alcohol (e.g., isopropyl alcohol), preservatives (e.g., methylisothiazolinone), and/or other liquids depending on the desired use of the wipes.

[0089] The liquid formulation 404 is fed through tubing 408 to reach a wetting station 410. As illustrated, the wetting station 410 includes a formulation bath 412 and shower heads 414, although in some examples the wetting station 410 may include only one or the other. The shower heads 414 spray liquid 404 onto the roll of wipes 402 from above as the roll of wipes 402 is transported through the wetting station 410 on the conveyor. At the same time, the roll of wipes is at least partially submerged in the formulation bath 412 to increase the amount of liquid contacting the roll of wipes at once. At least partially submerging the wipes can include, e.g., fully submerging the wipes, submerging the wipes halfway, running the wipes along the surface of the liquid formulation, etc. Submerging the roll of wipes 402 in the formulation bath 412 while concurrently showering the roll of wipes 402 with the shower heads 414 increases the amount of liquid absorbed by the wipes 402. In some implementations, the roll of wipes 402 can pass by the shower heads 414 and the formulation bath 412 separately (i.e., not simultaneously, as illustrated in FIG. 4). In some implementations, the wetting station 110 can recirculate formulation through the formulation bath 412 and shower heads 414.

[0090] The amount of time the roll of wipes 402 spends in the wetting station 410 is sufficient to allow the wipes 402 to become sufficiently saturated with the liquid formulation for their target purpose (e.g., to hold a sufficient amount of liquid to fit the desired purpose, such as cleaning, moisturizing, etc.). In some implementations, the wipes 402 are not fully saturated. In some implementations, the wet wipes 402 can be in contact with the liquid until the wet wipes 402 absorb a threshold amount of liquid (e.g., a threshold less than full saturation). For example, the wetting station 410 can produce, e.g., 25-30 wipes per minute.

[0091] Once the roll of wipes 402 passes through the wetting station 410, the wet roll of wipes 402 is transported to the packaging station 420 to package the wet roll of wipes 402, e.g., into flexible packaging, producing a packaged roll 402. The packaging station 420 include a wrapper 422 that places the wet roll of wipes 402 into packaging. The wrapper 422 can include, e.g., a flow wrapping machine, stretch wrapping machine, shrink wrapping machine, etc. For example, the wrapper 422 can form the packaging from a packaging material and place the wet roll of wipes 402 into the packaging material in a continuous, automatic operation. The packaging material directly contacts the outermost wipe(s) forming the exterior of the roll and holds the moisture within the roll of wipes.

[0092] In some implementations, the wrapper 422 includes a flow rapper in which the wet wipes 402 enter the flow wrapper on a conveyor belt. A continuous roll of film is distributed from underneath to lay onto the conveyor surface where the wet wipes 402 lay on top of the film. The film is folded up from the sides using fins as the roll and film travel along the conveyor.

[0093] The packing line 420 also includes a sealer 424 that seals the packaging around the wet roll of wipes 402. For example, the sealer 424 can include a heat sealing machine, an ultrasonic sealing machine, an adhesive sealing machine, etc. Once the sealer 424 seals the packaging around the wet roll of wipes 402, the packaged roll 402 is ready to be shipped to the consumer. The consumer can open the packaged roll 402 for use, e.g., within a reusable dispenser.

[0094] In some implementations, the sealer 424 can include a heat sealing machine that simultaneously seals the top edge, bottom edge, and back fin of the film around the wet wipes 402. At the same time the film is heat sealed around the wet wipes, a cutter blade cuts the completed wipe package from the continuous film roll. In some implementations, a blade can add a tear notch on the wipe package to make it easier to open the film packaging and access the wet wipes 402. In some implementations, the packaging station 420 can produce, e.g., 100 units per minute.

[0095] The packaging can be inexpensive to produce and ship. For example, the packaging can include a flexible film (e.g., formed of aluminum, plastic, etc.) that is lighter and cheaper than typical plastic tubing. In some implementations, the packaging can be environmentally sustainable, e.g., by including recyclable materials. The packaging can protect the roll of wipes 402 from damage and degradation, along with holding the absorbed liquid within the wipes (e.g., by preventing the liquid from evaporating).

[0096] As described above, in some implementations, the roll of wipes 402 are moved through the production line automatically. For example, the production line 400 can include conveyor belts, rollers, etc. to move the roll of wipes 402 through the production line 400 mechanically. In other implementations, a worker can move the roll of wipes 402 through each station of the production line.

[0097] In some implementations, wetting the roll of wipes (e.g., via the wetting station 410) takes longer than packaging the roll of wipes (e.g., via the packaging station 420). This can depend on, e.g., the liquid being used for wetting, the size of the wipes, the material of the wipes, the threshold for liquid absorption, etc. In some examples, the wetting station can form a bottleneck in the production line. In such a case, the wetting station can be expanded (e.g., increased in length) to reduce likelihood of a bottleneck occurring.

[0098] FIG. 5 illustrates a production line 500 having an expanded wetting station 510. For example, the wetting station 510 is extended lengthwise (as illustrated by double arrow 550) as compared to the wetting station 410 of FIG. 4. In some implementations, an expanded wetting station 510 can increase (e.g., double, triple, etc.) production speed. Extending the wetting station 510 allows the roll of wipes to pass through the formulation liquid over a greater distance. This can allow wipes to move at a greater speed while remaining in the liquid for the same amount of time. Because the wipes are moving at a greater speed, they can reach the packaging station 520 at a rapid rate, removing the bottleneck in the production line that may have been caused by a shorter wetting station line. In some implementations, the production line can include multiple wetting stations. The length of the wetting station can be proportional to the speed of the packaging station (e.g., such that the wetting station and the packaging station produce units at the same rate, e.g., 100 units per minute).

[0099] A liquid formulation 504 is produced and/or stored within a formulation container 506. The liquid formulation 504 is fed through tubing 508 to reach the expanded wetting station 510. As illustrated, the wetting station 510 includes a formulation bath 512 and shower heads 514, which function as discussed above for FIG. 4, although in some implementations, the wetting station 510 includes only one or the other.

[0100] The wetting station 510 is expanded relative to the wetting station 410 of the production line 400, as described above. For example, the wetting station 510 is extended lengthwise (e.g., illustrated by the double arrow 550). The wetting line 510 can be, e.g., double, triple, or quadruple the length of the wetting station 410 of production line 400. This can allow the wipes to pass through the liquid over a greater distance, as described above. The wetting line 510 also includes more shower heads 514 than the wetting station 410 of the production line 400. For example, the wetting station 510 includes twice as many shower heads 514 relative to the wetting station 410 of the production line 400. In some implementations, the wetting station 510 can include more shower heads 514, e.g., triple or quadruple the number of shower heads. Increasing the number of shower heads increases the amount of liquid in contact with the wipes 502, which increases the absorption rate.

[0101] Once the wet roll of wipes 502 pass through the wetting line 510, the wet wipes 502 pass to the packaging station 520 to package the wet wipes 502, e.g., using a wrapper 522 and a sealer 524, which function as discussed above for FIG. 4, resulting in a packaged roll of wet wipes 502.

[0102] Production line 400 and production line 500 are described as implementations after wipes are perforated and formed into rolls, e.g., to be placed in a film packaging. However, in some implementations, a production line can wet wipes during the process of forming the wipes and rolls of wipes from a base material.

[0103] FIG. 6 illustrates a production line 600 that includes a formation station 650 which forms wipes from a large base roll 652 of material, e.g., by cutting and/or perforating the material from the large roll. For example, the large roll 652 can include, e.g., cotton, polyester, polypropylene, wood pulp, rayon fibers, and/or other disposable materials. In some examples, the large roll 652 is considered a base material that has a width that corresponds to the width of the ultimate wipes, but that is not yet perforated into individual wipes. In some examples, the large roll 652 has a width that is wider than the width of the ultimate wipes. One advantage of the production line 600 is the ability to control the amount of fluid soaked into the wipes. For example, the production line 600 can include wetting the substrate at a single layer level, which allows for faster absorption and controlled distribution of liquid. Once a single layer of substrate passes through the production line, the substrate can be rolled continuously into smaller individual rolls.

[0104] In the production line 600, a wetting station 610 is included as a part of the formation line 650. Unlike the production lines 400 and 500, which included respective wetting stations after formation of the individual wipes, the wetting station 610 wets wipe material from the base roll 652 (e.g., at a single layer level, i.e., a single layer of substrate) prior to layering/perforation/cutting of the material into wipes. Wetting the substrate at a single layer level allows for distribution at every level of the wipe roll, increasing the speed of the wetting process to, e.g., match the speed of the packaging station. This can also allow for automatic transferring throughout the production line 600. The wetting station 610 receives a formulation liquid from, e.g., a formulation storage (not shown) and includes shower heads 614 to shower the wipe material as it passes through the wetting line 610. In some implementations, the wetting line can also include a formulation bath, e.g., similar to the formulation bath 412 described above with reference to FIG. 4. In some implementations, the wetting line 610 can be expanded to allow the wipe material to come into contact with the liquid over a greater distance, as described above.

[0105] The formation line 650 also includes a perforator 654. The perforator 654 perforates the wipe material from the base roll, thereby forming a length of material that is separated into individual wipes. The perforator 654 can include, e.g., a cylinder with sharp points that poke perforations into the material as the cylinder rolls along the material. In some implementations, the perforator 654 can also cut the material into desired lengths. For example, the perforator 654 can perforate, e.g., 50 wipes into a sheet of material, and then cut the material off to form a sheet of 50 perforated wipes. In some implementations, the perforator 654 can also cut the material into desired widths, e.g., a width corresponding to the height of the later roll of wipes. As illustrated, the perforator 654 is located downstream of the wetting station 610 such that wet material is perforated, although in some implementations, the material can be perforated by the perforator 654 before passing through the wetting station 610.

[0106] The formation line 650 also includes a roller 654 that rolls the perforated/cut wipes into a roll 602 for packaging. For example, the roller can include a metal sheet that is shaped to roll the wipes into a roll as they pass by the roller 654.

[0107] The production line 600 also includes a packaging station 620 to package the wet wipes 602, e.g., into flexible packaging, resulting in a packaged roll of wet wipes 602'. The packaging station 620 includes a wrapper 622 and a sealer 624 that operate as discussed above for FIG. 4.

[0108] Referring to FIG. 7, in an example method for producing a roll of wet wipes, a roll of wipes is exposed to a liquid formulation (700) such that the liquid formulation is absorbed by the wipes. The roll of wipes includes a length of wipes rolled into a roll, where the individual wipes are separated by perforations.

[0109] Exposing the roll of wipes to a liquid formulation includes one or both of showering the liquid formulation onto the roll of wipes (702) or at least partially submerging the roll of wipes into the liquid formulation (704).

[0110] The wet roll of wipes is packaged in a watertight packaging material (706). Packaging the roll of wipes includes wrapping the roll of wipes in the packaging material such that the packaging material directly contacts an outermost wipe on an exterior of the roll of wipes (708) and heat sealing the packaging material (710).

[0111] Referring to FIG. 8, in another example method for producing a roll of wet wipes, a wipe material is exposed to a liquid formulation (800) such that the liquid formulation is absorbed by the wipes. Exposing the wipe material to a liquid formulation includes one or both of showering the liquid formulation onto the wipe material (802) or at least partially submerging the wipe material into the liquid formulation (804).

[0112] The wet wipe material is perforated into individual wipes (806) and assembled into a roll of wipes (808), where the roll of wipes includes a length of perforated wipe material rolled into a roll.

[0113] The roll of wipes is packaged in a watertight packaging material (810). Packaging the roll of wipes includes wrapping the roll of wipes in the packaging material such that the packaging material directly contacts an outermost wipe on an exterior of the roll of wipes (812) and heat sealing the packaging material (814).

[0114] Other embodiments are within the scope of the following claims.