Abstract: Apparatus and methods are provided to minimize waste and improve quality and production in web processing operations. The apparatus and methods provide defect detection both before and after application of component patches to a traveling web to create a product. Web defect detection may be provided by way of at least one visual inspection station located upstream from the patch applicator. Patch defect detection may be accomplished by way of a visual inspection station located proximate the patch applicator. If defects are detected in either the traveling web or the component patch prior to patch application, patch application may be prevented until both a satisfactory web and patch are provided. If defects are detected after patch application, the resulting product may be culled. Furthermore, the apparatus may be provided with diagnostic software to warn against extant or imminent machine complications.

Abstract: Apparatus and methods are provided to minimize waste and improve quality and production in web processing operations. The apparatus and methods provide defect detection both before and after application of component patches to a traveling web to create a product. Web defect detection may be provided by way of at least one visual inspection station located upstream from the patch applicator. Patch defect detection may be accomplished by way of a visual inspection station located proximate the patch applicator. If defects are detected in either the traveling web or the component patch prior to patch application, patch application may be prevented until both a satisfactory web and patch are provided. If defects are detected after patch application, the resulting product may be culled. Furthermore, the apparatus may be provided with diagnostic software to warn against extant or imminent machine complications.

Abstract: A super absorbent distribution system for homogenous distribution throughout an absorbent core is disclosed. A super absorbent material is injected into a stream of absorbent fluff at an opposite direction to that of the stream of absorbent fluff. The super absorbent is blasted into the peak and outer surface of a cone shaped super absorbent barrier. The oncoming absorbent fluff also contends with a similarly shaped absorbent fluff barrier. The super absorbent material slows down as it hits the super absorbent barrier and oncoming fluff, then stops, then reverses direction and flows with the absorbent fluff as a homogenous distribution of super absorbent material and absorbent fluff. The combination of super absorbent material and absorbent fluff may encounter baffle members to further distribute the super absorbent material and absorbent fluff.