How Wet Wipes Are Manufactured: From Roll to Sealed Pack

Wet wipes manufacturing is a continuous converting process. It starts with large rolls of nonwoven fabric loaded onto an unwinder. The web is guided through folding plates that create the familiar interfolded stack, so each wipe pulls up the next.

In parallel, the lotion is prepared in controlled batches — treated water plus the formulation's ingredients — and dosed onto the folded web at a set moisture level. A cutting unit then divides the wetted stack to the target sheet count.

Each stack enters a flow-wrapper, where printed film is formed around it and sealed. Depending on the product, a resealable sticker or a plastic lid is applied on top. Packs are date-coded, checked, and packed into printed shipping cartons.

Quality control runs through the whole line: incoming material checks, in-process checks on weight, moisture and seal integrity, and a final release inspection per batch. At Castle, this process runs in Amman, Jordan on a line certified by the JFDA for Good Manufacturing Practices.