Methods of making personal care articles

A method of making a personal care article, the method comprising:

• placing a converting frame on an anvil plate assembly comprising an anvil plate;
• placing at least one lower substrate on the anvil plate and the converting frame;
• securing the at least one lower substrate within the converting frame;
• placing a cleansing composition on the at least one lower substrate and within a perimeter of a centering guide on the anvil plate;
• laying at least one upper substrate over the cleansing composition and the at least one lower substrate;
• placing the converting frame and the anvil plate assembly on a target location of a heat press;
• actuating the heat press to direct a heated seal plate onto the anvil plate, thereby contacting the at least one upper substrate to form a seal between the at least one upper substrate and the at least one lower substrate and thereby contain the cleansing composition between the at least one upper and lower substrates;
• separating the anvil plate assembly from the converting frame;
• placing the converting frame on a surface of a cutting press;
• placing a die assembly comprising a die over the at least one upper substrate on the converting frame, such that the die is facing the surface of the cutting press;
• and
• actuating the cutting press to drive the die assembly onto the converting frame to cut excess portions of the at least one lower substrate and the at least one upper substrate at or outwardly adjacent to the seal to form the personal care article.

A method of making a personal care article, the method comprising:

• unitizing a plodded extrudate cleansing composition to form a cleansing composition puck;
• placing a converting frame on an anvil plate assembly comprising an anvil plate, placing at least one lower substrate on the anvil plate and the converting frame and securing the at least one lower substrate within the converting frame;
• placing the cleansing composition puck on the at least one lower substrate and within a perimeter of a centering guide on the anvil plate, wherein the centering guide is substantially visible through the at least one lower substrate;
• laying at least one upper substrate over the cleansing composition puck and the at least one lower substrate;
• placing the converting frame and the anvil plate assembly on a target location of a heat press, wherein a first physical guide facilitates placement of the converting frame and the anvil plate assembly on the target location of the heat press;
• actuating the heat press to direct a heated seal plate onto the anvil plate, thereby contacting the at least one upper substrate to form a seal between the at least one upper substrate and the at least one lower substrate and thereby contain the cleansing composition puck therebetween;
• separating the anvil plate assembly from the converting frame;
• placing the converting frame on a surface of a cutting press;
• placing a die assembly comprising a die over the at least one upper substrate on the converting frame, such that the die is facing the surface of the cutting press, wherein a second physical guide facilitates placement of the die assembly on the converting frame;
• and
• actuating the cutting press to drive the die assembly onto the converting frame to cut excess portions of the at least one lower substrate and the at least one upper substrate at or outwardly adjacent to the seal to form the personal care article and to shape the cleansing composition therein;
• wherein the die and the die assembly define a die cavity having a depth that is less than a height of the cleansing composition prior to actuation of the cutting press.