Process and machine for forming an absorbent sanitary article

A process for forming an absorbent sanitary article comprising a pad having a direction of main extension and a frame for supporting the pad, the process comprising:

• a step of forming a frame of the absorbent sanitary article by layering a first composite web;
• a step of forming a pad of the absorbent sanitary article;
• a step of applying the pad to the frame by applying the pad to the first composite web;
• the step of forming the pad comprising:
• a step of making an absorbent core, comprising:
• a step of making a second composite web advancing along a feed direction;
• and
• a step of cutting the second composite web into a plurality of first lengths of absorbent core;
• a step of shaping the absorbent core, comprising:
• a step of preparing a succession of hollows in the second composite web, each of the succession of hollows being made by removing a corresponding portion of the second composite web before applying the pad on the first composite web;
• wherein the step of forming the pad further comprises a step of covering the absorbent core with an outer cover, the pad comprising the absorbent core and the outer cover;
• wherein the step of covering the absorbent core comprises a step of making a third composite web comprising the plurality of first lengths of absorbent core, the plurality of first lengths of absorbent core defining an intermediate layer of the third composite web.