• Login
    • Join
  • Subscribe Free
    • Magazine
    • eNewsletter
    Checkout
    • Magazine
    • News
    • Exclusives
    • Applications
    • Technology
    • Market
    • Other
    • Top 40
    • Buyers Guide
    • Hygiene Directory
    • More
  • Magazine
  • News
  • Exclusives
  • Applications
  • Technology
  • Market
  • Other
  • Top 40
  • Buyers Guide
  • Hygiene Directory
  • Current / Back Issues
    Features
    Editorial
    Columns
    Digital Edition
    Southeast Asia Edition
    eNewsletter Archive
    Editorial Guidelines
    Subscribe Now
    Advertise Now
    Top Features
    Biosphere Corporation: Expands into Baby Diaper Production in Ukraine

    Trends in Diapers: Sustainability, Natural Ingredients or Other Features?

    Baby Diapers: A Changing Market

    Ultrasonics for Nonwovens

    Hygiene Machinery Review
    Company Cameo
    Financial News
    Machinery Equipment
    New Products
    Nonwovens News
    Patent Review
    People in the News
    Supplier News
    Top News
    Live From Shows
    Top News
    Armbrust American Adds Meltblown Manufacturing

    First Quality Launches Incognito by Prevail

    Essity Launches Reusable Underwear Product

    Techtextil, Texprocess Postponed to 2022

    Ontex Honored for Mask Production
    Nonwovens Insights
    Online Exclusives
    Absorbent Core
    Adult Incontinence
    Antimicrobials
    Apparel
    Automotive and Transportation
    Chemicals / Adhesives
    Construction
    Contract Services
    Diaper, Baby
    Electronics
    Feminine Hygiene
    Fibers
    Filtration
    Flame Retardance
    Geotextile / Agrotextile
    Home Products
    Hygiene Film/Components
    Industrial / Institutional
    Inspection / Quality Control
    Machinery and Equipment
    Medical
    Wipes

    Armbrust American Adds Meltblown Manufacturing

    First Quality Launches Incognito by Prevail

    Essity Launches Reusable Underwear Product

    Shemesh Adds U.S. Headquarters

    TZMO USA, Special Needs Group Form Partnership
    Air Through Bonding
    Airlaid
    Carded/Carding
    Chemical Bonded
    Composite
    Meltblown
    Needlepunch
    Nanotechnology
    Spunbond
    Spunlace
    Thermal Bonded
    Wetlaid

    Armbrust American Adds Meltblown Manufacturing

    Radici Adds Meltblown Line

    Biosphere Corporation: Expands into Baby Diaper Production in Ukraine

    Nonwovens Industry’s Top 10 Breaking News Stories of 2020

    Jacob Holm to Expand Spunlace Capacity in Candler
    China
    Eastern Europe/Russia
    India
    Middle East/North Africa
    North America
    Pacific Rim
    South/Central America
    Turkey
    Western Europe

    Shemesh Adds U.S. Headquarters

    Domtar Sells Personal Care Unit

    Jacob Holm to Expand Spunlace Capacity in Candler

    Nice-Pak to Construct New Facility in Mooresville, IN

    United Sewing Automation Produces U.S.-Sourced and Manufactured PPE Face Masks
    Associations
    Contracts / Awards
    Education
    Facilities / Capacity
    Green / Sustainability
    Legal / Regulatory
    Market Data
    Mergers and Acquisitions
    Product Improvement / Innovation
    R&D/Basic Research
    Shows / Events

    Armbrust American Adds Meltblown Manufacturing

    Techtextil, Texprocess Postponed to 2022

    Shemesh Adds U.S. Headquarters

    Domtar Sells Personal Care Unit

    Record Mask Production from BelEmsa
    Chart
    Companies
    All Companies
    Categories
    Company Profiles
    Add New Company
    International Buyers Guide Companies
    Fagus GreCon, Inc

    Schott & Meissner Maschinen- und Anlagenbau GmbH

    Mechanical Specialties, Inc.

    Cellulose Solutions LLC.

    Omya International AG
    Brands
    Brand Owners
    • Magazine
      • Current / Back Issues
      • Features
      • Editorial
      • Columns
      • Digital Edition
      • Southeast Asia Edition
      • eNewsletter Archive
      • Editorial Guidelines
      • Subscribe Now
      • Advertise Now
    • Breaking News
    • Buyers Guide
      • All Companies
      • Categories
      • Company Profiles
      • Add Your Company
    • Applications
      • Absorbent Core
      • Adult Incontinence
      • Antimicrobials
      • Apparel
      • Automotive and Transportation
      • Chemicals / Adhesives
      • Construction
      • Contract Services
      • Diaper, Baby
      • Electronics
      • Feminine Hygiene
      • Fibers
      • Filtration
      • Flame Retardance
      • Geotextile / Agrotextile
      • Home Products
      • Hygiene Film/Components
      • Industrial / Institutional
      • Inspection / Quality Control
      • Machinery and Equipment
      • Medical
      • Wipes
    • Technology
      • Air Through Bonding
      • Airlaid
      • Carded/Carding
      • Chemical Bonded
      • Composite
      • Meltblown
      • Needlepunch
      • Nanotechnology
      • Spunbond
      • Spunlace
      • Thermal Bonded
      • Wetlaid
    • Market
      • China
      • Eastern Europe/Russia
      • India
      • Middle East/North Africa
      • North America
      • Pacific Rim
      • South/Central America
      • Turkey
      • Western Europe
    • Other
      • Associations
      • Contracts / Awards
      • Education
      • Facilities / Capacity
      • Green / Sustainability
      • Legal / Regulatory
      • Market Data
      • Mergers and Acquisitions
      • Product Improvement / Innovation
      • R&D/Basic Research
      • Shows / Events
    • Top 40 Companies
      • Chart
      • Companies
    • Online Exclusives
    • Hygiene Directory
      • Brands
      • Brand Owners
    • Slideshows
    • Experts Opinions
    • Videos
    • Podcasts
    • Infographics
    • Whitepapers
    • Jobs
    • Events
      • Industry Events
      • Live From Show Events
      • Webinars
      • Live From Asian Connections
    • Resources
      • Suppliers Gallery
      • Literature Showcase
      • Web Showcase
      • Home Page Showcase
    • About Us
      • About Us
      • Contact Us
      • Advertise With Us
      • Privacy Policy
      • Terms of Use
    Features

    Core Strength

    Low pulp or no pulp, one thing is for sure diapers are thinner than ever.

    Core Strength
    Core Strength
    Related CONTENT
    • Domtar Sells Personal Care Unit
    • Spunbond Report Predicts Continued Growth
    • Trends in Diapers: Sustainability, Natural Ingredients or Other Features?
    • Baby Diapers: A Changing Market
    • The Private Label Market
    Karen McIntyre, editor01.05.16
    One of the biggest weight loss success stories in the consumer markets is the disposable diaper. In the past decade, diapers have gone from thick and bulky devices loaded with fluff pulp to a shadow of their former selves, thinner yet more absorbent than ever before.

    Driving thinness are advances in core technology, which have lessened the amount of fluff pulp and increased the amount of superabsorbent polymer, which can absorb up to 800 times its weight in liquid, pulling urine from baby’s skin. These new diapers are not only thinner but more comfortable than ever before.

    This thinness has been driven by increasing superabsorbent: fluff pulp ratios within the diaper core. In 1985, the pulp-to-SAP ratio was 28:6 grams. By 2010, the ratio had evened out at 12:12 grams and has since gotten even lower. This trend has been driven by a consumers’ need for a thinner diaper and aided by more attractive SAP prices as well as technological developments by diaper suppliers and manufacturers alike. The thin diaper not only creates a more comfortable product for the baby to wear, it also lowers freight costs, opens up more shelf space and is more environmentally favorable overall.

    In terms of low or no pulp options, the two most well-known of these technologies—on the commercial front—are probably Pampers DryMax premium diapers, which use a limited amount of curly fluff pulp fibers, and Drylock Technologies, a European private label diaper maker that reportedly makes a completely pulp free core where the SAP is encapsulated between two layers.

    Drylock, led by former Ontex leader Bart Van Malderen, contains SAP within two small pockets formed by a combination of two layers kept in place with a low amount of thermoplastic materials.  These bonds are designed to allow controlled and gradual loosening when SAP are swallowed and expand. This design expands SAP volumes, avoiding a reduction in performance thanks to pressure increases.

    Pampers DryMax continues to be a leading branded diaper worldwide, while Drylock diapers, which are primarily sold as a private label brand, continue to grow throughout Europe. However, industry experts say the absence of pulp in the diaper is not as important as is the thinness of the overall product. In fact, Huggies’ latest generation of diapers are as thin as DryMax and reportedly contain about the same level of pulp but maker Kimberly-Clark has not been outspoken about the core technology. Instead, its marketing efforts have focused on softness and improved fit.

    From a technological standpoint, however, suppliers throughout the supply chain continue to offer ways to redesign the core that use little or no fluff pulp. For adhesive maker Bostik, determining how a low or no pulp core works is crucial to its success in the market, according to marketing manager Courtney Korselt. “We are always looking at the full solution and we are focused on how our adhesives work well with a standard core or with cores with higher SAP ratios. It is really important for us to be in touch with what is going on in the market.”

    Realizing that a change was coming within the elements of diaper design, Bostik began collaborating with SAP supplier BASF to gauge the interaction between the adhesive, the SAP and the other materials within the core. The result of the collaboration is a core design that uses SAP and an adhesive in a core structure that is completely pulp-free.
    This technology is not fully commercialized but is a part of the overall core learning efforts that Bostik has made to better support customers as they move from 50:50 SAP ratios to pulp-free diapers. Korselt explains that the use of pulp or lack thereof varies by geographies. In mature regions, the use of pulp free diapers has slowed with the exception of Drylock but in Asia there are many more interesting and thin products. Most of these are laminate structures that use adhesives or they are a compound core-type structure that can be assembled simply.

    SAP’s The Word
    SAP manufacturers like Evonik have obvious motivation for upping the SAP content in absorbent cores. Many of them have invested ambitiously in recent years and they are now looking for new ways to move that capacity. Manufacturers are offering interesting new technologies and competitive pricing to increase SAP’s role in the diaper core.

    In November, Evonik announced a new technology—developed in partnership with a small engineering company—to make a laminate structure combining layers of superabsorbents and nonwovens to serve as an absorbent core in hygiene products. This unique structure allows the diaper core to absorb and distribute fluid more quickly than competing structures.
    According to Markus Henn, global director, application technology for Evonik, the laminate is flexible and expandable in two dimensions. “This results in a unique structure so basically the laminate has two nonwoven layers and a SAP is placed in a compartment between the two,” he adds. “The specific technology that we are using is elastic fibers in between the nonwoven layers that resembled small pockets containing the SAP.”  

    The structure gives the diaper core a high level of stability. The elastic fibers or strands stick to the nonwovens and form an open cell structure. This ensures that the superabsorbent particles remain at the place where they are needed but also keeps the adhesive from infringing on the SAP properties. Therefore, the diaper is considerably more efficient—rewetting is significantly reduced while wearer comfort is enhanced considerably.

    In developing the product, which Evonik hopes to license to diaper makers, the company ran tests on a number types of nonwovens and even some tissue materials.
    Henn says the type of nonwoven used depends upon the use of the final product. “We have seen some indication of what types of nonwovens work or work better but we don’t really see too many limitations on what should be used,” he says. “The technology really allows the user to finetune the absorbent core and use the materials best suited for the application.”

    Herrmann credits a new helical anvil design which offers a minimal yet perfectly formed contact area per bond point for the technology. This ensures strong bonding while simultaneously displacing SAP granules. Since the process is gentle on the fibers, the bonded layers stay soft to the touch. The core former system enables clean continuous bonding of SAP structures without hot melt; two rotating ultrasonic drums, called sonotrodes, are positioned quarter lambda offset with a newly developed and patented anvil geometry made of helical springs to create perfect elliptical bond regions.





    The result is an ultrathin, yet soft and absorbent core, in which the superabsorbent granules are firmly “embedded” in the middle layer without the use of hot melt. At the same time they are well distributed without the preceding step of a patterned SAP feeding. In conventional diaper manufacturing this is a costly and demanding part of the process. The middle layer—similar in kind and functionality to “ADL” layers in conventional products—is bonded between the outer PP-based carrier and cover layers, and research has shown a better immobilizing function of SAP granules, both in dry and wet state, and a decreased tendency for gel blocking. When unbonded, the SAP granules enter the big pores of the embedding layer.

    On the Line
    Diaper machinery manufacturer Fameccanica has also committed to thinner diaper technology with a number of new forming technologies that reduce SAP content in the core. Among these is Hexacore, a solution for an entirely fluffless core suitable for application in baby diapers, heavy and light incontinence as well as for feminine hygiene pads. This Fameccanica patented structure, with expandable cells, enables the superabsorbent material to expand significantly inside the absorbent core. Also, the possibility to use differentiated glue types makes it possible to create preferential directions for expansion across the cells and to manage core integrity levels accordingly.

    On the lower pulp front, Fameccanica offers a trio of solutions for its customers to use thin cores. H-forming is the re-engineered forming system with a perfect flow distribution and optimal SAP/fluff mix with ratios of up to 50/50 offering pad integrity and weight control. The H-forming system is the standard forming system for machines up to 600 ppm. The U-forming system, which is capable of producing ultrathin absorbent cores with SAP content higher than 70%, is the standard forming system for the company’s high-speed baby diaper machines. The third technology uses intermitten SAP application to provide the advantage of targeting the amount of SAP in the middle of the diaper. This works in combination with the Fameccanica Optisap 700 loss-in-weight dosing system saving on average two grams per diaper.n
    Related Searches
    • nonwoven
    • fibers
    • private label
    • incontinence
    Related Knowledge Center
    • Absorbent Core
    • Diaper, Baby
    • Fibers
    Suggested For You
    Domtar Sells Personal Care Unit Domtar Sells Personal Care Unit
    Spunbond Report Predicts Continued Growth Spunbond Report Predicts Continued Growth
    Trends in Diapers: Sustainability, Natural Ingredients or Other Features? Trends in Diapers: Sustainability, Natural Ingredients or Other Features?
    Baby Diapers: A Changing Market Baby Diapers: A Changing Market
    The Private Label Market The Private Label Market
    Mondi Collaborates with Drylock on Paper-Based Diaper Packaging Mondi Collaborates with Drylock on Paper-Based Diaper Packaging
    Hello Bello to Begin Diaper Manufacturing in Waco Hello Bello to Begin Diaper Manufacturing in Waco
    2020: The Lost Year? Not for Nonwovens 2020: The Lost Year? Not for Nonwovens
    Hygiene Suppliers Go Natural Hygiene Suppliers Go Natural
    EWG Verified Diapers Launch Nationwide EWG Verified Diapers Launch Nationwide
    New Elastic Laminate for Masks Solves Elongation Challenges New Elastic Laminate for Masks Solves Elongation Challenges
    Unicharm to Launch Recycled Diaper in 2022 Unicharm to Launch Recycled Diaper in 2022
    Dorel Launches On-The-Go Disposable Kits Dorel Launches On-The-Go Disposable Kits
    Japanese Companies Develop New Recycling Technology for SAP Japanese Companies Develop New Recycling Technology for SAP
    Avery Dennison Publishes White Paper on ISO-Certified Diaper Materials Avery Dennison Publishes White Paper on ISO-Certified Diaper Materials

    Related Features

    • Diaper, Baby | Spunlace
      Biosphere Corporation: Expands into Baby Diaper Production in Ukraine

      Biosphere Corporation: Expands into Baby Diaper Production in Ukraine

      Consumer products company orders Andritz Diatec line; will add high quality diapers to its product lineup
      01.06.21

    • Diaper, Baby
      Trends in Diapers: Sustainability, Natural Ingredients or Other Features?

      Trends in Diapers: Sustainability, Natural Ingredients or Other Features?

      New niche brands penetrate the disposable baby diaper market
      Natalia Richer, Diaper Testing International 01.06.21

    • Diaper, Baby
      Baby Diapers: A Changing Market

      Baby Diapers: A Changing Market

      New brands, new marketing efforts have changed the way manufacturers speak to parents
      Karen McIntyre, Editor 01.06.21


    • Absorbent Core | Hygiene Film/Components
      Hygiene Suppliers Go Natural

      Hygiene Suppliers Go Natural

      Demand for safer ingredients, transparency guide innovation in a highly competitive market
      Karen McIntyre, Editor 12.11.20

    • Feminine Hygiene
      Feminine Hygiene: Room for More

      Feminine Hygiene: Room for More

      The rate of introduction of new menstrual care brands and products continues to redefine the category
      Tara Olivo, Associate Editor 11.12.20

    • Adult Incontinence | Diaper, Baby | Feminine Hygiene | Green/Sustainability
      Natural Hygiene: A Niche No More

      Natural Hygiene: A Niche No More

      Hygiene aisles are changing as more consumers show interest in natural and organic alternatives
      Tara Olivo, Associate Editor 06.10.20


    • Fibers
      Fibers Report

      Fibers Report

      As the nonwovens industry continues to face the challenge of balancing safety and efficacy with sustainability, new fiber and raw material choices will continue
      Karen McIntyre, Editor 06.10.20

    • Fibers
      Co-form Nonwovens Comprising of Cotton Flock Fibers

      Co-form Nonwovens Comprising of Cotton Flock Fibers

      Structures feature soft and pleasant hand, ideal for cosmetic use
      03.05.20

    • Diaper, Baby | India
      India Diaper Market

      India Diaper Market

      In 2023, two in five babies aged zero to two years in the APAC region will be born in India—creating a huge potential consumer base
      03.05.20


    • Diaper, Baby | Wipes
      Private Labels Prove their Point

      Private Labels Prove their Point

      Better performance, stronger marketing and improved packaging are redefining store brands
      Karen McIntyre, Editor 01.03.20

    • Diaper, Baby
      Trends in the Baby Diaper Market

      Trends in the Baby Diaper Market

      Diaper makers respond to diverse needs around the globe
      Tara Olivo, Associate Editor 01.03.20

    • Feminine Hygiene
      Feminine Hygiene Manufacturers Shift Focus

      Feminine Hygiene Manufacturers Shift Focus

      Growing concerns over the environment and women’s health have led to new product formats
      Karen McIntyre, Editor 11.08.19


    • Fibers

      Natural Fibers Take the Lead in Nonwovens

      The sustainability story continues to be strong in baby diapers and feminine hygiene products
      Karen McIntyre, Editor 06.05.19

    • Feminine Hygiene

      Hygiene Consumers Demand Greater Transparency

      BAHP is monitoring trends impacting U.S. baby and fem care markets
      Jane Wishneff, Executive Director, BAHP 06.05.19

    • Adult Incontinence | Diaper, Baby | Feminine Hygiene

      Unicharm Acquires Thai Diaper Maker

      Deal to buy DSGCL Group adds lower-priced brands in Southeast Asia.
      Karen Bitz-McIntyre, Editor 03.04.19

    Trending
    • Essity Launches Reusable Underwear Product
    • Armbrust American Adds Meltblown Manufacturing
    • Techtextil, Texprocess Postponed To 2022
    • First Quality Launches Incognito By Prevail
    • Minet Adds Spunlace Line In Romania
    Breaking News
    • Freudenberg to Establish Apparel Interlining Competence Centers
    • Minet Adds Spunlace Line in Romania
    • Lemu Group Engineers Mask-Making Machine
    • Armbrust American Adds Meltblown Manufacturing
    • P&G Reports 8% Sales Increase
    View Breaking News >
    CURRENT ISSUE

    January 2021

    • Biosphere Corporation: Expands into Baby Diaper Production in Ukraine
    • Trends in Diapers: Sustainability, Natural Ingredients or Other Features?
    • Baby Diapers A Changing Market
    • Ultrasonics for Nonwovens
    • Hygiene Machinery Review
    • The Private Label Market
    • View More >



    Cookies help us to provide you with an excellent service. By using our website, you declare yourself in agreement with our use of cookies.
    You can obtain detailed information about the use of cookies on our website by clicking on "More information”.

    • About Us
    • Privacy Policy
    • Terms And Conditions
    • Contact Us

    follow us

    Subscribe
    Nutraceuticals World

    Latest Breaking News From Nutraceuticals World

    NIH Study Compares Low-Fat, Plant-based to Low-Carb, Animal-Based Diet
    Gadot Positions Mineral Line for Vegan Market
    Nutritfy India to Launch Global Broadcast Channel Covering Nutrition
    Coatings World

    Latest Breaking News From Coatings World

    LINE-X Launches Dealer Program with International Truck
    PPG Reports Q4, Full-year 2020 Financial Results
    BASF Begins Implementing Ralignment of Global Business Services Unit
    Medical Product Outsourcing

    Latest Breaking News From Medical Product Outsourcing

    Cretex Companies CEO Steps Down
    Data Show Porex's Medical Device Filtration Materials Protect Against Virus, Bacteria Spread
    Endoscopic Hemostasis Devices Market Valued at $730 Million
    Contract Pharma

    Latest Breaking News From Contract Pharma

    Pfizer, BioNTech Enter Vax Pact with COVAX
    FDA Approves Janssen’s CABENUVA
    AGC Biologics Appoints Boulder Site GM
    Beauty Packaging

    Latest Breaking News From Beauty Packaging

    Coty Appoints Chief Procurement Officer
    Lageen Tubes Launches Mono-Material PE Tube Solutions
    Jason Jones Loses Battle with Covid-19
    Happi

    Latest Breaking News From Happi

    Carol’s Daughter Adds New Hair Products
    Moroccan Gold Series Launches NuDo Shampoo
    Youbody Debuts Waterless Body Wash
    Ink World

    Latest Breaking News From Ink World

    BOBST Demonstrates Future of Flexible Packaging Production at Virtual Open House
    Morancé Soudure France Adds Comexi F2 MC 10-color Flexo Press
    AR Packaging Acquiring Firstan Holdings Ltd
    Label & Narrow Web

    Latest Breaking News From Label & Narrow Web

    Gallus planning virtual event for March
    Lemu Group engineers mask-making machine
    Niagara Label upgrades with Nilpeter flexo press
    Nonwovens Industry

    Latest Breaking News From Nonwovens Industry

    Freudenberg to Establish Apparel Interlining Competence Centers
    Minet Adds Spunlace Line in Romania
    Lemu Group Engineers Mask-Making Machine
    Orthopedic Design & Technology

    Latest Breaking News From Orthopedic Design & Technology

    Cretex Companies CEO Steps Down
    Conformis Enters Development & Supply Agreement with SITES Medical
    Sectra, RSA Biomedical Sign Distribution Agreement for Implant Stability Tool
    Printed Electronics Now

    Latest Breaking News From Printed Electronics Now

    UDC Subsidiary Adesis' Website Wins 2020 MarCom Platinum Award
    Ambiq Wins IoT Semiconductor Company of the Year Award
    Ynvisible Names Michael Robinson CEO, Jani-Mikael Kuusisto SVP Ventures

    Copyright © 2021 Rodman Media. All rights reserved. Use of this constitutes acceptance of our privacy policy The material on this site may not be reproduced, distributed, transmitted, or otherwise used, except with the prior written permission of Rodman Media.

    AD BLOCKER DETECTED

    Our website is made possible by displaying online advertisements to our visitors.
    Please consider supporting us by disabling your ad blocker.


    FREE SUBSCRIPTION Already a subscriber? Login