• 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
    Ontex Honored for Mask Production

    Shemesh Adds U.S. Headquarters

    TZMO USA, Special Needs Group Form Partnership

    Radici Adds Meltblown Line

    Domtar Sells Personal Care Unit
    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

    Shemesh Adds U.S. Headquarters

    TZMO USA, Special Needs Group Form Partnership

    Executive Reports: Callaly Continues to Revolutionize Feminine Hygiene

    Domtar Sells Personal Care Unit

    Biosphere Corporation: Expands into Baby Diaper Production in Ukraine
    Air Through Bonding
    Airlaid
    Carded/Carding
    Chemical Bonded
    Composite
    Meltblown
    Needlepunch
    Nanotechnology
    Spunbond
    Spunlace
    Thermal Bonded
    Wetlaid

    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

    Freudenberg, Ratti Develop Process for Re-Using Silk Textiles for Insulation
    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

    Shemesh Adds U.S. Headquarters

    Domtar Sells Personal Care Unit

    Record Mask Production from BelEmsa

    Jacob Holm to Expand Spunlace Capacity in Candler

    Freudenberg, Ratti Develop Process for Re-Using Silk Textiles for Insulation
    Chart
    Companies
    All Companies
    Categories
    Company Profiles
    Add New Company
    International Buyers Guide Companies
    Top Polymer Enterprise, LLC

    Fagus GreCon, Inc

    Mechanical Specialties, Inc.

    Schott & Meissner Maschinen- und Anlagenbau GmbH

    Shemesh Automation
    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

    Do You Need a Materials Formatting Partner?

    Considerations for nonwoven health and hygiene product OEMs.

    Do You Need a Materials Formatting Partner?
    Do You Need a Materials Formatting Partner?
    Do You Need a Materials Formatting Partner?
    Related CONTENT
    • Ontex Honored for Mask Production
    • TFP Acquires PV3 Technologies
    • BAHP Announces 2021 Officers, Board of Directors
    • The Nonwovens Institute to Host Virtual Spunbond and Meltblown Course
    • The Private Label Market
    Jason Surman, Vice President of Sales, Web Industries Inc.11.10.17
    In today’s nonwoven health and hygiene products industry, OEMs and leading brands are laser focused on core competencies, costs and delivering their value proposition to consumers. And when launching new products, they are faced with important decisions about how to most economically and efficiently turn innovations into reality. How much do they tackle within the four walls of their operations? When does it make sense to partner with outside specialists?

    Following is an overview of key factors to address when answering these questions.

    Specialized Machinery for Diverse Material Weights, Widths
    Whether the end use is feminine hygiene products, adult incontinence protection or baby diapers, new raw material introductions can present manufacturing challenges. In some cases, OEMs are using thicker core materials. For example, new core materials can contain SAP (super absorbent polymers) as a ready to use material, and these can be thicker than previously used core materials. Then there are today’s soft, fabric-like topsheets, many of which are extremely thin and stretchable, as well as innovative ADLs (acquisition dispersion layer), which transport liquid to the product’s absorbent core. With many products being introduced in the market, there can be increased processing challenges around these unique new materials that need to be addressed.

    For any given consumer product, a brand may be working with nonwovens, films and foams having very different properties and characteristics. It can be difficult for a single manufacturer to invest in all of the right equipment to optimally process these diverse materials. Consider the issue of spooling vs. festooning. Traditionally, some OEMs used festooned materials; the festooning process leaves materials neatly folded over themselves. However, some newer materials are very delicate and can become creased or deformed if they are festooned. To prepare them to be fed onto an OEM manufacturing line, they ideally should be wound onto spools instead. This can require investment in new equipment, and be outside core strategies and capabilities. When looking for flexibility and scale, a third party converter may offer the best solution. 

    Many newer materials must be handled gently to achieve a stable spool without damaging, stretching or breaking the nonwoven. For thicker materials, it’s important to create spools of extra-large diameter to help maximize efficiency and reduce processing costs. Using this spooling example as a reference point, some questions to consider before investing in new material handling machinery are:
    • Is there space for additional equipment? If not, what are the costs of adding more space?
    • What additional labor costs will be associated with operating the new machinery?
    • Is there enough volume of work to spread these costs across different shifts?
    • Does the addition of this new capability enhance the business’ core competency?
    When OEMs turn to a materials formatting partner to perform certain processes, they can benefit from that partner’s economies of scale. For example, a formatter may have brought online the largest, fastest spooling machine in the world — a major investment. Due to the nature of its work, the formatter can utilize the machine for multiple customers, perhaps even around-the-clock. Accordingly, the formatter can often offer a compelling price to run orders on highly specialized equipment for its manufacturing partner.

    Another Perspective During Product Development
    A best practice is to engage with a materials formatting partner early in product development. Before doing so, strong non-disclosure agreements should be in place, and the OEM will want to have reliable references or a track record of positive past work experience with the converter. Only a proven, trustworthy partner should be invited to weigh in on sensitive R&D matters.

    How is this early involvement advantageous? In many cases, the converter can help an OEM ensure that the right material for end product needs will also meet expectations for production and total cost targets. For example, a new, thicker material may cost significantly more than another material to process because of the difference in input width and length, as well as the output spool length. Material handling partners that engage early on can help OEMs anticipate such challenges and work together towards the best solution.

    The same principle applies to nonwoven printing, which has become increasingly popular as personal product brands compete for consumers’ attention. As OEMs elevate the look, feel and performance of their hygiene products, they often want the best of both worlds:
    • Ultra-thin, soft materials for enhanced consumer comfort and discretion; and
    • A unique print that resonates with the consumer and differentiates the hygiene product from the competition on the shelf.
    Thin nonwovens can present real challenges in the printing process, in speeds, final appearance and rub off. In a worst case, this can throw off OEM projections for a new product’s retail price point and erode the target profit margin. Inline printing, which often employs inkjet technology, may appear to be an appealing option. Yet if the printer goes down, an entire product manufacturing line may need to stop until it can be repaired. By comparison, with high-speed wide web flexographic printing and inline slitting co-located within a single facility, a nonwoven printing specialist can deliver a material ready to go straight onto an OEM’s production line for long, stable manufacturing runs.

    Also, inline inkjet printing may only be suitable to support very simple, one-color designs on the nonwoven material, such as a diaper topsheet. Yet it may be strategically important for the OEM’s brand to stand out to shoppers with a more upscale-looking multicolored, multidimensional print.

    Here again, there can be big benefits if the OEM and its material formatting partner collaborate in the beginning phases of product development. Formatters can assist in material and graphics selection decisions that accommodate the desired performance and an economically viable production scenario.

    Another printing consideration, especially with nonwovens, is a choice of water-based or solvent-based ink systems. While water-based inks are environmentally friendly, solvent-based ink systems can help promote improved rub off, a major consideration in processing printing materials. Solvent-based ink printing systems can be challenging due to safety and environmental requirements, such as air permits and solvent contamination, and add cost and complexity to operations. Choosing a third party printer can help reduce this complexity and bring about the best option for performance, cost and design appeal.

    Preparedness for Known Constraints and the Unknown
    Whether a health and hygiene product manufacturer is launching a new product or simply trying to streamline existing operations, there are good reasons to forge alliances with outside materials formatting specialists. Such partners can serve as an extension of an OEM’s manufacturing base during times of short-term capacity constraints. In some instances, these constraints can be anticipated as the OEM projects the need to reserve in-house machinery for scaling up new product production.

    In other cases, it may be impossible to forecast how any one part of the OEM’s operations could become overwhelmed with demand or go down due to natural disasters or other unforeseen circumstances. In planning for these contingencies, it’s wise to qualify a converting partner during times of steady state. Then there will be a reliable resource available for future needs, ensuring redundancy in case of emergencies or spikes in demand. This can apply to everything from extrusion to slitting/rewinding to spooling, printing, kitting and packaging.

    Ultimately, the OEM and all of its supply chain partners benefit if the end product can be processed as quickly and cost effectively as possible, delivering great value to the consumer and increasing sales.


    Jason Surman is vice president of sales for Web Industries Inc., a Marlborough, MA-based provider of flexible material converting and end-product manufacturing services for the advanced composites, medical, health and hygiene, multi-layer insulation, and wire and cable markets. He can be reached at JSurman@webindustries.com or tel.: 508-573-7974.
    Related Searches
    • safety
    • equipment
    • environmental
    • packaging
    Related Knowledge Center
    • Machinery and Equipment
    • Contract Services
    Suggested For You
    Ontex Honored for Mask Production Ontex Honored for Mask Production
    TFP Acquires PV3 Technologies TFP Acquires PV3 Technologies
    BAHP Announces 2021 Officers, Board of Directors BAHP Announces 2021 Officers, Board of Directors
    The Nonwovens Institute to Host Virtual Spunbond and Meltblown Course The Nonwovens Institute to Host Virtual Spunbond and Meltblown Course
    The Private Label Market The Private Label Market
    Glatfelter to Buy G-P Glatfelter to Buy G-P's U.S. Operations
    Asaleo Care Buys Tom Organic Fem Hy Business Asaleo Care Buys Tom Organic Fem Hy Business
    Mondi Collaborates with Drylock on Paper-Based Diaper Packaging Mondi Collaborates with Drylock on Paper-Based Diaper Packaging
    Ontex Sustainability Efforts Recognized by Carbon Disclosure Project Ontex Sustainability Efforts Recognized by Carbon Disclosure Project
    2020: The Lost Year? Not for Nonwovens 2020: The Lost Year? Not for Nonwovens
    Nonwovens in Automotives Nonwovens in Automotives
    Hygiene Suppliers Go Natural Hygiene Suppliers Go Natural
    Responsible Flushing Alliance Forms Responsible Flushing Alliance Forms
    PFNonwovens Adds Second Phase to PA Expansion Plan PFNonwovens Adds Second Phase to PA Expansion Plan
    H.B. Fuller Launches Adhesive for Natural-Based Hygiene Products H.B. Fuller Launches Adhesive for Natural-Based Hygiene Products

    Related Features

    • Machinery and Equipment
      Ultrasonics for Nonwovens

      Ultrasonics for Nonwovens

      A round up of the latest technologies from ultrasonic suppliers
      01.06.21

    • Machinery and Equipment
      Hygiene Machinery Review

      Hygiene Machinery Review

      The world’s leading machinery suppliers offer improved technologies for hygiene products while developing face mask machines at record speed
      Tara Olivo, Associate Editor 01.06.21

    • Machinery and Equipment
      Ultrasonic Technology Review

      Ultrasonic Technology Review

      Demand for the technology grows within the nonwovens industry amid a pandemic
      Tara Olivo, Associate Editor 11.12.20


    • Machinery and Equipment
      WHO’S WHO In San Pro Machinery

      WHO’S WHO In San Pro Machinery

      A listing of equipment suppliers to the global feminine hygiene market
      11.12.20

    • Contract Services
      2020 Contract Manufacturing and Converting Review

      2020 Contract Manufacturing and Converting Review

      An update on providers of finishing, packaging, slitting, winding and other services to the nonwovens industry
      10.08.20

    • Machinery and Equipment
      2020 Machinery & Equipment Review

      2020 Machinery & Equipment Review

      Major suppliers of nonwovens and related machinery offer new technological developments
      Tara Olivo, Associate Editor 08.06.20


    • Machinery and Equipment
      Ultrasonic Technology Review

      Ultrasonic Technology Review

      Lower costs and a cleaner environmental footprint are key benefits to using ultrasonics
      Karen McIntyre, Editor 01.03.20

    • Contract Services
      Converter Round Up

      Converter Round Up

      An update on providers of finishing, packaging, slitting, winding and other services to the nonwovens industry
      10.11.19

    • Machinery and Equipment | Wipes
      nextLevel Wipes from Wet-laid/Spunlaced Nonwovens

      nextLevel Wipes from Wet-laid/Spunlaced Nonwovens

      Truetzschler, Voith collaboration targets flushability
      09.20.19


    • Machinery and Equipment
      2019 Machinery & Equipment Review

      2019 Machinery & Equipment Review

      Major suppliers of nonwovens machinery offer new technological developments.
      Tara Olivo, Associate Editor 08.05.19

    • Machinery and Equipment
      Machinery & Equipment Suppliers Embrace Industry 4.0

      Machinery & Equipment Suppliers Embrace Industry 4.0

      Automation, digitization, machine learning and more become standards in the nonwovens industry
      Tara Olivo, Associate Editor 08.05.19

    • Machinery and Equipment
      ITMA 2019 Wrap Up

      ITMA 2019 Wrap Up

      Nonwovens’ presence expands at textile and garment technology exhibition
      08.05.19


    • Machinery and Equipment
      Fast, not furious—Carton and bag packaging with a stacker

      Fast, not furious—Carton and bag packaging with a stacker

      A new stacker type from Optima promises added scope in production without compromising on processing speed.
      03.15.19

    • Machinery and Equipment

      Hygiene Machinery Review

      Companies continue to diversify into new product lineups and geographies while keeping up with digitization and artificial intelligence trends.
      Karen McIntyre, Editor 01.04.19

    • Machinery and Equipment
      Ultrasonics for Nonwovens

      Ultrasonics for Nonwovens

      A round up of the latest news from suppliers of ultrasonic technologies.
      Tara Olivo, Associate Editor 01.04.19

    Trending
    • Record Mask Production From BelEmsa
    • Domtar Sells Personal Care Unit
    • Executive Reports: Calally Continues To Revolutionize Feminine Hygiene
    • TZMO USA, Special Needs Group Form Partnership
    • TFP Acquires PV3 Technologies
    Breaking News
    • Super Strong Inks Survive Tough Environments
    • Ontex Honored for Mask Production
    • TFP Acquires PV3 Technologies
    • Shemesh Adds U.S. Headquarters
    • TZMO USA, Special Needs Group Form Partnership
    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

    BGG Obtains U.S. Patent on AstaZine Natural Astaxanthin for Heart Function During Exercise
    Qualitas Health/iwi Raises $10 Million in Investment Round
    Aker BioMarine Expands Krill Portfolio with Novel Protein Hydrolysate
    Coatings World

    Latest Breaking News From Coatings World

    Huntsman Finalizes Acquisition of Gabriel Performance Products
    PPG Completes COLORFUL COMMUNITIES Project at School in A. Bangsaothong Samutprakarn, Thailand
    dar-tech, inc. Becomes U.S. Midwestern Distributor for ZS Interpolymer
    Medical Product Outsourcing

    Latest Breaking News From Medical Product Outsourcing

    FineHeart Successfully Tests Wireless TET System
    Apria Healthcare Settles Whistleblower Lawsuit
    OraSure’s OMNIgene·ORAL Device Included in COVID-19 EUA Amendment
    Contract Pharma

    Latest Breaking News From Contract Pharma

    Valeo Pharma Appoints President, COO
    Metrion, LifeArc Extend Neuroscience Alliance
    Grifols Begins COVID-19 Plasma Treatment Trial
    Beauty Packaging

    Latest Breaking News From Beauty Packaging

    JLo Beauty Launches at Sephora & Amazon
    Unilever and Alibaba Group Join Forces
    Redken Unveils Acidic Bonding Concentrate Range
    Happi

    Latest Breaking News From Happi

    A Surge in Interest for Supplements & Vitamins
    Manscaped Expands Further in Europe
    Color Street Gives Back
    Ink World

    Latest Breaking News From Ink World

    dar-tech, inc. Becomes U.S. Midwestern Distributor for ZS Interpolymer
    Techkon USA, Konica Minolta Partner
    Alon Bar-Shany Appointed Chairman of Highcon Board
    Label & Narrow Web

    Latest Breaking News From Label & Narrow Web

    Exhibitor registration opens for virtual.drupa
    FTA planning in-person Forum & INFOFLEX
    Fortis Solutions Group achieves SGP certification
    Nonwovens Industry

    Latest Breaking News From Nonwovens Industry

    Super Strong Inks Survive Tough Environments
    Ontex Honored for Mask Production
    TFP Acquires PV3 Technologies
    Orthopedic Design & Technology

    Latest Breaking News From Orthopedic Design & Technology

    OrthoPediatrics Expands Agent Network in Three European Countries
    Studies Show FlareHawk Expandable Cage Delivers Favorable Fusion, Patient Outcomes
    Rapid Recovery Protocol Can Lead to Increased Range of Motion After TKA
    Printed Electronics Now

    Latest Breaking News From Printed Electronics Now

    UDC Subsidiary Adesis' Website Wins 2020 MarCom Platinum Award
    Roadsimple Modernizes Warehouse Ops with Zebra Technologies
    Graphene Flagship Launches Redesigned Website

    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