GDM
GDM is a worldwide leader in industrial market solutions for Hygiene products. Thanks to its Business Made Easy approach, the company provides a unique technological and consulting service at 360°: from the product to the design of the next generation of the whole production plant.According to the company, a complex historical situation has been caused by the global geopolitical crisis and the recovery from the Covid-19 pandemic, which is negatively affecting the whole industrial sector on different levels—component prices, availability and transports—and has created a complex situation for the hygiene segment. From GDM’s standpoint, as a machinery manufacturer, the company affirms it has only been indirectly affected by this picture, with the major backlash being showered on disposable hygiene products manufacturers.
Actually, GDM has relied on the strong partnerships forged throughout more than 35 years in the industry with its historical suppliers of raw materials and technology. This has allowed the company to secure critical materials – electronic ones in particular – bypassing the risk of stock disruptions. Being a part of Coesia Group has also strengthened GDM’s position, allowing it to maintain the lead time of its machines at approximately pre-Covid levels.
From 2015-2020, the adult incontinence segment has grown the most quickly within the disposable hygiene industry due to rising living standards, improved consumer awareness and greater product variety. In this context, the “Silver Society” is a rising phenomenon in developed countries and is influencing the market more and more, being the ideal target segment for any player in the field.
As of today, although taboos are lifting, there is still some embarrassment among adults about urinary incontinence, thus discretion is paramount. That is why the protective underwear has increased significantly. In response to this growth, GDM has introduced a dedicated product the AP3 Grey line – production speed at 300 ppm – characterized by: flexibility to ease size and product change for a wider range of materials, ease of use thanks to the linear layout of the machine and an improved process control on key product features and relevant production steps for higher quality.
In September, GDM customers had the possibility to experience the uniqueness of its complete turnkey solution for the Protective Underwear segment composed of the converting AP3 Grey line, the packaging SB40 Red Series A3 machine, the RI20 Industrial Palletizer by FlexLink (GDM’s sister company within Coesia Group) and the Digital Printing solution by Kodak.
The baby diaper segment, meanwhile is to a certain extent stable and demand remains strong for premiumization like leakage-free, comfort, enhanced waist elasticity and excellent performance. GDM’s inline laminated waistband process unit can produce and apply an in-line elastic waistband onto baby diapers. This feature, depending on where the waistband is applied, generates two advantages: when applied onto the topsheet, facing the baby’s body, it provides better product performance eliminating back leakage and when applied between backsheet and topsheet it ensures superior comfort increasing product elasticity.
In 2022, GDM has witnessed a significant increase in the number of requests received for newly supplied machines for feminine hygiene and adult incontinence lines at a global level while the baby diaper segment, open and pants style equally, have remained stable versus the previous year. More specifically, pants style format products are booming in the adult segment while lines for adult briefs are steady.
Downstream on the considerations about the demands for machinery and their geographies.
When it comes to doing business globally, what has set GDM apart is that it has always served the global marketplace by designing its technology to the specific needs of each of its clients, putting it in a proactive listening condition.
This, for example, has led the company to anticipate the desire for turnkey solutions – from converting to packaging and End-of-line management with GDM as single source supplier – making its proposal to the Disposable Hygiene machinery market one of a kind.
In the disposable hygiene segment, a significant overhaul of the digital strategy is taking place. Simplicity has been more in demand among industrial clients: with increasingly price-sensitive consumers chasing fewer goods with high-performing, eco-friendly features, the result is a tougher competition and rising production costs for manufacturers and industry players. That’s why more and more companies are looking for a technological moat to simplify operations, reduce production costs and improve quality and output.
For these reasons, GDM strongly believes in the complete digitalization of the production process, because it envisions great benefits for its customers: digitalization makes using its machines easier, dramatically improving user experience and boosting business continuity to unprecedented levels.
In this perspective, as a starting point of its Digital Transition, GDM has developed digital instruments – perfectly integrated with each other and working on different levels – supporting the production process.
After the huge success of OptiMate, the machine interface with connectivity and smart functions enhancing equipment’s quality and performance, GDM optimizes the disposable hygiene manufacturing operations with a new and upgraded portfolio of digital Industry 4.0 solutions, such as PerforMate and HyperMate.
PerforMate is a brand-new IIot platform for full-scale, real-time machine monitoring. By leveraging machine learning algorithms running on Coesia’s proprietary cloud infrastructure, PerforMate provides a bird’s-eye view of the production line through a personalized, easy-to-use dashboard, combined with asset monitoring, loss tree analysis, trends and alarm notifications.
HyperMate, on the other hand, is a cutting-edge factory automation solution that runs a production plant on autopilot. Through wireless sensor networks and AI, HyperMate raises productivity to a whole new level, turning a factory into a full-fledged, 21st-century Smart Factory.
The need for natural solutions, meanwhile, has morphed from niche solutions for green-conscious consumers into a fast-spreading, almost viral phenomenon. Similarly, natural hygiene products, market-adjacent to the natural personal care trend, are coming to the fore and, depending on the segment, even rising at double digits.
Among the main drivers, a big one is the steady pace of investments in the sector from established corporations, together with anti-plastic regulation and the rising environmental awareness in the public.
More and more consumers of disposable hygiene solutions are switching to natural and organic products — and companies are not standing by. Indeed, disposable hygiene manufacturers are making natural personal hygiene a cornerstone of their sustainable agenda, cutting down on plastics from fossil fuels and empowering waste reduction efforts.
Along this line, requests for flexible equipment capable to manage a wider range of raw materials, including those with a sustainability claim, are soaring.
GDM’s natural attitude for innovation blended with the “Business Made Easy” driving philosophy, makes GDM the perfect partner for this kind of solutions and even becoming an enabler for start-up companies or newcomers.
www.gdm-spa.it
Andritz Diatec
According to Ettore Paolini, general manager of Andritz Diatec, current market challenges continue to place a great burden on every company doing business in hygiene, which calls for flexibility, agility and an innovative spirit. In response, Andritz Diatec has designed and manufactured a wide range of converting machines and technology solutions to produce absorbent hygiene products (AHP) and other disposable products, such as food pads, medical products, laminates, disposable gloves, and head rests, for more than 30 years.In addition, development work at Andritz Diatec has focused on the progress of the technology range as a whole and its adaptation to specific markets and customer needs. Based on market analysis, the company has established three levels of machine speed, all offering an optimal quality/price ratio to provide the latest technology solutions at competitive prices, customized design and compact layout: aXcess is for machines at lower speeds, particularly suitable for emerging markets; eXcelle is the category for medium-high speed machines; while eXcelle pro covers high speed machines for high-volume markets.
In terms of AHP market growth and potential, the segment for adult incontinence products is still on the pole position. This has resulted in a state-of-the-art adult pant converting process with highest quality standards, such as the development of ultrasonic side seam solutions with excellent results in terms of bond strength and system reliability. As a result, operations and size changes are faster and easier. The modern forming system for higher SAP (superabsorbent polymers) concentration and the turning and placing system guarantee maximum process stability that has been successful in the premium adult hygiene market.
To ensure a top-level of production performance and keep the lines of its customers running smoothly, a full range of retrofit kits and upgrades are available. In addition, an operator-friendly maintenance results in reduced downtimes and thus saves costs.
At the forefront of these research an development efforts are market and customer needs, adds Fabrice Ferretti, head of sales. Currently, sustainability, especially reducing the use of plastics, saving energy and increasing efficiency, is the key consumer demand.
One key area is a specific glue-free or glue-reduced solution, that is important for pant products, where softness and “wearability” are key factors for end users. Not using glue in the process has advantages for both producers and end users. On the one hand, manufacturers save money on gluing equipment, glue storage and nonwoven raw materials. On the other hand, end users benefit from a soft fabric that is gentle to the skin being in contact with their body, ensuring a good fit and flexibility at the same time. In addition, less glue means a smaller environmental footprint, cleaner production processes and less material waste.
Another hot topic is the use of recycled pulp in an absorbent hygiene product. Here the company would like to highlight the strong network it has within Andritz Nonwoven. “Thanks to the synergies and support of Andritz Laroche in France, we have already been able to launch a first machine, capable of mixing recycled and virgin pulp, and producing high quality pads,” Ferreti says. “This system is fully integrated into a conventional converting line and is designed to increase the current working windows while maintaining the same production time as conventional products with 100% virgin pulp. A clear advantage is that the result is more sustainable with the same level of performance.”
To increase productivity and competitiveness for its customers in the still growing baby pants segment, the company has developed a new platform for high-speed production of baby pants. In some cases, the average capacity is not sufficient to handle the expected volumes. Therefore, the new line can produce up to 800 ppm and offers the same advantages as a medium speed solution, i.e. compact design, flexible resizing, easy operation, high quality of the final product, ultrasonic technologies and reduced level of scrap.
Consumer demands vary between regions and markets. It is linked to specific market conditions and requirements. E.g., Europe and North America are areas historically more focused on innovations and performance improvement (digital products, energy saving). Africa, Middle East, and Latin America on flexibility, compact design, and affordable price. Just to name a few examples.
In fact, it can be challenging to serve different needs and market requirements. However, as long-time player in the market and its lean and smart organization, Andritz is compelled to seek out innovative solutions to fulfill customer demands. Therefore, it offers technology especially according to market needs and has well demonstrated in the past the capacity to adequate people and customized solutions. In addition, the synergies and combined strengths of all Andritz Nonwoven companies provide unrivalled expertise for the benefit of its customers. With Andritz Nonwoven’s great sales and service organization, it can rely on a strong network.
Sustainability is the meta-topic and more than just a trend in the nonwovens industry, according to Paolini. “It is a serious responsibility for the whole world in the decades to come,” he says. “The urgent need to reduce the use of plastics, save energy and increase efficiency is a clear innovation factor for the nonwovens industry – also for Andritz – and has led to newly developed production processes and products on the market.”
Thus, Andritz is continuously working on forward-looking technologies with a compact footprint, easier transportation, less manpower, optimized energy consumption, glue-free solutions, and recycling technologies – solutions to achieve greater sustainability and a greener future.
“However, this issue does not only concern us as a machine supplier, but the entire industry and supply chain, which includes raw material suppliers, roll goods producers, converting companies, retailers, and finally the end-user,” Paolini adds.
www.andritz.com
W+D
According to Andrea Allar, product manager Hygiene at W+D BICMA, the market for hygiene equipment has been impacted by increasing raw material prices, which have led to reduced investment in the main markets. Investment in emerging markets, meanwhile, continues to be strong.“W+D is constantly looking for our customer needs and try to adopt our machines accordingly,” Allar says. “Our new pants machine is a good example since we found a way to reach 800ppm with a simplified ultrasonic bonding system for the side seam. Thanks to a special design, the side seam bonding is very exact and narrow, while at the same time guaranteeing a perfect bonding strength.”
Other new developments include an Underpad machine series which features W+D’s quick size-change concept and offers options which are presently common in this market. W+D decided to focus on underpad machines because of growing demand in the market. Here, its expertise, along with BICMA’s experience in core forming and hygiene product converting processes, made it a good moment to add this important category to its portfolio.
Additionally, W+D is focusing on creating a new platform concept for the different categories which offers customers a modular machine concept resulting in reduced maintenance and operation costs. The platform concept gives the right answer to its customers requirement for higher OEE for converting machinery.
“Besides known demands such as quick size-change, low down-time, high reliability, efficiency and an excellent service, the need for flexibility and upgradability has become more important than in the past,” Allar adds. “This is due to the dynamic evolution of new, sustainable raw material and product concepts in a changing world.
“It is challenging, yes, but challenges make you stronger. It is an advantage of W+D BICMA to have decades of experience, a strong engineering power, and expertise in the entire range of technology – from smallest panty liner up to largest adult diaper. We are also grateful to welcome several new team members on board, all of them with substantial experience in responsible positions in the hygiene industry. They are a perfect contribution to our team and further enhance our deep understanding of customer needs and market trends.”
Subject to the raw material characteristics, machine adaptations might be needed, such as replacement of ultrasonic by other bonding systems. With specific retrofit expertise, W+D BICMA is ready to support customers in upgrading their existing equipment and make it fit for sustainable products.W+D BICMA has developed a bunch of sustainable innovative product and wrapping alternatives, saving raw materials, reducing product costs, and cutting down plastic waste. Examples of such concepts are a winged menstrual pad with no waste, TO-GO Ministack featuring 4-5 folded pads packaged in one reclosable pouch to reduce single-wrap plastic, as well as Green Manta – an inline paper-envelope process for menstrual products.
www.w-d.de
Anqing Heng Chang Machinery Co., Ltd
As a leading enterprise in the industry, Anqing Heng Chang Machinery Co., Ltd (HCH) continues to focus on research and development, allowing it to launch some new technologies, such as unmanned feeding technology, high-speed ultrasonic application, etc., mainly for multinational customers who have a higher demand for equipment speed and product upgrade.One of the booming trends in the industry continues to be the growth of pants-style hygiene products for baby, feminine care and adult incontinence applications. On the other hand, the demand for processing more environmentally friendly raw materials hasn’t been as strong from the company’s point of view.
Describing the disposable hygiene market overall, HCH believes overall demand will keep growing, considering the low market penetration of some categories in developing countries.
www.aqhch.com.cn/en/
Zuiko
Since the onset of the pandemic, Zuiko has been working with suppliers to minimize the effect of the supply chain disruptions. Despite this, rescheduling was sometimes unavoidable and necessary for many projects. “Even now, we still feel the effects of supply chain disruptions but are continually working to keep our projects on-schedule,” says sales manager Curtis Woo. “Thankfully, our customers are very understanding and patient.”Zuiko’s chief focus has been to help customers succeed by designing machines that lower production costs and add value to the products. “We are working on new machine concepts that lower power consumption and minimize raw material usage without affecting product performance nor quality,” says Woo. “In parallel, we are also working on next generation technologies that improve on some of our most successful inline absorbent core and stretch material converting processes. These value-added technologies are intended to work with our new concept designs and can be retrofitted into currently running machines.”
By proposing new machine and product ideas, Zuiko hopes to help customers be more proactive and help them stay ahead of the market and price competition.
Customer requirements depend heavily on the region/market, and there are differences even within the region/market. This is why it is so important for the company to listen to customers. Customizing every machine is challenging, but doing so helps customers manufacture competitive products.
Zuiko’s latest technologies minimize material usage, which reduce production costs but also make each product more sustainable.
www.zuiko.co.jp n