Diaper Manufacturing

Diaper Manufacturing:
Raw materials: Its ability to Absorb. Cotton material used in cloth Diapers is Absorbent, but synthetic Polymers far exceed the capacity of natural Fibers.

This Pad is composed of two essential elements: a hydrophilic, Polymer and a fibrous material. The Polymer is made of fine particles of an Acrylic acid derivative, such as sodium Acrylate, potassium Acrylate, or an Alkyl Acrylate.

Other parts of the Polymer: have the ability to chemically link with different Polymer molecules in a Process known as Cross linking. When a large number of these Polymeric chains are Cross linked, they form a gel network that is not water soluble but can Absorb vast water.

NonWoven Fabric: The Absorbent Pad is at the core of the Diaper. It is held in place by NonWoven Fabric Sheets, form the body of the Diaper. Traditional Fabrics are made by weaving together Fibers of Silk, Cotton, Polyester, Wool.

The Manufacturing Process:

Formation of the Absorbent Pad: At various points in the chamber, pressurized nozzles spray either Polymer particles or fibrous material onto the Conveyor surface. The bottom of the Conveyor is perforated, as the Pad material is sprayed onto the belt, vacuum is applied from below so that the Fibers are pulled down to form a flat Pad.

After the Pad has received a full dose of Fiber and Polymer: it proceeds down the Conveyor path to a roller near the outlet of the forming chamber. This roller removes a portion of the Fiber at the top of the Pad to make it a uniform thickness.

Preparation of the NonWoven: 3 Sheets of NonWoven Fabric formed from Plastic Resin using the meltblown Process as described above. These Sheets are produced as a wide roll known as a web, which is then cut to the appropriate width for use in Diapers. There is a web for the top Sheet and another for the bottom Sheet.

Disposable Diaper: At some point in the Process, Elastic Bands are attached to the backing Sheet with Adhesive. After the Diaper is assembled, these Elastic Bands contract and gather the Diaper together to ensure a snug fit and limit leakage.

Assembly of the Components: There are still three separate Components, the Absorbent Pad, the top Sheet, and the backing Sheet. These three Components are in long strips and must be joined together and cut into Diaper-sized units. The long roll is then cut into individual Diapers, folded, and packaged for shipping.

How much does it cost to manufacture a Diaper: According to market research, the average price of a premium disposable Diaper is 24 cents whereas private label products typically retail for 19 cents per piece.

How long can a baby wear a wet Diaper: Diapers are great, they have an incredible ability to Absorb and hold a lot of urine and poop, but even they have limits. A Diaper can only hold so much, and while some state that they can Absorb up to 12 hours of wetness at night times this is debatable, especially as your baby grows.

Wishing you all the best,
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