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iResolve - http://iresolve.eu Sat, 27 Feb 2021 16:41:02 +0000 Joomla! - Open Source Content Management en-gb Drylock Technologies : a new player in the diaper arena http://iresolve.eu/index.php/component/k2/item/98-drylock-technologies-a-new-player-in-the-diaper-areana http://iresolve.eu/index.php/component/k2/item/98-drylock-technologies-a-new-player-in-the-diaper-areana Drylock Diaper

After many rumors the new diaper from Drylock Technologies has been released. It is currently sold under brand Toujours as private label for supermarket chain Lidl.

It started in Germany and it is expected to spread in other country depending on the capacity of new diaper manufacturer.

Drylock Technologyes is the new venture of a long-time private label hygiene executive Bart Van Malderen that is getting back into European diaper markets. The biggest distinctive feature of this venture is that diapers they are going to produce will be the first fully fluffless diaper ever (at least for EU market). And they will be the only alternative to DryMax technology from Pampers that introduced a couple of years ago the almost fluffless diaper core. In fact Pampers contains a small amount of fluff (so called curly fibers) in the product altough its main function is to acquire and distribute liquid and not to absorb it.

Core is made of super absorbent polymer encapsulated between 2 layers. The distinctive feature is that SAP is contained in small pockets formed by combination of two layers and are kept in place without (or with a very low amount) additional thermoplastic material but only by means of bonds all over the 2 webs. These bonds are designed to allow controlled and gradual loosening when SAP swallow and expand. This design provide space for SAP volume growth and avoid reduction of SAP performances because of consequent pressure increase after swallowing. More liquid is absorbed and more bonds are broken releasing more space.

The new diaper is made of a new fluffless core consisting of SAP in larger quantity than standard diaper. In order to avoid gel blocking phenomena Drylock uses a very thick acquisition layer (around 150 gsm) that grant some softness to the product. This gives to the product a very thin profile and possibility to claim a great saving in shelf space and transport cost. Additionally it provides great benefit to the user because it fits perfectly as an underwear.

Technology used to produce this core is not so innovative because it is derived by printing process. But it is the first time it is used in diaper manufacturing. It should consists of a drum with a clustering means, an injection nozzle to provide SAP into perforated side of previous means and a system to transport carrier web in a position to properly receive SAP. More info  in the coming days. Stay tuned. 


Product Design Mon, 29 Oct 2012 06:20:19 +0000
Zero waste wings for sanitary napkins http://iresolve.eu/index.php/component/k2/item/97-zero-waste-wings-for-sanitary-napkins http://iresolve.eu/index.php/component/k2/item/97-zero-waste-wings-for-sanitary-napkins Zero waste wings for sanitary napkins

At first look sanitary napkins seem all very similar. They are all made of a central chassis, usually straight or slightly contoured, and a pair of "wings" to position the product on the user's underwear.

State of the art design wants the full product cut from a single web. The outcome is 30% of your material goes in trim. Is it possible to find another way to produce it and save all that raw materials? Of course the answer is yes. Other manufacturers found a solutions and now their patents are on the way to expire. 

How to innovate your sanitary napkin design?

Many types of sanitary napkins exist on the market. But all of them can be divided in 2 big categories: “shaped” and “winged”. The latter is the most appreciated by women because they are equipped with lateral tabs, commonly called "wings", that help the positioning of the product on the underwear and protect the underwear itself from the contact with body fluids that might not be immediately absorbed by the sanitary napkin.

The wings extend from the longitudinal sides of the sanitary napkin and can be attached to the underwear folding them on the external part of the garment, thus enveloping completely or partially the part of the underwear on the opposite side of the sanitary napkin.

Generally these wings are integrally formed by one or more layers constituting the sanitary napkin itself, and particularly by the union of the lateral edges of the inner material and the outer material.

A mechanical cut, usually of rotary type, is used to shape outer profile from a single web although consisting of multiple materials laminate.

This very standard process has a major drawback: material scrap.

The waste is in some cases from 20 to 40% of the total material used, due to the fact that the wings are present only in the central part of the product. This results obviously in a very significant cost.

Among other drawbacks there is also the fact that the tool for cutting the profile is closely connected to the profile itself. In fact, being the outline rather complex to be drawn, the cutting tool is generally delicate, expensive and must be replaced periodically when worn out. This represents a cost since the replacement of the tool, which involves a machine stoppage, is often long, even in case of product change over on the same production line, and is often not a simple activity. 

To produce sanitary napkins of different sizes or with a different wing design is mandatory to stop the machine and replace the cutting tool according to the new product profile, and this results in an increase of production costs. Moreover the strict link between tool profile and product leads to an important cost increase of the whole production line because for each product size it will be needed at least 2-3 tools to keep line running with spare tools while worn tools are regrinding.

It is more and more common develop alternatives processes to save as more material as possible.  According these new methods wings are manufactured from a separate web and attached to the main product body in a later stage along the process. In this way you can shape wings reducing to zero (or almost to) material trim.

A new smashing technology can be applied to production of sanitary napkins in order to further simplify the whole process and reduce capital investments. It consists of the following steps:

- cutting at least one sheet of suitable material in order to form the absorbent product wings, with a non-rectilinear profile in such a way as to create, on a single web, two identical specular sequence of wings;

- putting alongside the two wings sequences in phase so that said profiles look specular, thus forming a sequence of pairs of opposed and symmetrical wings sequences;

- linking pairs of opposed wings with a release paper;

- cutting said web along a transversal line in order  to isolate a pair of opposite wings including release paper patch;

- transferring the wing pair and release paper patch to absorbent product central structure for a following seam.

The manufacturing process according to this system here described allows the significant reduction of the scrap material, in particular for the production of the wings, resulting therefore less expensive.

But the process above described, providing phases (in particular cutting) simplified compared to standard processes, significantly reduces the complexity of the production equipment. Some patents are present around this construction. Take care to design it properly or acquire a valid license.

Product Design Thu, 20 Sep 2012 04:48:34 +0000
Pampers Change 'N Go http://iresolve.eu/index.php/component/k2/item/82-pampers-change-n-go http://iresolve.eu/index.php/component/k2/item/82-pampers-change-n-go

Pampers Change 'n GoAt the beginning of baby diaper history generally it was used a simple textile piece of cotton for this type of articles. This could be washed and reused many times but with poor performance and bulky appearance. To improve it evolved in a disposable product using high absorbtion powder in the core that allowed a slimmer product.

Moreover other features were added to the same disposable product (elastic panel, mechanical closures, printed and very soft materials). It is today a product so sophisticated that is a pity to throw it away after a single use. Many producers have been looking a way to improve the effectiveness of single diaper and increase its life. At the beginning it was obtained simply by increasing total capacity of absorbtion for a single diaper. But very soon it was clear it was not a direction suitable for ever.

A simpler and effective way to extend diaper life was to use inserts or additional cores. Hereunder some applications are listed as example.




Those inserts had a common characteristic, or at least it appears at first glance as such: the absorbent insert typically is removable only from interior. The overgarment must be removed from the wearer in order to remove the insert.

Pampers introduced a new baby diapers in US. For the time being it seems it is available just if ordered on line but we are waiting for some other news in the next weeks (available in store?)

This diaper is very innovative because it introduce a new structure design to include additional functionalities to the standard product.

It is named Change 'N Go and consists of a baby diaper having a replaceble absorbent core. This can be replaced "on the fly" while baby is wearing the diaper.

The great innovation Pamper Change 'N Go brings on the market is the following: from now on there will be no need to remove diaper from the wearer when the insert is needed to be changed.

A few applications, listed here, disclose a specific design





consisting of a pocket, a space between backsheet and topsheet, configured to receive an absobent insert therin. In the backsheet it is provided a slit to easily access to the pocket. Moreover it is provided a flap that is positionable in an open configuration and a closed position. When it is in closed position the flap covers the slit and inhibits contact between the diaper wearer and absorbent insert positioned in the pocket.

Product Design Mon, 20 Aug 2012 20:47:46 +0000
Pampers Cruiser Active Fit Dry Max http://iresolve.eu/index.php/component/k2/item/81-pampers-cruiser-active-fit-dry-max http://iresolve.eu/index.php/component/k2/item/81-pampers-cruiser-active-fit-dry-max

Dry Max DrawingA new baby diapers with very limited amout of fluff is available in some markets. It has been told it is fluffless but in reality it is not completely true.

The product is Pampers Crusiser(with Dry Max technology) in US and other commercial names in other countries. (like Active Fit) They are manufactured and distributed by P&G.

Chassis is the same as the old version with rigid front flaps and elasticated rear ears. Onto rear ears a couple of tape with hook are placed to be fasten on loop landing zone in the front of diapers.

This product is quite new because absorbent core is made of 2 nonwovens wrapped around a mix of SAP. SAP is kept in position witout use of any fluff but only with a special glue. This system allow to place SAP only where it is needed (and you will see there is no SAP in the back) and of course to save a lot of fluff.

In a size 5 in US you will find about 14g of SAP (and positioning glue). In this way the same absorbency of previous product version is guaranteed.

As we have stated at the beginning it is not completely true it is fluffless because the acqusition layer is still made of fluff. As the previos product there is a patch consisting of a web (usually a resin bonded material) and a layer of curly fibers without any SAP. This is a design very peculiar and it is needed to give to consumers the feeling of a (altough very little) thickness. A completely fluffless core with a very thin product could cause some complaints from the market. Anyhow this design allow to keep the same structure of previous product in contact with the skin of babies. It should reduce possibilities to generate negatives (eg rushes) because hte product is more or less the same.

Here you will find some drawings showing the Pampers Cruiser structure obtained throug a reverse engineering approach.

More detailed info are available.

Product Design Mon, 20 Aug 2012 20:38:30 +0000
Fluffless Core for Baby Diapers http://iresolve.eu/index.php/component/k2/item/78-fluffless-core-for-baby-diapers http://iresolve.eu/index.php/component/k2/item/78-fluffless-core-for-baby-diapers

fluffless_coreAll baby diaper manufacturers are looking for new and more efficient core structures. Up to now cores are made of a mix of fibers (generally fluff) and superabsorbent polymer (SAP). The firsts represent the matrix to stabilize the second and keep it more or less fixed into the core.

Moreover fibers have the function to distribute fluid along the core and bring to SAP something to swallow. After last developments and new SAP generations this fluff function has became less and less important.

Therefore a goal for all hygiene absorbent product producers is to eliminate usage of fluff and obtain a core made of SAP only. This would lead to a thinner core and less expensive product.

Development stream to obtain a fluffless core is the positioning of SAP in small spot on 2 different webs. Afterwards these spots are covered with a glue and bonded together. The result is a sandwich of 2 webs with SAP in the middle. Number of spots and their positions can be varied along the core obtaining a very low SAP grammage in the back and high density in the central part where capacity is more needed.

Technology used to produce this core is simple because it consists of engraved rolls to distribute SAP at specific rate but be aware because already many patents were already filed to cover almost completely this subject.

Some market tests are already on going from big manufacturer and we can expect some news in the next months.

Product Design Mon, 20 Aug 2012 20:15:04 +0000
Always Infinity http://iresolve.eu/index.php/component/k2/item/77-always-infinity http://iresolve.eu/index.php/component/k2/item/77-always-infinity

infinityAlways Infinity is the name in US of a new sanitary napkin started to be distributed in major markets around the world. In Italy it is sold with name LINES E' starting from last July. Its absorbent core consists of a new and unique material called (in US) Infinicel. It is a sort of foam made of super absorbent polymer that is claimed to absorb 10 times its weight. Moreover the absorbent core has some holes in the center to facilitate absorption and some transversal channels in the back to increase fit.

It is incredibly soft and flexible and it seems it will lead a new development pathway for future products of this class. Of course it is sold as a premium product.

As far the chassis structure it is very simple with an asymmetric shape (the back is wider than the front) and double wings (as sometime it is possible to find in products coming from far east). Wings are elasticated on the sides as already seen in the past on P&G products. 

Cover consists of a very soft nonwoven perforated in a central stripe onto the absorbent core.

Packaging is aligned to a product that want to be a premium product: it is a carton box witha small transparent window to see the coulored product inside. As usual sanitary napkins are trifolded and packaged one by one in a confortable and convenient coloured pouch. On the box there is a very long list of patents.

Here it is possible to find a drawing with main dimension for regular size.

Product Design Mon, 20 Aug 2012 20:07:44 +0000