With the progress of society and the improvement of people's living standards, the awareness of hygiene has been continuously enhanced, and the use of diapers has become increasingly widespread. This article will provide a detailed introduction to the manufacturing process and core technology of diapers, and explore the development trends of the industry by combining market data and case studies.
The Layered Structure of Diapers
The raw materials of diapers generally include non-woven fabric, tissue paper, high-absorbency core layer (absorbent resin and fluff pulp), bottom film (PE film), elastic bands, adhesive tapes (front + left and right), and waistband elastic, among others. Despite the wide variety of styles available on the market, the basic structure remains largely the same. Generally speaking, from top to bottom, it can be divided into four parts: the surface cover layer, the distribution layer, the absorbent core layer, and the bottom layer, with the absorbent core layer being the most crucial part. The basic structure of adult and baby diapers is the same; the only difference is that due to the larger volume of excretion caused by adult incontinence compared to babies, some manufacturers add an extra layer of absorbent sanitary paper between the bottom film and the absorbent core layer to increase the absorption capacity and enhance the anti-leakage ability.
Market research data shows that the market penetration rate of adult diapers is gradually increasing, which is closely related to the aging population and the increasing attention to adult incontinence care. For example, in some developed countries, the usage rate of adult diapers has reached a relatively high level. In China, with the development of the elderly care industry and the shift in consumer attitudes, the adult diaper market is also showing a rapid growth trend.
The Manufacturing Process of Diapers
In terms of the manufacturing process, diaper pads are simpler in processing technology compared to diapers, as they lack the steps of waistband adhesive tape and peripheral forming. The following is the manufacturing process of basic type diapers:
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Pulp Crushing: The pulp is crushed to achieve the fineness suitable for subsequent processing.
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Forming: The crushed pulp is mixed with fluff pulp and other raw materials in a certain proportion and processed through forming equipment to create an absorbent core layer with a specific thickness and shape.
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Fixing Absorbent Core and Absorbent Paper (Spraying Adhesive): The absorbent paper is fixed on the absorbent core layer using a spraying adhesive process to ensure their close combination and improve absorption performance.
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Embossing: The absorbent core layer is embossed using an embossing machine to create a certain pattern and structure, which helps with liquid diffusion and absorption.
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Cutting: The embossed absorbent core layer is cut to the required size and shape, preparing for the subsequent forming process.
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Peripheral Forming of Absorbent Core and Absorbent Paper: The cut absorbent core and absorbent paper are processed for peripheral forming to give them a three-dimensional structure, facilitating assembly with other components.
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First Forming Cutting: The formed absorbent core is cut for the first time according to the product design requirements to determine its required length.
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Fixing PE Film and Elastic Bands (Spraying Adhesive): The PE film is fixed to the bottom of the absorbent core layer, and elastic bands are fixed in the appropriate positions using a spraying adhesive process to ensure the fit and comfort of the diaper.
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Adhesive Tape Area for Arbitrary Attachment: An area for arbitrary adhesive tape attachment is reserved on the diaper to facilitate user attachment and fixation.
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Applying Self-Adhesive Tape: Self-adhesive tape is installed in the adhesive tape area to ensure good adhesion for easy use by consumers.
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Peripheral Forming: The diaper's periphery is formed to give it a complete appearance and structure.
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Longitudinal Tri-Folding: The formed diaper is longitudinally tri-folded to reduce its volume for easier packaging and transportation.
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Second Forming Cutting: The longitudinally tri-folded diaper is cut for the second time to ensure accurate size and neat appearance.
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Horizontal Tri-Folding: The cut diaper is horizontally tri-folded to further reduce its volume and improve packaging efficiency.
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Conveying: The folded diapers are conveyed to the packaging area using conveying equipment.
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Arranging: In the packaging area, the diapers are arranged in a certain order and quantity to facilitate subsequent packaging operations.
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Packaging: Suitable packaging materials and equipment are used to package the arranged diapers, ensuring their integrity during transportation and storage.
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Sterilization (Ethylene Oxide, Non-Destructive Sterilization): The packaged diapers are sterilized using ethylene oxide or non-destructive sterilization technology to ensure product hygiene and safety.
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Finished Goods Storage: The sterilized finished diapers are stored in the warehouse, awaiting shipment.
Taking a well-known diaper brand as bubandi, it strictly follows the above process in production and has set strict quality inspection standards at each key link. For instance, after the absorbent core layer is formed, an absorption performance test is conducted to ensure its ability to quickly absorb liquids. After packaging, each pack of diapers is weighed and visually inspected to ensure product quality. It is this strict control over the production process that has enabled the brand to gain a good reputation and a high market share.
The Core Technology of Diapers
Dryness is an important indicator that determines the comfort level of diapers. It has three key indicators: absorption speed, re-wet amount, and leakage situation. Among them, the absorption speed and re-wet amount are crucial to the "absorbent core layer," while the ability to prevent leakage depends on the design of the "distribution layer." Therefore, these two parts are also the key links for outstanding products.
Absorbent Core Layer
The absorbent core layer determines its water absorption capacity and is composed of two key raw materials: superabsorbent polymer (SAP) and fluff pulp. SAP is a polymer material with high water absorption capacity, capable of absorbing dozens of times or even hundreds of times its own weight in water. Fluff pulp is a natural fiber material with good breathability and softness, which can cooperate with SAP to form an efficient absorption system. In actual production, the performance of the absorbent core layer can be optimized by adjusting the proportion of SAP and fluff pulp, achieving the best balance in absorption speed, absorption amount, and re-wet amount.
Many Diaper Manufacturers have adopted special SAP particles in its products, which have been processed through a unique process. As a result, the absorption speed of the absorbent core layer is more than 30% faster than that of ordinary products, and the re-wet amount has been reduced by about 20%. The application of this technology has significantly improved the dryness of diapers, providing users with a more comfortable experience.
Distribution Layer
The distribution layer is a special non-woven material placed between the surface cover layer and the absorbent core layer. It can effectively help liquids quickly conduct from the surface cover material to the inside and diffuse longitudinally, allowing liquids to quickly leave the user's skin and be evenly absorbed by the core layer. This prevents the core layer from becoming locally thick due to concentrated absorption, which would hinder the subsequent absorption of urine by SAP. The design of the distribution layer is also crucial for preventing leakage. By reasonably designing the structure of the distribution layer, liquids can be guided to flow in a specific direction, reducing the risk of lateral diffusion and leakage within the diaper.
Some advanced diaper brands have adopted a multi-layer distribution layer structure, with each layer having different functions. For example, the outermost distribution layer is mainly responsible for quickly conducting liquids, allowing them to quickly leave the user's skin. The middle layer of the distribution layer serves to diffuse and buffer, evenly distributing the liquids to the absorbent core layer. The inner layer of the distribution layer closely cooperates with the absorbent core layer to ensure that liquids are quickly absorbed. This multi-layer distribution layer structure design has significantly improved the anti-leakage performance of diapers.
Non-Woven Fabric
Non-woven fabric is the part that covers the outside of the absorbent core layer. Traditional fabrics are made by weaving natural fibers such as silk, cotton, and wool, while non-woven fabric is generally made by arranging short fibers or long filaments of plastic resins like nylon and polyester in a directional or random manner to form a fiber web structure. The structure is then reinforced by mechanical, thermal bonding, or chemical methods. Non-woven fabric has characteristics such as moisture resistance, breathability, flexibility, and light weight, making it particularly suitable for the production of absorbent hygiene products. In diapers, the role of non-woven fabric is not only to provide a comfortable surface but also to prevent liquid penetration and maintain the dryness of diapers.
In recent years, with the continuous development of non-woven fabric technology, some new types of non-woven fabrics have been applied to diaper production. These new types of non-woven fabrics have better breathability and softness, offering users a more comfortable feel. For example, a brand has launched ultra-soft non-woven fabric diapers. The surface non-woven fabric of these diapers uses special fiber materials and processing techniques, making the surface of the diapers softer and comfortable to touch. Even with prolonged use, they will not cause skin irritation.
Development Trends of the Diaper Industry
(i) Development of Environmentally Friendly Diapers
With the increasing awareness of environmental protection, consumers' demand for environmentally friendly diapers is also gradually increasing. Environmentally friendly diapers mainly use biodegradable materials and natural fibers to reduce environmental pollution. For example, some brands have launched diapers made from natural materials such as bamboo fiber and corn fiber. These materials not only have good absorption performance but also can degrade naturally after use, being more environmentally friendly.
According to market research institutions' predictions, the market share of environmentally friendly diapers will increase year by year in the next few years. It is estimated that by 2030, the market share of environmentally friendly diapers will reach more than 30%. This will encourage more companies to increase their investment in the research and development and production of environmentally friendly diapers, promoting the sustainable development of the entire industry.
(ii) Prospects for Intelligent Diapers
Intelligent diapers are an emerging development direction in the diaper industry in recent years. Intelligent diapers are equipped with built-in sensors and smart chips that can monitor the user's urination in real-time and send reminder messages to users through mobile applications. This intelligent design not only facilitates users' use but also improves the utilization efficiency of diapers and reduces waste.
At present, some high-end brands have launched intelligent diaper products, which have received a good response in the market. With the continuous progress of technology and the reduction of costs, intelligent diapers are expected to be more widely used in the next few years and become an important growth point in the diaper industry.
Diapers, as an upgrade product of traditional industrial papermaking and domestic paper, have seen a continuous increase in market penetration rates and fierce market competition in recent years. Understanding the manufacturing process and core technology of diapers not only helps consumers better choose suitable products for themselves but also enables companies to continuously improve product quality and enhance market competitiveness. With the development of environmentally friendly diapers and intelligent diapers, the diaper industry will usher in a broader development space.
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