Diaper and Incontinence Manufacturing

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Diaper and Incontinence Manufacturing

The use of disposable diapers has widely spread over the last few decades, especially in Europe and North-America, where cloth diapers were long-ago replaced with disposable alternatives. As developing markets become aware of the advantages of using disposable products, so does the baby diaper market. Most recently, with the incline of an older population, the experimentation and development of incontinence or adult diapers have become a fast growing trend. Valco Melton supports the industry with continuous innovations in this area and a large selection of hot melt and cold gluing application products. To learn more, contact one of our non woven specialists today.

Diaper Manufacturing

Side Sealing

During the Side Sealing of Incontinence and Diaper Products of mainly "T" or "H" shape diapers, the point is to make sure a good seal is made between the top sheet and the back sheet at both sides of the diaper. It can be done with both slot coat and bead applications. The typical adhesive used for this application is a PSA generally called 'Construction Adhesive,' known to have a good adhesion ratio.

Perfumes and Lotions

Perfume and lotions are sometimes applied to diapers. The perfume can be acknowledged as a hot-melt-like liquid, in which case it may be applied with slot coat applicator. In contrast, the substance's formula may be oil based.  In this case, a cold glue dispensing system would be best suited for the job. Spray application is not the most cost-effective option, as most of the perfume is dispensed into the air. To avoid wasting product, a precise bead application is better utilized. Because perfumes and lotions are highly corrosive, having the proper equipment fitted with ceramic seats and/or nylon and steel module bodies will most likely make a big difference in regards to maintenance.

Elastic Waist Attachment

The Elastic Attachment in the Waist of a Diaper is the elastic band located in the rear of the waist area used to provide a closer fit to the end-user's waist. Typically both slot and spray applications are used during this process. The more common adhesive used for this application is a PSA generally called 'Elastics Adhesive,' known to have a strong cohesion ratio.

Pad Integrity

An application for pads of diapers and incontinence products is sometimes done to add integrity to the fluff core and avoid core deformation that may occur when the SAP (Super Absorbent Paper) is insulted. The typical adhesive used for this application is a PSA generally called 'Construction Adhesive,' known to have a good adhesion ratio.  Another adhesive known as 'Integrity Adhesive' supports a deeper core penetration for even stronger integrity.  

 

Waist Construction

In the Waist Construction of Diapers and Incontinence Products, several elastic strands adhere to a band of nonwoven, that once bent, acts as a waist band. Although typically applied with spray, a slot application also provides great results without having to deal with air always involved in all spraying systems. The typical adhesive used for this application is a PSA generally called 'Elastics Adhesive,' known to have a good cohesion ratio.


Leg Elastics

In Leg Elastics of Diaper & Incontinence Manufacturing, elastic strands are adhered to the inner area of backsheet of a diaper to provide a close fit with the end user's legs and retain liquids within the diaper. Normally done with spray, a slot application also supports great end-results with the additional advantage of not having to deal with the added process of air involved in all spraying systems. The typical adhesive used for this application is a PSA generally called 'Elastics Adhesive,' known to have a strong cohesion ratio.

Leak Cuff Elastics

In the Leak Cuff Elastic Application of Diapers & Incontinence Products, also known as Flap Elastics or Cuff Elastics, elastic strands are stuck to the leak cuffs of the diaper to provide a better fit with the end user's body, as well as to retain any liquid inside the diaper. Normally done with spray, the slot additionally supports great results with the advantage of not having to deal with the process air involved in all spraying systems. The typical adhesive used for this application is a PSA generally called 'Elastics Adhesive,' known to have a strong cohesion ratio.  

Hook

In Hook Applications on Diaper and Incontinence Products, velcro stripes are glued to the ear tabs, or, when using a cloth-like Frontal Tape, to the side panel. Typically hooks are glued with a slot, but sometimes multi-beads are used as well. The typical adhesive used for this application is a PSA generally called 'Elastics Adhesive,' known to have a good Cohesion ratio.

Back Ears, Front Ears, and Side Panel

In the Adhesive Application of Back Ears, Front Ears and the Side Panel on diaper and incontinence products, the ear tabs or fasteners are glued to the diaper. They can be glued at one side, when attached over the topsheet, or at both sides as a reinforcement.  When gluing both sides, the diaper holds the ears between the topsheet and the backsheet like a sandwich. For this application, slot is typically preferred, but sometimes because of possible process interference, one of the sides is glued with spray while the other is glued with a slot. The typical adhesive used for this application is a PSA generally called 'Elastics Adhesive,' known to have a strong cohesion ratio.

End Sealing

During the End Sealing of Incontinence and Diaper Products, mainly "T" or "H" shape diapers, the point is to make sure a good seal is made between the top sheet and the back sheet at both ends of the diaper. It can be done with both slot coat and spray. When using using spray, the pattern must overlap along the entire width of the diaper to avoid end-product leakage.  The typical adhesive used for this application is a PSA generally called 'Construction Adhesive,' known to have a good adhesion ratio.

Top Tissue and Bottom Tissue

The top tissue and bottom tissue of a diaper or incontinence product are layers of paper that are placed over and/or under the absorbent pad to help keep the SAP (Super Absorbent) in its place and reduce waste of this material throughout the diaper manufacturing process. These layers are most commonly glued with a spray application to reduce adhesive consumption. The most common adhesive used for this application is a PSA called "Construction Adhesive," generally known to have a good adhesion ratio.

Acquisition Distribution Layer

The Acquisition Distribution Layer in diaper and incontinence manufacturing, also known as ADL or AQL, is a patch of material used on top of the absorbent pad as a reservoir to give time for the SAP (Super Absorbent Paper) to work. This patch is normally bonded to the inner area of the Top Sheet. Because breathability is important, the preferred choice for this application is non contact spray. Typically the adhesive used for this application is a PSA generally called 'Construction Adhesive,' known to have a good adhesion ratio.

Frontal Tape

The Frontal Tape, also known as the Landing Zone, Loop, or Frontal Patch, is the rectangular shaped band of material located in the frontal area of a diaper that is used to fix the side fasteners around the user's waist. Normally made of PP, or a cloth-like material, it is bonded to the back sheet of the diaper either using either a slot coat or spray application. The typical adhesive used for this application is a PSA generally called 'Construction Adhesive,' known to have a good adhesion ratio.

Tack Down

'Tack-Down' refers to the small intermittent adhesive application in diapers and incontinence manufacturing that keeps the leg cuffs folded down near the edges of the diaper. The Tack Down application is normally done with either slot coat or spray applicators. The typical adhesive used for this application is a PSA generally called 'Construction Adhesive,' known to have a good adhesion ratio.


Barrier Leg Cuff Attachment

In Barrier Leg Cuff Attachment of diapers and incontinence products, also known as Flap Attachment or Leak Cuff Attachment, raised cuffs made of hydrophobic nonwoven are used and designed to prevent leakage at the legs. Most of the time, these cuffs are attached to the topsheet using a slot coat or a bead application. The most common adhesive used for this application is a PSA called 'Construction Adhesive,' generally known to have a good adhesion ratio.


Barrier Leg Cuff Construction

In diapers and incontinence applications, Barrier Leg Cuff Construction, also known as C-Fold and Flaps Construction, raised cuffs made of hydrophobic nonwoven are used and designed to prevent leakages on the legs. Although the adhesive used in the leak cuff elastics may be used to bond the cuff's fold, there may be a dedicated adhesive application to carry out this process using a continuous bead or single module spray applicator. The most common adhesive used for this application is a PSA called 'Construction Adhesive,' generally known to have a good adhesion ratio.

Top Sheet Construction

In the Top Sheet Construction of diapers and incontinence products, also known as NW Construction or Nonwoven Construction, the top sheet is the inner face of the diaper that touches an end-user's skin. It is usually made of Spunbond PP nonwoven. The adhesive is applied along the entire diaper to bond this layer to the lower layers of the diaper. Because liquids need to get through, breathable adhesive applications such as a non-contact spray, are more typically the preferred choice. The most common adhesive used is a PSA named 'Construction Adhesive,' generally known to have a good adhesion ratio.

Outer Cover Construction

In Diapers and Incontinence Outer Cover Construction, also known as Cloth-Like Back Sheet Construction, a cloth-like back sheet is an enhanced version of the back sheet film material.  It looks more like a soft cloth than a hard plastic. To achieve this result, an external, non-woven layer is bonded to the polyethylene back sheet. The typical adhesive used for this application is a PSA named 'Construction Adhesive,' generally known to have a good adhesion ratio.

Back Sheet Construction

In the Back Sheet Construction of diapers and incontinence applications, also known as PE Construction or Outer Cover Construction, the back sheet is the outer layer of the diaper. This layer is made of film, normally PE (polyethylene) or a textile laminate designed to keep the liquids contained.  In this application, adhesive is applied along the full length of the diaper's outer layer to appropriately bond it to all upper layers, leaving only specific, unglued areas for leg elastics.  The typical adhesive used for this application is a PSA generally known as 'Construction Adhesive' which holds a strong adhesion ratio.