Best Ways to Improve Converting Costs for Diaper Manufacturing

Posted on December 13, 2017 by Author’s JD Belshe

Disposable diaper manufacturing is not easy. While it may seem as simple as sandwiching an absorbent pad between two nonwoven fabric sheets – doing it well requires some great business decisions.

You already watch the costs of raw materials needed for diapers and you work hard to make sure you have the right equipment to make quality diapers. However, with a ton of competition in the disposable hygiene product manufacturing industry, profit margins are usually tight and finding good ways to limit converting costs often determines your profitability.

  1. Controlling Waste
  2. Limiting Defects
  3. Minimizing Operating Costs

Controlling Diaper Manufacturing WasteDiaper Glue & Adhesive

Limiting waste in your manufacturing process can take many forms. For example, things like updating diaper designs to minimize waste of absorbent and nonwoven materials can generate savings. Also, ensuring proper application of adhesive spray or coating to make sure excess glue is not wasted can bring significant adhesive savings. Or, with the fast manufacturing speeds found in diaper manufacturing any equipment limitations at different speeds will cause issues. Making sure that all your equipment can provide top quality performance not just at full speed, but even operating accurately during slower ramp up speeds can reduce waste and save your company money.

Address Diaper Defect Problems

Most disposable diaper defects are found in elastics around the diaper waist and leg sections or in the folded diaper ears. Correcting diaper defects like those in the middle of operations can be costly. But, the impacts can be even worse if defects are not identified before being shipped and instead go on to damage your diaper business’ reputation. Finding analytic ways to identify defects quickly during operations will improve product quality and help build customer loyalty.

Issues like poor apDiaper Manufacturing Machinesplication of glues can create defects in whole batches of disposable diaper elastics or back ears. As glue applications are regularly as small as 0.02 to 0.25 grams in diapers, it can be impossible to see the defects caused when glue is not applied properly. Adding some key analytic capabilities to your diaper production line, like a glue flow meter to measure glue applications to ensure that proper amounts of glue are being applied, can help prevent large defect runs and save your company money while continuously building customer loyalty with your high-quality products.

Minimize Operating Costs for Diaper Manufacturing Machines

When you buy disposable diaper manufacturing machine equipment you of course always compare costs from competitors to optimize the initial investment and ownership costs, but do you also review ways to minimize operating costs? Do you also check reliability and average maintenance costs? What about spare parts costs?

When your factory is processing 1,000 diapers per minute, any operating delay no matter how small costs money. And if it takes longer than a few minutes to correct, that single delay will start costing your business a lot of money. It only makes sense to choose equipment you can trust at prices that give a clear ROI. Make sure you do your research. Not just on how freshly installed equipment runs, but also on maintenance costs and repair part options for the years ahead.


Learn more about eliminating disposable diaper defects with FlexFlow – the intelligent adhesive flow metering system

Get Your Free Valco Melton Audit to Reduce Waste, Address Defects & Minimize Operating Costs.