Last month, Cottonsie launched a new plant-based diaper that replaces plastic with 100% breathable cotton in key diaper layers, including the topsheet, backsheet, acquisition distribution layer (ADL) and core wrap.
 
According to the company, cotton is a natural, breathable fiber that supports a drier, healthier microclimate that can minimize the incidence of diaper rash. While the diaper includes synthetic materials to optimize performance, the majority of the diaper is plant-based—and 82% of it biodegrades within just 18 months.

Unlike conventional diapers made mostly of plastic, Cottonsie uses 100% natural cotton in nearly every area that touches a baby’s skin. “Plastic diapers are clogging our landfills and leaching toxins into the environment,” says Nicole Richards, founder and CEO of Cottonsie. “We created Cottonsie to give parents a real alternative: a high-performance, comfortable diaper made mostly from natural, biodegradable materials—and priced accessibly for everyday use.”
 
Nonwovens Industry spoke with Richards about the path to creating Cottonsie diapers and the sustainable hygiene products market.
 
Nonwovens Industry (NWI): What was the inspiration behind the launch of Cottonsie diapers?
 
Nicole Richards (NR): The idea for Cottonsie came from my background in textiles and polymers, specifically, the challenge of making cotton behave more like plastic when it comes to moisture transfer. Cotton is such a beautiful, natural material—soft, breathable, and environmentally-friendly—but it’s also known for holding onto moisture, which isn’t great when that moisture is sitting right next to a baby’s delicate skin. I developed a patent-pending method that transforms how cotton handles liquid, allowing it to release and transfer moisture more like synthetic plastic-based materials found in conventional diapers. With that breakthrough, we were able to create a diaper that’s made with 100% cotton in the topsheet, backsheet and ADL—offering the comfort of cotton with the performance of plastic. While our diapers do contain synthetic ingredients to enhance performance, including spandex in the leg cuffs for a comfortable fit, and plastic ear tabs for safety and quality, as well as a biodegradable superabsorbent polymer (SAP) to prevent leaks, most of the parts of the diaper that touch the baby’s and parent’s skin has been swapped out for cotton.
 
NWI: What was missing from the baby diaper market that your brand can offer? How do Cottonsie diapers compare to other brands that use cotton, or other plant-based options?
 
NR: What we saw missing from the market was a truly green diaper—something that goes beyond the marketing. A lot of brands use terms like “plant-based” or “eco-friendly,” but when you read the fine print or run a materials analysis, it’s clear most of the diaper is still plastic. Some brands include a small amount of plant-based plastic, such as PLA, but it is often encased in conventional plastic—making it more of a marketing gimmick than a genuine environmental benefit. Even though PLA starts as a plant, such as corn, sugarcane or sugar beets, the heavy chemical processing involved turns it into a synthetic plastic that can break down into microplastics. In addition, this process often relies on metal catalysts and petroleum-based inputs that are typically not disclosed to consumers. Cottonsie™ takes a completely different approach. We use real, natural cotton—not just as a marketing hook, but as the core of our product. We use 100% cotton in key layers, including the topsheet, backsheet, and ADL. That means we’re not just adding a trace of cotton for feel-good appeal. We’re building the diaper around cotton because we believe it’s best for babies and the environment.
 
When compared to brands claiming to incorporate cotton, there’s a clear difference. For instance, the few products that claim to incorporate cotton into their diaper products only contain a relatively small amount of cotton, with some containing next to no cotton, while continuing to rely on polyester or polyethylene for the main structural components. There are even diapers that say they’re “cotton-enhanced” but contain less than 2% actual cotton overall. We’ve tested some through independent third-party labs, and the results show a predominance of petroleum-based plastics.
 
NWI: Can you tell us how cotton is used in Cottonsie diapers? What challenges did you face in incorporating cotton, and how were those overcome?
 
NR: Cotton is at the heart of every Cottonsie diaper. While many brands may add a touch of cotton here and there, we use 100% natural cotton in the topsheet, backsheet, and acquisition distribution layer (ADL). Naturally, incorporating that much cotton came with its own set of challenges. One of the biggest was that a fully cotton-based diaper can’t yet completely replace certain synthetic components without sacrificing quality. That’s why some synthetic materials are still used—to ensure optimal fit, performance, and protection against leaks and blowouts. Another major challenge was managing cotton’s natural absorbency. Cotton tends to hold onto moisture, which could lead to a wet surface against a baby’s skin. To address this, we developed a patent-pending moisture management system that fundamentally changes how cotton interacts with liquid. It enables fast absorption, efficient strike-through, and significantly reduces rewet—so the diaper’s surface stays dry and comfortable, even after multiple uses.
 
NWI: Have you seen a shift in consumer demand for sustainable/plant-based diapers? If so, what do you believe is driving this change?
 
NR: Yes, absolutely. There’s been a real shift in what parents are looking for. More and more, they’re questioning what’s in the products they use every day, especially when it comes to their babies. I think a big driver is environmental awareness—people understand that conventional diapers can take hundreds of years to break down, and they don’t want to contribute to that kind of waste if they have other options. There’s also a growing concern around health and safety. Parents are reading labels more carefully, they’re aware of issues like microplastics, PFAS, fragrances, and dyes, and they want products that are cleaner and gentler. Some are even switching to reusable cloth diapers, which shows how strong the motivation is. At the same time, improvements in technology have made it possible for brands like ours to offer a sustainable option that doesn’t compromise on performance.
 
NWI: Where do you see the market for eco-friendly hygiene products heading in the coming years? What obstacles do you think the industry needs to overcome to make sustainable products more mainstream?
 
NR: I think we’re going to see continued growth in eco-friendly hygiene products across the board. Parents are leading the charge, but the trend is expanding into all categories of personal care. Still, there are some real challenges that the industry needs to face head-on. Cost is a big one. Sustainable materials and processes are more expensive, and that can make eco-friendly products less accessible. Over time, with scale and innovation, we believe that will change—but it’s a hurdle right now. Another issue is perception. Some consumers still think sustainable products don’t perform as well, especially in categories like diapers, where function is everything. That’s why it’s so important for companies like ours to prove that you can have both performance and sustainability. And finally, we have to address the problem of greenwashing. When brands make exaggerated or misleading claims about sustainability, it creates confusion and skepticism in the market. That hurts everyone—including the companies that are really doing the work. Transparency and honesty are key if we want to build long-term trust with consumers.

www.cottonsie.com