Legal requirements and changing consumer behavior make sustainable production methods in diaper manufacturing a necessity. At the same time, companies are under pressure to optimize their costs and remain competitive. Ultrasonic welding offers an innovative solution that combines ecological and economic advantages.

Manufacturing diapers without adhesives

Traditionally, large quantities of adhesives are used in diaper production, especially for elastic entrapment. Global demand for adhesives used in the manufacture of diapers is estimated at around 450,000 tons per year, with about 180,000 tons of that used for elastic entrapment alone.

This enormous amount of chemical adhesives can be saved by using ultrasonics as a bonding technology for diapers and many other hygiene products. This optimizes both the consumption of resources and the cost and CO2 balance of manufacturing.

Sustainability in diaper production: the product carbon footprint counts

The elimination of adhesives also automatically minimizes the energy consumption that was needed before to heat up the chemicals. Although energy is also required for ultrasonic bonding, it is only used locally and extremely efficiently in the joining areas.

This results in energy savings of up to 60–70% compared to conventional bonding techniques. Lower energy consumption not only results in a better product carbon footprint for the diapers, but also lowers energy costs for the diaper manufacturers.

Increase recyclability: a plus for the circular economy

The use of ultrasonic bonding helps improve the recyclability of diapers. Without the use of adhesives, the sorted purity of the materials used is ensured, facilitating the recycling process and supporting the circular economy.

Achieving sustainability goals through adhesive-free manufacturing

Companies are under increasing pressure to meet both legal and their own sustainability targets. Switching to ultrasonic bonding in diaper production makes it possible to meet these targets more efficiently.

By reducing CO₂ emissions and using fewer chemicals, companies can improve their environmental performance while also meeting the increasing demands for sustainable production processes.

Costs and sustainability: ultrasonic bonding offers enormous potential

Increasing sustainability in manufacturing is no longer just an environmental issue. It also offers concrete economic advantages. Using less material, lower energy costs and minimizing the number of rejects can help companies reduce their operational production costs by up to 90 percent. At the same time, they benefit from a positive image among increasingly environmentally conscious consumers.

Conclusion: a sustainable way to manufacture diapers

The integration of ultrasonic bonding technology into diaper production offers a promising opportunity to increase sustainability in the manufacturing of hygiene products.

By reducing the use of adhesives, saving energy and improving recyclability, manufacturers can not only minimize their environmental footprint, but also establish more efficient and environmentally friendly production processes. In addition, the technology offers significant cost advantages and paves the way for future-oriented manufacturing.

Find out more about the advantages of ultrasonic welding for diapers, femcare and other hygiene products.

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