Project Report For Diaper Manufacturing

Project report for Diaper Manufacturing is as follows.

An absorbent pad and non-woven fabric sheets make up the two main parts of disposable diapers. The diaper’s soft, water-retentive core is made up of the absorbent pad’s super absorbent polymer (SAP) and fibrous wood pulp substance. 

Super absorbent polymers, which are frequently utilized in the manufacture of disposable diapers, are byproducts from other industrial sources, which enables producers to save the expenses associated with diaper production while reusing polymer particles that would otherwise be too refined for use elsewhere. 

These SAPs, which boost the total absorbance and water retention capacity of the diaper, are chemical-based items produced from derivatives of acrylic acids, such as sodium polyacrylate (the most popular), potassium acrylate, and alkyl acrylate. 

They are similar in size and function to very tiny sponges. The thinness of the diaper is made possible by the small size of the polymer particles, which also helps to reduce the bulk or overall size of the diaper by allowing it to have less wood pulp filling. 

Adult disposable diapers are currently made from two different types of super-absorbent polymers; one type absorbs more liquid while having a lower retention capacity, and the other type has a higher retention capacity while having a lower absorption volume. 

The particular nappy product being offered will determine the ultimate polymer selection, however, at this phase, choosing an SAP is frequently motivated by the desire for a higher absorption volume.

On a conveyor belt system, the polymer and wood pulp particles are vacuum-formed together during the assembly stage. A cohesive and flattened fluff core that may be divided into diaper-sized pieces is produced by repeatedly applying polymer-fiber mixtures using pressurised sprayers. 

With the superabsorbent polymer concentrated in the core and the fibrous fluff surrounding it, a layered “sandwich” of wood pulp fibre and polymer particles is produced as a result.  The diaper’s “shell” and flexible shape are then added by stitching non-woven fabric sheets to the absorbent pad.

While the majority of fabrics are created by weaving together fibres made of wool, silk, cotton, or polyester, non-woven materials are created by a variety of thermal, mechanical, and chemical processes using plastic fibres made of nylon, polyester, polypropylene, or polyethylene resins. 

Plastic resins like polypropylene and polyethylene are melted, cooled, and condensed to generate permeable and non-permeable sheets for the diaper during a dry-laid procedure known as the “melt-blown” method, which is how non-woven textiles used for disposable diaper production are created. 

The plastic fibers in the sheets are flattened and bonded by being pressed with heated rollers before being cut to size for the widest diapers possible.