New Polyols Reduce Carbon Footprint From Covestro

Under the name cardyon™, Covestro is developing and marketing new polyether carbonate polyols that are produced with the aid of carbon dioxide (CO2). With Desmopan® 37385A the company now offers the first representative of a new series of thermoplastic polyurethanes (TPU) containing polyether carbonate polyols

Compared to conventional TPU materials, the new TPU products leave a lower carbon footprint and help close the carbon cycle. They also conserve fossil resources and, unlike many bio-based materials, do not compete with food production.

“With the new TPU, our customers can reduce the carbon footprint of their products and as a result play a pioneering role in sustainability vis-à-vis their competitors,” explains Georg Fuchte, TPU expert at Covestro. “This is especially true for companies in the consumer goods industry, which often manufacture products with a short lifespan.”

Excellent mechanical properties

Desmopan® 37385A has a hardness of 85 Shore A. Its mechanical properties are at least at the level of conventional TPU grades of similar hardness, and even exceed some of them. For example, it has a tensile strength of 36 megapascals. The elongation at break reaches 660 percent (DIN 53504). The plastic is designed for extrusion, but is also suitable for injection molding. “The application spectrum covers typical applications of conventional TPU grades with comparable hardness and ranges from soles and upper shoe components to sportswear, handles and knobs to packaging for sensitive electronics,” says Fuchte.

Different product variants

Covestro plans to expand the new TPU series with variants of different hardness. A product with a hardness of 95 Shore A, for example, whose melt cures rapidly during processing, is well advanced in development. “We are thus targeting applications in which economic production in short cycle times is particularly important,” explains Fuchte. Covestro cooperates closely with companies and research  institutions to use CO2 technology as a synthesis platform for other large-scale chemical raw materials. For example, work is underway on new CO2- based polyols for rigid polyurethane foams that could be used, for example, in the thermal insulation of buildings, in automobiles and in sports equipment. At the Dormagen plant, Covestro already operates a production plant that produces CO2-based polyols for flexible polyurethane foams. The latter are used in the commercial production of upholstered furniture and mattresses.

Alternative Adhesive for Textile Industry from Kordsa

Kordsa, which operates in the field of composite technologies with tire and construction reinforcing, has produce a new adhesive collaborating with Continental. This new technology can be the new standard adhesive of the textile reinforcing materials industry.

Kordsa introduced its new invention which it developed with Continental at the beginning of 2018 at Tire Technology in Hannover. Kordsa Technology Director Devrim Özaydın said that, “Since 2008 we have been working on an environmentally friendly adhesive formula with a non-resorcinol and formaldehyde free in the field of tire technologies. While we are developing the chemical structure, Continental has also developed application-related technologies.”

Devrim Özaydın said that they think this new technology could be the new standard adhesive of textile reinforcing materials sector. Özaydın added, ”We will present all information to the world with the right of  free  use in order to be the new standard of the industry.” Devrim Özaydın stated that they achieved to change the formula used in the tire cord fabric bath within the framework of this cooperation and stated that the formula they have reached is more ecofriendly formula that can be an alternative to the resorcinol formaldehyde formula which has been used for 80 years. In addition, Kordsa carry out studies on new technologies to increase energy efficiency and reduce its carbon dioxide emissions by taking the environmental effects into consideration in the İzmit R & D center. For example, it developed a new concept in the finishing process with the Minidip project , while the ABC project achieved an average energy saving of 10 to 15 percent on twisting machines.

Kordsa has 218 approved patents

In the first half of 2018, Kordsa is among the global leaders with the number of patents published in the patent research database. Özaydın said, “We increased our total patent portfolio by approximately 60 percent in 2017. As of July 2018, we have 174 inventions worldwide, 717 patent applications and 218 approved patents.”

Awarded R & D Centers

Kordsa’s first R & D center in Izmit was established in 2008. In 2016, with the investment of 30 million dollars, they established the second R & D centers in the Composite Technologies Center of Excellence, which they implemented together with Sabancı University. This center is the first carbon cloth and prepreg manufacturers who support the basic research to the production of prototype parts in Turkey.

Kordsa to expand its global footprint in aerospace industry with a new US investment Kordsa has signed a definitive agreement to acquire approximately 96% share of Axiom Materials Acquisition LLC, total enterprise value of USD 181 million, which provides advanced composite for aerospace and industrial applications. composite technologies that we entered with our first investment in 2013. We realized Composite Technologies Center of Excellence investment in 2016. As part of our inorganic growth targets, following the acquisition of three composite firms in 2018, we have taken the necessary steps to acquire yet another composite company based in the US. In order to leave behind long approval processes in aircraft parts and space vehicles, we set out to acquire Axiom Materials, an approved supplier for aerospace industry. With this acquisition, we will lead the advanced composite technologies for the next generation industrial and transportation applications, as well as the aerospace industry.

Akbaşlar Tekstil Conducts R & D Studies For Electronic Textiles That Control Health Status

Turkey’s largest “integrated textile enterprises” in the area Akbaşlar Tekstil gives great importance to textile R & D activities. It succeed innovations in textile sector by producing heat and cold resistant fabrics in outerwear.

Akbaşlar Tekstil R&D Center; was established in 2015 by getting approval from the Ministry of Science, Industry and Technology. The company, which has Turkey’s 12th R & D Center, having a team of 40 people specialized tasks. In the company’s R & D Center; production and process development, product development, design, patent, chemistry analysis and physical testing units, women’s outerwear, sportswear and defense industry pro- jects are being carried out.

Serving the group of women’s outerwear and sport technical textiles, the company works with sustainable fiber products in outerwear. Akbaslar Textile takes care to use chemicals containing natural raw materials in its products. The company that keeps pace with technology and makes innovations; wind and water impermeable, providing moisture transfer, produces products create air conditioning effect that heat and cold resistant. At the same time, the company produces towel fabrics that can quickly absorb water and evaporate quickly. In addition to working on women’s outerwear and sportswear, Akbaşlar Tekstil has been conducting R&D studies on electronic textiles recently. The company carry out works on products that measuring and analyzing one’s vital functions and monitoring the health status of the person in electronic textile. The product produced by the company as a result of R & D activities will provide pulse, heartbeat and breath control. Aiming to increase the number of patents and utility models in electronic textile products, Akbaşlar Tekstil aims to realize EU projects among its targets.

Berteks Produces Odorless and Non-flammability Fabric

Berteks, which has been in operation for nearly a century, continues to provide services by adding strength to its power every day. Growing with the knowledge and experience that goes on for three generations, Berteks develops itself with new technologies. The company, which has a high standard of production quality, has more than a thousand employees.
Berteks manufactures 30 million sqm of fantasy curtain fabrics annually in the machine park where the latest model weaving machines are located. The company exports to more than 200 countries on 5 continents and holds the field in the home textile market. About 80 percent of the company’s production is fancy yarns, drapery and upholstery fabrics, decorative roller blinds, zebra, pleat and polyester screen curtains, home decoration and glass balcony curtain systems, cartel and book production.
About 40% of the production is made up of technical textiles, the company has 22 registered brands, 2 patents, 8 beneficial models and 16 designs.
Berteks, which allocates approximately 5% of its turnover to R&D, has been serving in the R & D department with its team of 45 people since December 2016. The company aims to develop more inno- vative, modern, value-added products with its R & D center. The company has been working on energy-producing cur- tains lately. Nonlammability feature is developed in fabrics produced with special coating. In addition, these products will be provided with a high level of dirt-repellent antibacterial.
Berteks also has an acoustic curtain. The curtain is made of fabric that absorbs sound waves. The fabric that minimizes the sound in the environment is preferred in many areas. The product is mainly sold to European countries.
Because of the glass fiber used in roller blind PVC fabrics, Berteks produced polyester screen fabric instead of odorless fabrics in summer months. This product is odorless and it has a Non-flammability feature.
The company also has TÜBİTAK (The Scientific and Technological Research Council of Turkey) 1501 projects. With the developed machine project, an increase in productivity is achieved and a work that strengthens the industry 4.0. The company’s has fabric projects which clean production will be in its 1501 projects. At the same time, Berteks is developing university-industry coopera- tion with 1505 projects.

Australian Researchers Support Smart Garment Technology for Parkinson’s Patients

A team of researchers from Neuroscience Research Australia (NeuRA) and UNSW Sydney has received a grant from The Michael J. Fox Foundation and the Shake It Up Australia Foundation for Parkinson’s Research to test eHealth and smart garment technologies to prevent falls in people with Parkinson’s disease.

NeuRA’s Dr Matthew Brodie and Associate Professor Kim Delbaere, who lead the study, are working with industry partner Sensoria Health and aim to make StandingTall-PD the leading eHealth solution for maximising mobility and preventing falls in people with Parkinson’s disease.

“Existing dopamine therapies offer benefit in treating motor dysfunction in Parkinson’s but may not alleviate gait and balance challenges,” says Jamie L. Hamilton, PhD, MJFF Associate Director. She adds, “this project has the potential to become an affordable option to address gait and balance issues and improve overall quality-of-life for people with Parkinson’s.”

The neuro-rehabilitation program, known as StandingTall-PD, uses visual, audio and sensory cues to help rewire the parts of the brain that control walking in people with Parkinson’s. The program aims to prevent freezing-of-gait and falls, and enhance participants’ independence.

How does the program work?

Participants will be given a NeuRA training mat with colour-coded stepping targets, a pair of Sensoria Smart Socks, an iPad and phone. The program, practised daily, will encourage participants to step on coloured stepping targets that match a series of colours displayed on their iPad. At the same time, they will listen to rhythmic auditory cues like music and a metronome beat that are synchronised with the vibrating Smart Socks.

The combination of visual, audio and sensory elements helps to form new connections in less affected parts of the brain, leading to improved walking ability.

The program enables participants to self-manage and monitor their own progress via an app on their phone. The app can also trigger stimuli during everyday activities, such as vibration in their Smart Socks, if they are in danger of experiencing freezing-of- gait, falls or if they show signs of shuffling feet.

Clinicians can also monitor participants’ progress remotely and adjust the program to provide ongoing and personalised continuity of care.

Lenzing’s New Brand VEOCEL™ Responds to Increasing Concerns for Sustainability in the Nonwoven Market

Producing quality fibers from renewable wood raw materials with environmentally friendly and innovative technologies, Lenzing Group has conducted a survey with 3.900 women consumers of wet wipes and hygienic products living in Europe, North America and Asia.

The survey was conducted by SSI, an independent market research company. When consumers in the survey were asked which environmental concerns were more important for them, biodegradability (over 60%) and recycling (approx. 45%) was the top answers.

Eco-friendly production is an issue, not only the consumers, but also the manufacturers and brands focus on. Especially the manufacturers of wet wipes and toilet wipes are making significant investments in this area in line with the increasing awareness on the flushableness and durability of fibers obtained from petrochemicals. Setting the global standards in fibers,Lenzing has taken a very important step in this field last year. The group’s brand, VEOCEL ™, positioned in the nonwoven industry, has announced the Eco Disperse technology, which enables production of flushable toilet wipes.

Flushable Products

Wolfgang Plasser, Global Business Management Vice President at Lenzing AG Nonwoven Group, said that they are continuing their work with the VEOCEL ™ brand in the nonwoven market since June 2018. Plasser said, “The VEOCEL™ fibers are certified clean and safe, biodegradable, from botanic origin and produced in an environmentally responsible production process.” The most important advantage of the Eco Disperse technology products, which are considered to be the most advanced fibers in the brand’s portfolio, is that the product is completely soluble after mixing with the water thanks to its short cutting length and strong fine diameter. These features make it possible to flush products such as wet wipes. Wolfgang Plasser, Global Business Management Vice President at Lenzing AG Nonwoven Group, said that “You need to pass a series of seven tests to reach flushability level and to be able to claim that your product is flushable.” These groups of tests were launched by INDA and EDANA together in the US and Europe under what is referred to as GD4. This gives a guideline to players in the flushable nonwovens market. The application requires to meet two targets. One is to be able to do the cleaning job and the other is to disintegrate completely while flushed without blocking the sewage systems. This was a tricky thing and took us a while to develop such a product.”

Designed to be used in wet toilet wipes, this fiber contains nonwoven fabrics with 20% of the new Veocel Lyocell fibres and 80% of wood pulp. The fiber could reach 90% disintegration within 30 minutes, faster than the passing INDA/EDANA benchmark.

It can also be used in the baby wipes!

Stating that as Lenzing they focus on 100% biodegradable, single-use nonwoven segment, Wolfgang Plasser said that the wet wipes products come to the fore in the category of single-use products. Plasser also said that they foresee that the VEOCEL™ with Eco Disperse technology, which has a wet strength of about 50% higher than viscose fiber, will be used in non-flushable industrial products and baby wipes in the coming period.

A sustainable alternative

Uğur Uyansoy, Nonwoven Segment Business Development and Sales Manager at Lenzing Elyaf AŞ., said that “Turkey is a developing market in the nonwovens and is open to sustainable solutions. Thanks to their botanical origin and their biodegradability, the VEOCEL ™ fibers are an eco-friendly and sustainable alternative. Our fibers can be used in the body wipes, wet wipes, baby wipes, wet toilet wipes, and even for the surfaces in addition to beauty products such as make-up cleansing wipes. The added value benefits of the VEOCEL ™ Lyocell fibers, such as high absorbency, natural smoothness and biodegradability can gain a different perspective for the nonwoven market.”

Lenzing Ranked first by Canopy for Sustainable Wood Sourcing

The Lenzing Group has once again been rated the number one producer of wood-based fibers (out of 31 globally) in the world with respect to the responsible procurement of wood, the key raw material in cellulose fiber production. This is the conclusion of the Hot Button Report published recently by the Canadian environmental organization Canopy.

“We are proud of this top ranking. It underpins our role as a leader in sustainability and gives our customers confidence that we have the right practices in place to prevent the use of wood and pulp from ancient and endangered forests”, says Stefan Doboczky, Chief Executive Officer of Lenzing. “Sustainable wood and pulp sourcing has long been given the highest priority by the Lenzing Group. Forest protection is crucial for Lenzing, not least because of the loss of biodiversity and climate change, which are becoming ever more important issues.” Responsible sourcing and sustainability are key elements of Lenzing’s corporate strategy. They help preserve global forests and prevent deforestation, which in turn make a substantial contribution to climate protection.

The Hot Button Report proves once more that there is a low risk for buyers using Lenzing fibers. Lenzing was one of the first wood-based fiber producers to complete and publicly release the results of its CanopyStyle Audit in 2017 confirming this. In 2019, the company will complete its second annual audit.

LENZING’S ACHIEVEMENTS IN SUSTAINABILITY

In 2018, Lenzing adopted additional due diligence measures when sourcing from high-risk countries, a decision positively noted by Canopy. Lenzing’s innovative TENCEL™ Lyocell fibers with REFIBRA™ technology, in which cotton scraps are partly used as a raw material, have been welcomed by the market as a product that takes pressure off the use of wood as a raw material. REFIBRA™ technology is the most advanced concept in the wood-based fiber market that clearly incorporates circular economy features on a commercial level.

Canopy also praised Lenzing for using its influence to help advance a conservation legacy in the heart of Canada’s boreal forest. Lenzing communicated its support and encouragement for formal protection of the Broadback Forest to government and First Nation decision makers.

Orion Engineered Carbons Announces Investment In Acetylene Carbon Black To Drive Technological Strength In Batteries And Other Premium Segments

Orion Engineered Carbons S.A. (NYSE:OEC), a worldwide supplier of specialty and high-performance Carbon Black, announced on November 1, 2018, that it has reached an agreement to acquire Acetylene Carbon Black manufacturer Société du Noir d’Acétylène de l’Aubette, SAS [SN2A] from LyondellBasell Industries Holdings B.V. and its French affiliate. SN2A was founded in 1987 and is headquartered at Berre l’Etang, near Marseille, France.

Acetylene Black is an ultra-pure premium Specialty Carbon Black distinguished by its high electrical and thermal conductivity. Lithium-ion batteries and high-end electrical cables are key applications for this material.

“SN2A brings us a skilled team, proven technology and an operating plant. With this platform we are going to significantly strengthen our capabilities in the lithium-ion battery market and broaden our position in other attractive markets,” said Corning F. Painter, Chief Executive Officer of Orion Engineered Carbons. “This bolt-on acquisition is a perfect fit with Orion’s focus on Specialty Carbon Blacks. We look forward to welcoming the SN2A team to Orion and bringing Acetylene Black into our portfolio.”

The agreement with LyondellBasell includes provisions for a secured long-term feedstock supply. Orion plans to strengthen production capabilities at the Berre l’Etang facility.

The transaction closed on October 31, 2018.

About Orion Engineered Carbons S.A. (NYSE: OEC) Orion is a worldwide supplier of Carbon Black. We produce a broad range of Carbon Blacks that include high-performance Specialty Gas Blacks, Furnace Blacks, Lamp Blacks, Thermal Blacks and other Carbon Blacks that tint, colorize and enhance the performance of polymers, plastics, paints and coatings, inks and toners, textile fibers, adhesives and sealants, tires, and mechanical rubber goods such as automotive belts and hoses. Orion runs 13 global production sites and four Applied Technology Centers. The group has approximately 1,409 employees worldwide. For more information visit our website www.orioncarbons.com.

Type Of Lotion To Be Used In Infant Clothes And Improving Product Performance Based On Application Area

Çağla Bektaş / Senior R & D Engineer – Chemical Engineer

Evyap Sabun Yağ Gliserin Sanayi ve Ticaret Anonim Şirketi

ABSTRACT

Today, disposable diapers are high performance products designed to keep the sensitive baby skin dry and healthy. Diapers are basically composed of nonwoven fabric in contact with the skin, disintegrated cellulose and biologically inert polymers. Diapers may contain additional raw materials such as lotions, perfumes and/or creams depending on consumer preference. Considering the sensitivity of the baby skin, the compatibility of these raw materials with the skin and its performance on the finished product are of paramount importance. In this study, parametric studies have been conducted on lotion and/or perfume type, application system, application area and optimization of odor density on diaper. According to the study result, in addition to suppressing the odor after using the diaper, it was made possible to provide the diaper for consumers by minimizing the amount of wetness released to the skin from critical performance parameters.

 

Key Words: Diaper, lotion, perfume, lotion application, perfume application, diaper performance, odor density, perfume, cream

 

INTRODUCTION

One of the most important consumer products in the 20th century is smaller, cheaper, more useful and more environmentally friendly disposable diapers. [1]

As a result of the development and commercialization process, which started as a mere cellulose layer, today diapers comprise various parts such as a breathable/nonbreathable backsheet that forms the outer layer of the diaper and prevents the urine from infecting the baby’s clothing, a topsheet –the top layer of the diaper in contact with the baby skin–, adhesive side tapes used to attach the diaper to the baby, frontal tapes, where the side tapes adhere to each other when the diaper is dressed on the baby, elastic&nonelastic back ears with side tapes, the absorption and distribution layers placed under the topsheet (ADL; acquisition / distribution layer,) leg cuffs (barriers) used to prevent the urine from overflowing from the legs and the elastic leg barrier used in the backsheet, the superabsorbent polymers (SAP) used in the absorbent core layer, the pulp (cellulose) to provide a homogeneous distribution of the SAP particles on the absorbent core layer in the absorbent core layer, the nonvowen/tissue core cover which holds the SAP and the pulp together, the front ear which makes it easier for the mother to hold the baby while dressing, and the lotion specially developed to prevent bad smells after using the diaper and all the glue raw materials that make all these components stick to each other.

A Typical diaper layers are shown in Figure 1. [1]

 

 

Figure 1: Layers of a typical diaper

Diapers have the basic features that consumers expect, such as not causing rash, dryness, absorbency, resistance to long-term use, and minimizing bad odors after using. The lotion applications used in diapers help the diaper to suppress the bad odors after using, as well as affect the critical performance characteristics such as the duration of urine-sucking (strike throught time) and the amount of wetness released from the wet diaper to the skin depending on the type of lotion used and the application area. For this purpose, perfumes or cream applications can also be used.

In the study shared in Figure 2, perfume areas (85) were created in the backsheet layer (26) with the diaper’s outer surface to ensure that urine does not pass through the baby’s undergarment in order to suppress the bad odor in the diaper. Perfume areas have binders (82), which contain perfume releasing agents (65). Binders are attached to the outer surface (52) of the backsheet raw material. The perfume releasing agents and the binder are also protected by a strip (80), which separates them from the outer surface. The pulling strip preferably comprises a material containing polyethylene, polypropylene, nonwoven and/or a cellulosic substance. When this strip is removed, the separating agents make an odor explosion and/or a constant state diffusion. Perfume releasing agents may also provide a mechanism for entrapping the odor into the microcapsule in the urine. [2]

 

Figure 2: A side view of the perfume area showing a type of microcapsule before separation of the pulling strip from the perfume area (Fig. 2), a side view of the perfume area during separation of the pulling strip from the perfume area (Fig. 2A) [2]

Looking at the working principle of the microcapsule technology shown in Figure 2; it can be seen that it works by releasing the perfume out when the diaper is put on the baby, and taken off from the baby or while it is on the baby, since it is exposed to friction effect. The pulling strip produces a shear force to facilitate the breakage of the microcapsule along its upper portions, thus releases the perfume from the peeled part of the pulling strip. [2]

Looking at the principle of preventing odor from urine in the diaper, the odor is entrapped by the capsule being torn off and the perfume exploding or by the controlled release of the perfume through diffusion over time. The odor is entrapped with a structure like zeolite or activated carbon. [2]

The amount of perfume used in the diaper in the market is subject to the control of the manufacturer’s preference by changing the following parameters:

  • Microcapsule size and wall thickness
  • Type of connector used
  • Type of binder used
  • Amount and type of perfume used
  • Tearing/explosion strength of microcapsules
  • Number and distribution of microcapsules
  • Adhesion resistance of a binder according to the breaking resistance of microcapsules

Microcapsules can be made by chemical encapsulation or by mechanical encapsulation. These different techniques lead to production of microcapsules in different sizes, alternative materials for composition of the capsule shell and various different functional materials inside the shell.  Attaching the binder (with microcapsules) is possible by methods of air knife, engraving and pressing including silk screening, gravure coating and flexographic techniques. The binder (with microcapsules) can be applied as a continuous or discontinuous pattern on the outer surface of the backsheet. [2]

In another study, as shown in Fig. 3 and Fig. 4, a study was conducted for lotion application on the topsheet layer, which is the top layer of the diaper contacting the baby skin, was studied. Lotion application on the topsheet was conducted in 2 different ways:

  1. Application of lotion on the topsheet raw material before combining with other raw materials making the diaper

Figure 3: Spraying lotion directly on the topsheet raw material [3]

  1. Application of lotion on the topsheet, which is the top layer of final product during diaper production

Figure 4: Spraying the lotion directly on the topsheet of finished product during diaper production [3]

The amount of lotion composition applied to the topsheet depends on the proportion of the molten lotion composition to the sprayed amount from the spray station and to the speed parameters at which the conveyor belt passes under the spray station. [3]

In the study, the benefits of the lotion applied to the topsheet are explained as follows:

  • The lotion composition changes the skin’s surface energy, and forms a “barrier” to reduce the skin’s interaction with the feces.
  • It makes it easier to clean by reducing the tendency of feces to adhere to the skin.
  • Less lotion is required to apply the desired level of therapeutic or protective lotion. [3]

Looking at the lotion and/or perfume applications recorded in the literature, it is observed that the works carried out by application areas with microcapsule applications are limited due to their difficulty of use in diaper production lines working at high speeds. At high speed and in long production lines, microcapsules cause breaking of the capsule due to mechanical stretching and pressing forces they are subjected to while passing through conveyors, rollers and printing equipment. For this reason, the lotion and/or perfume is released before the product enters in the package. In cases where the lotion is applied to the top layer of the diaper such as topsheet, however, the lotion plugs the liquid passages of the nonwoven fabric layer, and blocks the capillary paths, thus prevents the urine transmission to the substrate. And this affects the diaper’s critical performance parameters such as STT (strike through time) and the amount of wetness released into the skin (rewetting). In this study, lotion and perfume applications are examined whereby lotion and perfume are easily applied in production lines and they positively affect the diaper’s critical performance parameters. Since lotion and perfume applications are conducted at the same time in the study, it will be referred to as lotion application in the following chapter’s of the study. Many parametric studies on the type of lotion used, application area, application method and odor density were carried out. The studies were compared with the lotion application of the reference product. The lotion application method is applied on the reference product with an air pressure of 1.5 bar. The lotion tank in the air-pressure system is as shown in Figure 5. Application on the diaper with air-pressure lotion application equipment is shown in Figure 6.

Figure 5: The lotion application tank in the air-pressure system

Figure 6: Application to baby diaper with air pressurized lotion application equipment

MATERIAL AND METHOD

The trials consisting of numerous parametric studies have been conducted for the case where the existing odor density is optimized with the applied lotion amount while changing the used lotion type and lotion application area, odor notes are optimized in the new lotion type, no stain observed on the baby diaper together with the new lotion application area and corrosion is minimized with elimination of water based lotion use in the production system and diaper performance is improved while making all these changes. Nordson LP 90 lotion application system has been used as an alternative to the reference air pressurized lotion application system during the studies and the visual of the system is provided in Figure 7.

Figure 7: Nordson LP 90 lotion application system

 

  1. 1st Parametric Study for Baby Diaper Lotion Type, Application Area, System and Conditions

The trials no. 1-12 from 23 trials set out in Table 1 have been performed with Nordson LP90 system by using oil based lotion 1 containing 5% perfume with no allergen substance, designed compatible with the baby skin. The trials no. 13-23 have been performed by using water based lotion, air pressurized lotion application system containing the same 5% perfume. The trial no. 23 is the study representing the reference and where 5% water based lotion is conducted with air pressurized lotion application system in 1.5 bar.

Table 1: Trial list of 1st Parametric Study for Baby Diaper Lotion Type, Application Area, System and Conditions

  Hertz Bar Lotion Application Area Application System Lotion Type
1 50 Under Absorbent Core Nordson LP90 Oil Based Lotion 1
2 60 Under Absorbent Core Nordson LP90 Oil Based Lotion 1
3 70 Under Absorbent Core Nordson LP90 Oil Based Lotion 1
4 40 Inner Backsheet Nordson LP90 Oil Based Lotion 1
5 50 Inner Backsheet Nordson LP90 Oil Based Lotion 1
6 60 Inner Backsheet Nordson LP90 Oil Based Lotion 1
7 40 Outer Backsheet Nordson LP90 Oil Based Lotion 1
8 30 Outer Backsheet Nordson LP90 Oil Based Lotion 1
9 20 Outer Backsheet Nordson LP90 Oil Based Lotion 1
10 40 Leg Elastic Edge Nordson LP90 Oil Based Lotion 1
11 50 Leg Elastic Edge Nordson LP90 Oil Based Lotion 1
12 30 Leg Elastic Edge Nordson LP90 Oil Based Lotion 1
13 1.5 Leg Elastic Edge Air pressurized system Water Based Lotion
14 2 Leg Elastic Edge Air pressurized system Water Based Lotion
15 1.5 Inner Backsheet Air pressurized system Water Based Lotion
16 2 Inner Backsheet Air pressurized system Water Based Lotion
17 2.5 Inner Backsheet Air pressurized system Water Based Lotion
18 1.5 Outer Backsheet Air pressurized system Water Based Lotion
19 1 Outer Backsheet Air pressurized system Water Based Lotion
20 2 Under Absorbent Core Air pressurized system Water Based Lotion
21 1.5 Under Absorbent Core Air pressurized system Water Based Lotion
22 2.5 Under Absorbent Core Air pressurized system Water Based Lotion
23 1.5 On the Absorbent Core Air pressurized system Water Based Lotion

 

  1. 2nd Parametric Study for Baby Diaper Lotion Type, Application Area, System and Conditions

The trials no. 1-8 from 17 trials set out in Table 2 have been performed with air pressurized system by using water based lotion containing the same 5% perfume. The trials no. 9-14 have been performed by using oil based lotion 2 and air pressurized lotion application system containing 5% perfume. The trials no. 15-17 have been performed by using oil based lotion 1 and Nordson LP90 lotion application system containing 5% perfume. The trial no. 1 is represented in 1.5 bar where 5% water based lotion is applied on the absorbent core in Table 2.

 

 

Table 2: Trial list of 2nd Parametric study for Different Lotion Type Applications with the Baby Diaper

  Hertz Bar Lotion Application Area Lotion Application System Lotion Type
1 1.5 bar On the Absorbent Core Air pressurized system Water based Lotion
2 3 bar Under the Absorbent Core Air pressurized system Water based Lotion
3 3.5 bar Under the Absorbent Core Air pressurized system Water based Lotion
4 4 bar Under the Absorbent Core Air pressurized system Water based Lotion
5 3 bar Inner Side of Backsheet Air pressurized system Water based Lotion
6 3.5 bar Inner Side of Backsheet Air pressurized system Water based Lotion
7 4 bar Inner Side of Backsheet Air pressurized system Water based Lotion
8 3 bar Under the Absorbent Core Air pressurized system Oil Based Lotion 2
9 3.5 bar Under the Absorbent Core Air pressurized system Oil Based Lotion 2
10 4 bar Under the Absorbent Core Air pressurized system Oil Based Lotion 2
11 3 bar Inner Side of Backsheet Air pressurized system Oil Based Lotion 2
12 3.5 bar Inner Side of Backsheet Air pressurized system Oil Based Lotion 2
13 4 bar Inner Side of Backsheet Air pressurized system Oil Based Lotion 2
14 75 Hertz Under the Absorbent Core Nordson LP90 Oil Based Lotion 1
15 65 Hertz Inner Side of Backsheet Nordson LP90 Oil Based Lotion 1
16 70 Hertz Inner Side of Backsheet Nordson LP90 Oil Based Lotion 1
17 75 Hertz Inner Side of Backsheet Nordson LP90 Oil Based Lotion 1

 

  1. 3rd parametric study for Different Lotion System Applications with the Baby Diaper

6 trials set out in Table 3 have been performed with air pressurized lotion application system. The trial no. 1 represent the reference water based lotion containing 5% perfume. The trials no. 2-6 have been performed by using oil based lotion 1 and air pressurized lotion application system containing 5% perfume.

Table 3: Trial list of 3rd Parametric study for Different Lotion System Applications with the Baby Diaper

  Hertz Bar Lotion Application Area Lotion Application System Lotion Type
1 1.5 On the Absorbent Core Air pressurized system Water Based Lotion
2 4 Under the Absorbent Core Air pressurized system Oil Based Lotion 1
3 4.5 Under the Absorbent Core Air pressurized system Oil Based Lotion 1
4 5 Under the Absorbent Core Air pressurized system Oil Based Lotion 1
5 5.5 Under the Absorbent Core Air pressurized system Oil Based Lotion 1
6 6 Under the Absorbent Core Air pressurized system Oil Based Lotion 1

 

  1. 4th parametric study for Different Lotion Concentration Applications with the Baby Diaper

7 trials set out in Table 4 have been performed with air pressurized lotion application system. The trial no. 1 represent the reference water based lotion containing 5% perfume. The trials no. 2-4 have been performed with oil based lotion 1 containing 15% perfume and the trials no. 2-7 have been performed by using oil based lotion 1 and air pressurized lotion application system containing 10% perfume.

Table 4: Trial list of 4th Parametric study for Different Lotion Concentration Applications with the Baby Diaper

  Hertz Bar Lotion Application Area Lotion Application System Lotion Type
1 1.5 On the Absorbent Core Air pressurized system Water Based Lotion
2 3 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 15% perfume modified
3 4 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 15% perfume modified
4 5 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 15% perfume modified
5 3 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 10% perfume modified
6 4 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 10% perfume modified
7 5 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 10% perfume modified

 

RESULTS

  1. 1st Parametric Study Results for Baby Diaper Lotion Type, Application Area, System and Conditions
    • Odor Density Determination

Table 1 includes the trial list with 23 parameters where 5% oil based lotion 1 is performed by using Nordson LP90 system and 5% water based lotion is performed with air pressurized system. The first evaluation on the baby diaper samples conducted for identifying the odor density by the odor specialist. The trials have been compared with the reference sample no. 23 in Table 1. Those no. 3, 6, 7 and 11 having oil based lotion 1 have been found to have the similar odor density with the reference, evaluated by the odor specialist. Those no. 14 and 22 having water based lotion have been found to have the similar odor density the reference, evaluated by the odor specialist. The trials no. 1, 2, 4, 5, 8-10, 12, 13, 15-21 included in Table 1 have failed in terms of odor density when compared with the reference and they have been disqualified for the following tests.

  • Stain control

It has been investigated whether or not there is any stain resulting from lotion application by conducting visual controls for the trials no. 3, 6, 7, 11, 14 and 22 in Table 1 whose odor density parameter is found to be similar to the reference. The trial samples for the stain control have been compared with the reference no. 23. The visual of the reference sample is provided in Figure-8.

Figure 8: Reference sample no. 23

Stain formation has been found on the backsheet surface in the trial no. 3. The visual of the stained sample is provided in Figure-9.

Figure 9: Lotion stain in the sample no. 3 in Table 1.

No stain formation has been detected on the baby diaper in the trial no. 6-7.

No stain formation has been detected on the baby diaper in the trial no. 11.

Stain formation has been found on the leg elastics area in the trial no. 14. The visual of the stained sample is provided in Figure-10.

Figure 10: Lotion stain in the sample no. 14 in Table 1.

No stain formation has been detected on the baby diaper in the trial no. 22.

  • Performance control

Table 5: Performance results of Trial 1

  3 6 No. 11 & 14 22 No. 23
3. Rewet (gr) 0.39 0.45 0.95 1.44
3. STT (sn) 64 67 63 55
Lotion Type Oil Based Lotion 1 Oil Based Lotion 1 Oil based Lotion 1 & Water Based Lotion Water Based Water Based
Lotion Application System Nordson Nordson Nordson & Air Pressurized System Air Pressurized System Air Pressurized System

 

Rewet performances of the trials no. 3 and 6 are significantly better when compared with the reference no. 23 according to the data shown in Table 5. STT performances are close to the reference and there is no significant difference in terms of performance with the reference. As the lotion applied on the leg elastics edge no. 11 and 14 has not affected rewet and STT performance of core, so performance has not been evaluated here. In the trial no. 22, rewet performance is better when compared with the reference. But, no performance improvement has been observed as it has been observed in the trial no. 3 and 6. As the lotion applied on the outer surface of the backsheet, backsheet couldn’t get dried immediately on outer side of the fabric in the trial no. 7. Therefore, this application has been found to be difficult in practice and performance evaluation has not been conducted.

  1. 2nd Parametric Study Results for Baby Diaper Lotion Type, Application Area, System and Conditions

 

  • Odor Density Determination

Table 2 includes the trial list with 17 parameters where 5% oil based lotion 1 is performed by using Nordson LP90 system and 5% oil based lotion 2 and 5% water based lotion have been performed by using air pressurized system. The first evaluation on the baby diaper samples has been conducted for identifying the odor density by the odor specialist. The results of the trials have been compared with the reference sample no. 1 in Table 2. Those no. 2, 3 and 4 having water based lotion have been found to have the similar/better odor density with the reference, evaluated by the odor specialist. The trial no. 14 conducted by using oil based lotion 1 have been found to have the similar/better odor density with the reference, evaluated by the odor specialist. The trials no. 5-13 and 15-17 included in Table 2 have failed the odor density test when compared with the reference and they have been disqualified for the following tests.

  • Stain control

It has been investigated whether or not there is any stain resulting from lotion application by conducting visual controls for the trials no. 2, 3, 4 and 14 in Table 2 whose odor density parameter is found to be similar/better to the reference. The trial samples for the stain control have been compared with the reference no. 1. The visual of the reference sample is provided in Figure-8.

No stain formation has been detected on the baby diaper in the trial no. 2-4 and 14.

  • Performance control

Table 6: Performance results of the Trial 2

No. 1 No. 2 No. 3 No. 4 No. 14
3. Rewet (gr) 1.42 1.27 1.19 1.14 0.87
3. STT (sn) 64 70 71 69 60
Lotion Type Water Based Lotion Water Based Lotion Water Based Lotion Water Based Lotion Oil Based Lotion 1
Lotion Application System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Nordson LP90 System

 

Rewet performance of the trial no. 14 is significantly better when compared with the reference no. 1 according to the data shown in Table 6. STT performances are close to the reference and there is no significant difference in terms of performance with the reference. Rewet performance has been better when compared with the reference in the trials no. 2, 3 and 4; however, no performance improvement has been observed as it has been observed in the trial no. 14.

  1. 3rd Parametric Study Results for Baby Diaper Lotion Type, Application Area and Conditions
    • Odor Density Determination

Table 3 includes the trial list with 6 parameters where 5% oil based lotion 1 and 5% water based lotion have been performed by using air pressurized lotion application system. The first evaluation on the baby diaper samples conducted for identifying the odor density by the odor specialist. The results of the trials have been compared with the reference sample no. 1 in Table 3. Required odor density similar to the reference has not been acquired in all samples according to the evaluation by the odor specialist.

  • Stain control

The trial samples for the stain control given in Table 3 have been compared with the reference no. 1. The visual of the reference sample is provided in Figure-8.

No stain formation has been detected on the baby diaper in the trial no. 2-6.

 

  • Performance control

Table 7: Performance results of Trial 3

  No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
3. Rewet (gr) 1.46 0.12 0.20 0.17 0.15 0.21
3. STT (sn) 68 62 66 61 70 59
Lotion Type Water Based Lotion Oil Based Lotion 1 Oil Based Lotion 1 Oil Based Lotion 1 Oil Based Lotion 1 Oil Based Lotion 1
Lotion Application System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System

 

Rewet performances of the trials no. 2-6 are significantly better when compared with the reference no. 1 according to the data shown in Table 7. STT performances are close to the reference and there is no significant difference in terms of performance with the reference.

  1. 4th Parametric Study Results for Baby Diaper Lotion Type, Application Area and Conditions
    • Odor Density Determination

Table 4 includes the trial list with 7 parameters where 10% and 15% oil based lotion 1 and 5% water based lotion have been performed by using air pressurized lotion application system. The first evaluation on the baby diaper samples conducted for identifying the odor density by the odor specialist. The results of the trials have been compared with the reference sample no. 1 in Table 4. Odor density of the sample no. 2 evaluated by the odor specialist has been found similar to the reference. As odor density of the samples no. 3-4-6-7 is higher than the reference and odor density of the sample no. 5 is weaker than the reference, they have been disqualified from the evaluations.

  • Stain control

The trial samples in Table 4 have been compared with the reference no. 1 for the stain control. The visual of the reference sample is provided in Figure-8.

No stain formation has been detected on the baby diaper in the trials no. 2-7.

  • Performance control

Table 8: Performance results of Trial 4

  No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7

 

3. Rewet (gr) 1.46 0.27 0.30 0.25 0.35 0.38 0.29
3. STT (sn) 68 62 66 61 62 59 65
Lotion Type Water Based Lotion Oil Based Lotion 1- 15% perfume modified Oil Based Lotion 1- 15% perfume modified Oil Based Lotion 1- 15% perfume modified Oil Based Lotion 1- 10% perfume modified Oil Based Lotion 1- 10% perfume modified Oil Based Lotion 1- 10% perfume modified
Lotion Application System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System

 

Rewet performances of the trials no. 2-6 are significantly better when compared with the reference no. 1 according to the data shown in Table 8. STT performances are close to the reference and there is no significant difference in terms of performance with the reference.

FINDINGS and DISCUSSION

The samples related to each trial performed under parametric studies have been respectively subjected to the following evaluations:

  • Determination of odor density similarity between trial sample and reference sample by the odor specialist
  • Determination of lotion stain control on the product in the trial samples which odor density is detected to be similar with the reference sample
  • Determination of the finished product performance tests results which odor density is detected to be similar with respect to the reference sample and no stain observed on it

 

The findings related to the study conducted accordingly are as follows:

23 trials have been conducted in the 1st parametric study contained in Table 1. The trial no. 23 represents the reference and the other 22 trials have been compared with this reference sample. The samples related with these trials have been firstly evaluated by the odor specialist for determination of the odor density. The trials which odor density are found to be similar with the reference sample no. 23 are the trials no. 3, 6, 7, 11, 14 and 22. As odor density similar to the reference has not been determined in the other trials, they have been noted as failed. As lotion stain has been determined in the trials no. 3 and 14 that are successful in determination of odor density, these trials have been noted as failed. As it is estimated when the lotion application area in the process is taken into consideration in the trials no. 7 and 11, this will cause complication in the process during routine production, backsheet inner side and leg elastics edge applications have been removed from the trials in the following trials. The trials no. 6 and 22 have successfully completed the criteria of odor density, stain and performance in the list of parametric studies in Table 1.

17 trials have been conducted in the parametric study contained in Table 2. The trial no. 1 represents the reference and the other 16 trials have been compared with this reference sample. The samples related with these trials have been firstly evaluated by the odor specialist for determination of the odor density. The odor density of the trials no. 2, 3, 4 and 6 have been found successful when compared to reference sample by odor specialist. As odor density similar to the reference has not been determined in the other trials, they have been noted as failed. No stain occured for these 2, 3, 4 and 6 trials and noted as successful in terms of stain control.  When comparing for the final product performance, all samples have better rewet and STT performance from the reference sample no. 1, they have been deemed successful. However, there is still an area to be improved for rewet performance.

6 trials have been conducted in the parametric study contained in Table 3. The trial no. 1 represents the reference and the other 5 trials have been compared with this reference sample. The samples related to these trials have been firstly evaluated by the odor specialist for determination of the odor density. Since similar odor density has not been achieved in all trial samples with respect to the reference no. 1, all trials are notes as failed.

7 trials have been conducted in the parametric study contained in Table 4. The trial no. 1 represents the reference and the other 6 trials have been compared with this reference sample. The samples related to these trials have been firstly evaluated by the odor specialist for determination of the odor density. Only odor density of the trial no. 2 has been founded to be similar with the reference sample no. 1 and have been noted as successful. Since the similar odor density has not been achieved in the other trials, they have been noted as failed. The trial no. 2 have become successful in the criteria of odor, stain and performance controls.

CONCLUSION

Given all parametric trial studies conducted in Table 1, Table 2, Table 3 and Table 4, similar odor density with respect to the reference, no lotion stain and the best finished product rewet performance is achieved in the trial no. 2 given in Table 4 with 0.27 gr rewet performance. Upon the release of the diapers produced in this manner, the expectation of the consumer will have been met in the most accurate way.

REFERANCES

[1] Dyer, D., “Seven Decades of Disposible Diapers: A record of Continuous Innovation and Expanding Benefit”, 2005, Edana.

[2] EP0957869B1, “Diaper Having Perfume Zones”, P&G, 2016

[3] US6118041A, “Diaper Having a Lotioned Topsheet”, P&G, 2000

Oerlikon to Cooperate with Shaoyang

Oerlikons business unit Nonwoven will cooperate with the Chinese machine and plant manufacturer Shaoyang Textile Machinery for nonwoven solutions in the hygiene market.

The aim of both cooperation partners is to jointly advance the international sales of Spunmelt lines for hygiene applications in the field of disposable nonwovens outside China. Oerlikons business unit Nonwoven will be responsible for the entire project in the future. To this end, the Neumünster-based company will contribute its know-how in plant engineering to the partnership.

Additionally, Oerlikon acquires the CE certifications of all exported Shaoyang Spunmelt lines. Oerlikon will also be responsible for product and process guarantees and will provide worldwide customer services outside China. Shaoyang Textile Machinery, on the other hand, supplies the Spunmelt plant technologies. “With Shaoyang Textile Machinery, we have found a renowned Chinese plant manufacturer with extensive know-how in the construction of Spunmelt plants for hygiene applications, which achieves international standards with its nonwoven qualities,” explains Oerlikon Manmade Fiber Segment CEO Georg Stausberg.

Rainer Straub, Head of Oerlikons Nonwoven Business Unit, adds: “The partnership enables us to gain a foothold in the highly competitive hygiene market. Our many years of engineering experience guarantee our customers production lines according to international standards for high-quality nonwovens”.