Nippon Shokubai recently announced that the company has developed a SAP (super absorbent resin) recycling technology for diapers.
Japan Shokubai's SAP production ranks first in the world. As the global demand for diapers continues to grow, recycling the diapers that have been incinerated with SAP can reduce greenhouse gas emissions and help reduce environmental impact.
This technology is jointly developed by the three companies of Nippon Shokubai, Total Care System (Fukuoka City) and Livedo Company (Osaka City). Total Care System has a good track record in recycling diapers, and Livedo is a professional manufacturer of diapers in Japan.（Click to share to LinkedIn）
What is SAP?
SAP is a super absorbent resin, the English full name is Super Absorbent Polymer, and it is an important material for the diaper core layer. It has a high water absorption function of absorbing water several hundred to several thousand times heavier than itself, and has excellent water retention performance. Once it absorbs water and swells into a hydrogel, it is difficult to separate the water even under pressure. Therefore, it is widely used in various fields such as personal hygiene products, industrial and agricultural production, civil engineering and construction.
Super absorbent resin is a kind of macromolecules containing hydrophilic groups and cross-linked structures. It was first produced by Fanta et al. by grafting starch with polyacrylonitrile and then saponifying. According to the raw materials, there are starch series (grafted, carboxymethylated, etc.), cellulose series (carboxymethylated, grafted, etc.), synthetic polymer series (polyacrylic acid, polyvinyl alcohol, polyoxy Ethylene series, etc.) several categories. Compared with starch and cellulose, polyacrylic acid superabsorbent resin has a series of advantages such as low production cost, simple process, high production efficiency, strong water absorption capacity, and long product shelf life. It has become a research hotspot in this field.（Click to share to Facebook）
Apart from SAP, what are the main materials for diapers?
The materials used to make diapers usually include non-woven fabrics, toilet paper, high-absorbent core layer (absorbent resin and fluff pulp), bottom film (PE film), elastic, adhesive tape (front + left and right), waist elastic band, etc. Although the current styles of diapers on the market are dazzling, but the basic structure is similar. Generally speaking, diapers can be specifically divided into four parts: surface covering layer, flow guiding layer, absorbent core layer and bottom layer from top to bottom, of which the absorbent core layer is the most important component.（try Suntech diapers machine）
Adult diapers are basically the same as baby diapers. The only difference is that the amount of excretion caused by adult incontinence is more than that of babies. Therefore, some manufacturers add a layer of absorbent toilet paper between the base film and the absorbent core to increase the absorption of the diaper. , The purpose of enhancing the anti-infiltration capability.
Diapers core technology
An important indicator that determines the comfort of a diaper is dryness. It has three main indicators: absorption speed, back seepage amount and side leakage. Among them, the absorption speed and the amount of re-permeation mainly depend on the "absorbent core layer", while the ability to prevent side leakage depends on the design of the "flow guide layer" of the diaper. Therefore, the core layer and the diversion layer have become the key link to achieve excellent diapers.
1. The absorbent core determines the water absorption of the diaper. It is composed of two important raw materials: Super Absorbent Polymer (SAP) and Fluff Pulp.
2. The flow guide layer is a special non-woven material placed between the surface layer and the absorbent core layer. It can effectively help the liquid to be quickly transmitted from the surface layer coating material inward and diffuse longitudinally, so that the liquid is very It quickly leaves the user's skin and is evenly absorbed by the core layer, so that the diaper will not be locally thickened due to concentrated liquid absorption and hinder subsequent urine absorption by SAP.
3. Non-woven fabric is the part covering the outer surface of the absorbent core. Traditional fabrics are woven from natural fibers such as silk, cotton and wool, while non-woven fabrics are usually made of plastic resin, such as nylon, polyester, acrylic, etc. The fibers or filaments are oriented or randomly arranged to form a web structure, which is then reinforced by mechanical, thermal bonding or chemical methods. Non-woven fabric has the characteristics of moisture-proof, breathable, flexible and light weight, and is especially suitable for the production of absorbent sanitary products.
Diapers production process
In terms of production process, compared with diapers, paper diapers reduce the waist tape and peripheral molding process, and the process is relatively simple. Below we take basic diapers as an example to briefly describe how to use the above materials to produce a finished diaper:
Pulp → crushing → forming → fixing the absorbent core layer and absorbent paper (spraying glue) → embossing → cutting, forming the absorbent core layer and absorbent paper periphery → first forming and cutting, the required length of the absorbent core layer → fixing the PE film And elastic line (spraying glue) → freely sticking tape area → upper self-adhesive tape → peripheral molding → longitudinal three-folding → second molding and cutting → horizontal three-folding → conveying → arrangement → packaging → sterilization (ethylene oxide, Non-destructive sterilization) → finished product storage.
2.Panels waist circumference
3.Poly base film
4.Liner center surface
6.Pad cotton core
7. Surge diversion layer
Partially enlarged structure:
1.panels waist circumference
2.Outer cover cloth&flap
3.Poly base film
7.liner center surface
8.Core wrap wrap surface
9.Pad cotton core
10. Surge diversion layer
2.Panels waist circumference
1) Panel outside nonwoven
2) Panel inside nonwoven
3) Panel elastics waist band
1.pad cotton core
2.Poly side wrap sheet
3.Liner side wrap sheet center surface layer side wrap surface layer
4. Surge diversion layer
5.Liner center surface
6.Folded cotton core folded
1.outer cover cloth&flaps outer non-woven fabric
2.Poly base film
3. Folded absorbent wrap
4.Folded outer cover cloth&flaps with elastics outer non-woven fabric and rubber band are folded together
1.Outside nonwoven waist outer layer non-woven fabric
2.Panel elastics waist band
3.Inside nonwoven waist circumference
4.Slit into 2 panels into two waists
Overall product structure:
Suntech manufactures intelligent diapers according to the standard of "Jinggong Intelligent Manufacturing", which effectively improves the production speed, output and quality of diapers, and facilitates the production of diapers. Welcome to inquire in detail.