The following tables give approximate minimum
costs of typical baby diaper and sanitary napkin machines. These should
be treated only as guidelines since there are many different manufacturers
in Americas, Asia and Europe that offer different levels of machinery
and after-sales support.
It is important to note that when choosing a machine
manufacturer you are choosing a business partner for a minimum of
7 to 10 years, so price should not be the only factor that you consider.
This is where our expert assistance is key to the future success of
your venture. Please contact us to discuss how we can assist in machine
selection and technical support. Contact
Note: There
are home-based machines on sale with extremely low
outputs. We do not show or list these machines since we do not feel
that their product can compete against that of the automatic machines
shown below. We feel that their use should only be considered when
there is no possibility of outside competition being introduced to
a small local market.
|
Machine
speed |
Product
type |
Minimum
Cost |
Baby
Diaper Machine |
Slow speed -100dpm |
Economy |
$200k |
| |
Medium Speed -250dpm |
Medium /Premium |
$400k |
| |
High speed -400dpm |
Premium |
$1,400k |
| |
Top speed -800dpm |
Premium |
$2,000k |
| |
Machine
speed |
Product
type |
Minimum
Cost |
Sanitary
Napkin Machine |
Slow speed - 200ppm |
|
$100k |
| |
Medium Speed -
350ppm |
Econ/Premium |
$300k |
| |
High speed - 500ppm |
Premium |
$800k |
| |
Top speed - 1000ppm |
Premium |
$1,000k |
Second-hand
Machines
There is a market in second hand manufacturing machinery.
However, there is more risk involved in the purchase of such a machine
directly from the vendor, we would always recommend purchase from
a machine manufacturer or reputable machine modifier who will give
some guarantee of performance.
If you wish to check the options available in this market please click
on the following link and describe, with as much detail as possible,
the product that you wish to produce and the preferred machine output
or speed. Second-hand
machines
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Machine
Photos
Baby Diaper
Machine
This is a baby diaper machine from Asia. The photograph shows
the main working area of the machine from formation of the absorbent
core to the final bi-fold of the finished diaper.
In production, a fluff pulp mill will be positioned at the right
hand end of the machine and normally a counter/stacker will
be at the left hand end to count the diapers and align them
before they are pushed into the manually held bag or into the
automatic packaging machine. |
 |
 |
Adult
Diaper Machine
This is basically a larger version of the baby
diaper machine. In some cases the material feeds are brought
at right angles to the machine as can be seen in this photograph. |
Sanitary Napkin Machine
Sanitary napkin Machines can be designed to run with fluff
pulp or airlaid absorbent core. It is also possible to have
tri-fold option as well as straight product.
A machine can also be designed to run panty shields, but
change-over times between products tend to make this inefficient
|
|
*As part of our Feasibility Study Service we list the
overall dimensions of machines as well as production and storage areas
required. also all other machinery that you will need such as stacker,
packaging machines and compressors * Feasibility
Study
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Product
Recipe
Below
is a typical recipe for a baby diaper. In this case it is a Maxi or
Large size, the best selling size worldwide.
The
manufacturer has estimated in this example that he averages 4% waste
for the diaper raw materials and 2% for the packaging. Company manufacturing
procedures must be set up clearly at the outset to ensure that these
waste levels are accurately monitored and controlled. This is one
of the key factors in success or failure in the industry.
We
will assist you by creating these detailed recipes for your product
and material costs. We will provide the material costs adjusted for
your geographical area and size of production unit.
| |
PRODUCT SPECIFICATION : |
|
Maxi 28 |
33+9 |
|
|
| |
|
|
(Sq. cm, cm). |
(Grams) |
(Grams) |
(Cents) |
| |
Units |
Price |
Area/Lgth |
Weight |
Waste |
Cost |
| Fluff |
$/Tonne |
|
|
20.465 |
4% |
0.000 |
| SAP |
$/Tonne |
|
|
9.000 |
4% |
0.000 |
| Tissue 18gsm |
$/Tonne |
|
1014.0 |
1.876 |
4% |
0.000 |
| Non-woven |
$/1000m2 |
|
1617.0 |
3.719 |
4% |
0.000 |
| Backsheet |
$/Tonne |
|
1592.5 |
3.758 |
4% |
0.000 |
| ADL 40gsm |
$/1000m2 |
|
182.0 |
0.728 |
4% |
0.000 |
| Foam elastic |
$/1000m2 |
|
36.0 |
0.194 |
4% |
0.000 |
| Hook Tape |
$/ m. |
|
5.2 |
0.600 |
4% |
0.000 |
| Loop Frontal |
$/1000m2 |
|
86.0 |
0.420 |
4% |
0.000 |
| Leg Elastic |
$/Tonne |
|
84.0 |
0.052 |
4% |
0.000 |
| L/Cuff Elastic |
$/Tonne |
|
39.2 |
0.024 |
4% |
0.000 |
| L/Cuff N/w |
$/1000m2 |
|
490.0 |
1.127 |
4% |
0.000 |
| Elastic Glue |
$/Tonne |
|
|
0.300 |
4% |
0.000 |
| LC El Glue |
$/Tonne |
|
|
0.130 |
4% |
0.000 |
| Constr. glue |
$/Tonne |
|
|
0.850 |
4% |
0.000 |
| LC Con Glue |
$/Tonne |
|
|
0.150 |
4% |
0.000 |
| Lotion |
$/Tonne |
|
|
0.200 |
4% |
0.000 |
| R.M.Total |
|
|
|
42.000 |
|
0.000 |
| |
|
|
|
|
|
|
| |
|
Price |
Pack Size |
|
|
Cost |
| Bags |
$/unit |
0 |
28 |
|
2% |
0 |
| Boxes |
$/unit |
0 |
168 |
|
2% |
0 |
| Wrap |
$/roll |
0 |
21504 |
|
2% |
0 |
| Pallet |
$/unit |
0 |
2688 |
|
2% |
0 |
| Pack Total |
|
|
|
|
|
0 |
| |
|
|
Total material cost |
|
(Cents) |
|
| |
|
|
Overhead cost |
|
(Cents) |
|
| |
|
|
Total Cost/diaper |
|
(Cents) |
|
| |
|
|
Total Cost/bag |
|
($/bag) |
|
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Productivity
In order to operate your new manufacturing company
profitably, you should aim to fill at least one shift of production
on your proposed machine. The following example will show what production
level you can expect from these machines.
The efficiency is normally assumed to be circa 70% of available production.
This can be exceeded if size changeovers are minimised and operators
are well trained.
At the start of manufacture with untrained staff or with more basic
machines an approximate efficiency of 60% should be assumed.
Baby Diaper example-
Economy diaper machine producing 250 diapers per minute - 4
sizes
Guideline 70% efficiency for working time
Example: Assuming 8 hour shift with 30 minute break = 7.5 hours working.
Daily production = 250 x 7.5 x 60 x 70% = 78,750 per day.
Annual production = 240 x 78,750 = 18.9 million diapers per year for
one shift.
(Assuming 5 day working week and 4 weeks holiday shut-down per year)
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Feasibility
Study
Process
We
offer all of the specialist knowledge needed to produce a financial
feasibility of your factory set-up.
The local information will be supplied by you, but with our assistance,
see 'Client Input' column below.
All other information will be supplied by us, see the 'DCS Input'
column below. This is not an automated process, we will work with
you to discover your particular requirements in both product and machine.
The process will be carried out in a step by step manner. On receipt
of your enquiry, we will send you an input form on which we will request
the main parameters such as product quality, machine output and maximum
investment level. Before proceeding with the study, please read all
of the information in the above sections, there is no point in proceeding
to a study if the machine costs shown or the production levels are
obviously outside your scope.
On
receipt, we will process your information using our knowledge of the
machines, materials and processes. We will search for the particular
machine which is most suitable for your needs and request an up-to-date
price from machine manufacturers that will then be used in the study.
If you decide to proceed with the project, the outline budget targets
for the new company will already be known.
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Study
Inputs
Cost headings |
Cost Items |
DCS Input |
Client Input |
| |
Fixed Overheads
|
Main machine financing |
Main machine specification & cost |
Financing rates |
| Collateral machinery/equipment |
Spec. & costs coll. machines |
Financing rates |
| Rent, rates, insurance |
Production and storage area |
Rental rates |
| Admin./management |
Normal management levels |
Management rates |
|
|
Variable Overheads
|
Direct labour costs |
Machine and stores personnel |
Labour rates |
| Power/water |
Power and water requirement |
Power rates |
| Consumables |
General cost level |
|
| Repairs and maintenance |
Predicted cost level |
Technician rates |
|
|
Production Level
|
Machine capacity |
Production figures per shift |
Preferred machine cost or speed |
| Machine efficiency |
Predicted annual efficiencies |
|
|
|
Materials and Packaging
|
Raw materials |
Product recipe and material costs |
Local freight, duties and charges. |
| Bags |
Bag costs |
Pack sizes |
| Boxes/wrapping/pallet |
Box, wrapping and pallet costs |
Box sizes |
|
|
Waste
|
Machine waste |
Predicted waste levels |
|
| Quality rejects |
Predicted seconds levels |
|
|
|
Sales, Marketing, Distribution
|
Sales costs |
Advice on sales requirements |
Marketing information |
| Advertising |
Advice on marketing |
|
| Freight costs |
Quantities per container |
Freight charges |
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Results
of study
1) You will receive a fully priced
Product Recipe showing the cost of a
typical product in spreadsheet format, so that material prices and
overhead can be varied as you wish. We can supply tables for one or
all of the sizes requried.
2) You will receive the estimate of the total fixed and variable overheads
in spreadsheet format. Overheads.
3) You will receive a spreadsheet clearly illustrating the feasibility
of your project based on the product and the machinery. This model
will allow you to vary your inputs and shift numbers to quickly visualise
how your scheme will work with different costs and/or sales levels.
The main key output being the real cost of the disposable product
including all overheads which you can subtract from your target selling
price to calculate your net profit margin.
4) You
will receive a full report summarising the assumptions made in the
study and our recommendations for product, machine and factory set-up.
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Cost of Feasibility Study
Please contact us if you wish to avail
of our feasibility study carried out with the personal involvement
of our Technical Consultant, Mr. Philip Hardy. We will then send you
our outline questionnaire to begin the process and advise of the cost
. Mail us.
After a one or two week period working
with us on the details of this report, we guarantee that you will
end up with a clear and concise understanding of the real margins
that will be available for your local operation. If you are not happy
with the service, we will refund your money. The entire study period
should take no more than 2 weeks, depending on the speed with which
all of the local and supplier information can be gathered.
The fee for this study is minimised since our target is to work with
you on the company set-up, should it proceed. However, there is no
obligation on your part to continue to use our services after the
study has been completed.
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Factory
Set-up
If
the study shows that the project is feasible and you wish to proceed
with the factory set-up, the next stages of the process can be ooutlined
as follows:
1)
Machine selection
Machine selection is the most crucial decision in the process since
the machine manufacturer will by your key 'partner' in the enterprise
for the first 7 to 10 years. A reliable machine and a good customer
support from the machine manufacturer are the backbone of a successful
manufacturing company. We strongly advise that you use our expertise
during selection. We can draw up the required specifications, send
out the enquiries and advise in all negotiations.
2) Factory preparation
We can advise you on the general areas required for production
and storage. After selection of your premises, we can assist in final
machine and production layout.
The size of the power and compressed air supplies will be defined
by the machine manufacturer. If preferred, we can offer a turnkey
contract where we will install all machinery and hand-over the machine
in running mode.
3)
Raw Material sourcing
We can assist you in the sourcing of all raw materials from
vendors around the world. We have a database of suppliers and prices
that will be used to ensure that you get the best quality and the
best deals available.
4) Staff recruitment
We can provide a full specification of number and types of
personnel to be hired at start-up. We can assist with the training
of operators and management.
We can also provide some expert staff to assist in start-up and machine
operation until local staff are fully trained.
5)Production and Quality systems
We can provide for you and help you to set up all of the
Production and Quality systems that you will require to control the
flow of materials and finished goods.
We
can provide all or part of the items above. After your feasibility
study, we hope that you will discuss this with us so that we can reach
agreement on how best to help you to achieve a smoothly running and
profitable manufacturing plant.
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