If you are, or want to be, involved in any facet of the manufacture or sale of baby diapers, sanitary napkins, adult incontinence or similar absorbent products, please read through our pages and contact our Consultant, Philip Hardy, by phone, fax or e-mail.
New
Companies |
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Absorbent Disposable Products
Baby Diapers, Adult Diapers, Shaped Pads
Sanitary Napkins, Panty Shields
Underpads
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If you are an entrepreneur or a manufacturer of other products and have seen an opportunity in your country for the production and sale of diapers, sanitary napkins or underpads - we can take you there. We are not selling you a particular product or a machine - our only aim is to help you to set up a successful and profitable manufacturing company. |
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| Outline
Information Below is some information on the industry which will help you to understand the scale of investment required for a manufacturing plant. After reading it, please go to the Feasibility Study section where we describe exactly how you can achieve a complete and accurate understanding of the potential profits of diaper, napkin, panty-shield or underpad manufacturing. |
All high speed disposables machines are purpose-made to suit exact client requirements. They vary greatly in price based on the following main parameters:
- Machine speed
- Product features
- Product quality
- Machine reliability/efficiency
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.
Minimum Cost Slow speed -100dpm $200k Medium Speed -250dpm Medium /Premium $400k High speed -400dpm Premium $1,400k Top speed -800dpm Premium $2,000k
Minimum Cost Slow speed - 200ppm Economy
$100k Medium Speed - 350ppm Econ/Premium $300k High speed - 500ppm Premium $800k Top speed - 1000ppm Premium $1,000k
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
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
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 : (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)
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)
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.
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 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 Machine capacity Production figures per shift Preferred machine cost or speed Machine efficiency Predicted annual efficiencies 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 Machine waste Predicted waste levels Quality rejects Predicted seconds levels Sales costs Advice on sales requirements Marketing information Advertising Advice on marketing Freight costs Quantities per container Freight charges 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.
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.
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.
