Buying questions
How many nonwoven layers are in a diaper?
Five or six, each with a different job. The weights run from 15 to 30 gsm, and the differences are structural rather than decorative.
At a glance
Specification at a glance
| Layer | Typical material | Weight |
|---|---|---|
| Top sheet | Hydrophilic spunbond or ES | 15 to 25 gsm |
| Acquisition layer | Through air bonded bicomponent | 40 to 60 gsm |
| Core wrap | Light spunbond or tissue | 10 to 17 gsm |
| Back sheet | Spunbond plus breathable film | 15 to 25 gsm |
| Side panels | Spunbond, elastic laminate | 25 to 40 gsm |
Why top sheet and back sheet differ
The top sheet must pass liquid fast and stay dry, so it is hydrophilic and light. The back sheet must block liquid and pass vapour, so it is hydrophobic and laminated. Same machine, opposite requirements.
Where the cost sits
The core and the film usually dominate cost; nonwoven is a smaller share but decides comfort. Optimising nonwoven weight without testing strike through and rewet is how products get cheaper and worse at the same time.
Check the claim before it goes on the pack
Send the claim you want to make and the market it sells in. We reply with what the material can support and what it cannot.
Questions
Common questions
Which layer is most important?
The core for capacity, the top sheet for the feel of dryness. Buyers judge on the second.
Can the top sheet be spunlace?
Rarely, on cost. Spunbond and ES dominate, with the acquisition layer providing bulk.
Is the back sheet breathable?
Premium products use a breathable film laminate. Standard products use a plain film for cost.