Dukane develops adhesives-free attachment for hygiene items; new Ultrasonic Attachment/Lamination technologies attaches elastic strands to the nonwoven substrates in manufacturing of hygiene products

Sample article from our Tissue & Hygiene

St. Charles , June 15, 2023 (press release) –

Dukane, the leader of full-service plastic bonding corporations, continues to show the way with their development of new Ultrasonic Attachment/Lamination technologies for manufacturers of hygiene products. Dukane continues to engineer innovations that provide its customers with world-class end-to-end solutions, shorter developmental lead times, and outstanding executional design flexibility.

Dukane has been the category leader in Ultrasonic Sealing technologies for decades and continues its quest to strive for excellence in solving unique manufacturing issues for its customers.

Some of the key products produced in the hygiene market are adult protective underwear and baby disposable diapers. The global adult protective underwear market is expected to grow at an annual rate of nearly nine percent over the next five years. The growth’s key issues are cleanliness, product availability, cost, ease of wear, and an aging population. Covid-19 also had a lasting effect on the use of disposable hygiene products by creating an uber awareness of the need for these products. Underdeveloped countries have also begun to adopt a unique
understanding of reversing social stigmas around incontinence and other hygiene issues, opening the doors for new sales opportunities in foreign countries.

The global baby diapers market was valued at USD 82.59 billion in 2022 and is expected to grow at a compound annual growth rate of 4.9 percent from 2023 to 2030. The market is projected to witness higher demand over the coming years due to the rising awareness of child health in general.

The above market growth and key market indicators have created an opportunity for Dukane to bring to market an improved process for manufacturing in baby and adult product categories. Advancements in technology have led to significant improvements in fit characteristics and sustainability driven by Dukane attachment/lamination processes that eliminate the need for adhesives in the manufacturing of hygiene products.

“We have been the leader in providing solutions for manufacturers of hygiene products for over 40 years. With the acquisition of Aurizon Ultrasonics in 2019, we can now deliver the fastest and most diverse product portfolio of adhesive-free solutions in the business. Why is it important? Because it means adhesives are no longer necessary for hygiene manufacturing processes.” said Dukane Product Manager, Hygiene/Packaging, Justin Lafferty.

Dukane’s new attachment technology addresses a lot of manufacturers’ concerns when it comes to putting elastic bonds into hygiene products. The most obvious is that it COMPLETELY ELIMINATES ADHESIVES from the process by attaching elastic strands to the nonwoven substrates, softness, and breathability.

Don’t forget ROI. This technology from Dukane removes cost overhead from managing materials and additional downtime for cleaning adhesive residue from equipment while eliminating the need for expensive petroleum-based materials, additional labor, and utility costs.

Let’s talk about end-user salability. Improved product comfort and no adhesives mean a softer, odor-free product with better breathability, improved elastic performance, maximum product discretion, and minimal VPL when wearing the product.

“One of our main drivers in engineering this new adhesive-free Ultrasonic elastic attachment for nonwovens was to see how we could help customers reduce their carbon footprint, address their sustainability concerns for the future, and make their products better. This engineering marvel stands to eliminate over 1 million pounds of adhesive per machine in just the first year alone,” said Dukane Market Manager, Hygiene, Dan Sorenson.

Dukane spent the better part of last year and the first part of this year promoting advancements in the Ultrasonic nonwoven welding platforms, and they are now proud to promote their adhesive-free ultrasonic elastic attachment technology. They would like to invite interested parties to visit their state-of-the-art Kimberly Center of Excellence for personal care, nonwovens, and packaging solutions to see just how adept they are at solving process-specific solutions. They are very aware of their customer’s need to become the best they can be in their respective manufacturing verticals and are leveraging all the assets in their toolbox to offer clients
every opportunity to succeed!

Dukane continues its commitment to assisting customers in need of nonwoven ultrasonic welding solutions with an acute awareness and attention to detail when it comes to providing those solutions while taking into account the need for shorter developmental timelines, increased ROI, reduced cost of doing business, and an unparalleled service commitment rivaled by none worldwide.

Headquartered in St. Charles, Illinois, DUKANE is an awardwinning laser and ultrasonic laser technology leader focused on a customer-centric approach. We develop solutions that meet the
unique requirements of each customer’s application. DUKANE is a global organization that represents the most extensive plastic welding portfolio in the world, with international assistance available 24 hours a day. Operating in major verticals that include automotive, medical, electronics, packaging, nonwoven, food, automation, and cutting, we bring to bear on each solution over 100 years of technological experience! Dukane operates facilities
and offices throughout North America, Europe, and Asia. Learn more at dukane.com, follow @dukane on Twitter, follow Dukane on LinkedIn, and like Dukane on Facebook.


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Jason Irving
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