Seven Decades of Disposable Diapers
Seven Decades of Disposable Diapers
Seven Decades of Disposable Diapers
DISPOSABLE DIAPERS
Table of Contents
Introduction
1.
2.
3.
4.
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Endnotes
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Introduction
One of the most significant consumer products of the twentieth century, the disposable diaper
(or nappy in some usages) continues to evolve rapidly in the early twenty-first century,
becoming smaller, cheaper, easier to use, friendlier to the environment, and more ubiquitous
every year. Today, more than nine of every ten diaper changes in the developed world and a
growing percentage elsewhere are disposables. The disposable diaper provides a modern
solution to an age-old needto keep infants clean, dry, and safe from infectionswhile
liberating parents from an age-old problemto clean up after infants and small children during
the earliest years before potty training.
The story of the disposable diaper begins more than a century ago, but it became commercially
viable in Europe and North America seven decades ago, in the late 1940s. Its evolution was
hardly smooth, however, and the huge success it has become was hardly foreseen at the outset.
In taking a long view of the product, it may be helpful to think about its development in four
distinct periods:
1.
2.
3.
4.
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In the long scheme of human history, the cotton cloth diaper is a relatively recent arrival.
Its period of ascendancy extended from the mid-19th century to the late-20th century.
From the beginning, users recognized the limitations of cloth diapers, especially leakage,
discomfort, and cleanup.
As early as the 1850s, inventors and entrepreneurs were looking to overcome these
limitations and offer consumers diapers that were moisture-proof, more absorbent,
disposable, and hygienic.
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Meanwhile, J&Js senior management pushed to diversify the companys businessa challenge
that Chicopee management embraced eagerly. In the late 1940s, Chicopee also introduced an
array of cellulose-based disposable products for hospitals and consumers such as bed coverings,
absorbent pads, feminine protection pads, adult incontinence products, and baby products.
This last category included CHUX Disposable Diapers, soft and absorbent with waterproof
backing and designed to provide complete baby protection without panties and aimed at the
needs of the traveling American family. CHUX was the first one-piece model, although it did
not have a fastening system. Chicopee also sold a lower-cost two-piece diaper for more
frequent use. The CHIX Pad and Panty combined a highly absorbent pulp fiber disposable
insert and a waterproof pant with snaps for easy fastening.7
In many Western European countries and in North America, manufacturers were well aware of
opportunities created by post-World War II population growth, although most believed that
disposable inserts and diapers would remain novelty items given a significant price premium
over cotton diapersa factor of ten or more, depending on the model. Disposables were
marketed through pharmacies, hospitals, medical supply houses, and department stores.
Demand built up gradually, although faster in Sweden, in part because consumers valued the
clear advantages of disposables and a strong domestic paper industry could offer them at a
relatively low premium over the price of imported cotton diapers.
In the 1950s, another Swedish company, textile-maker Mlnlycke, took over technical and
market leadership from Paulistrm, continuing to develop two-piece models. Mlnlyckes QuikDiaper (also called Instant Diaper), introduced in 1957 featured a pear-shaped insert that was
tailored to the babys body and was especially effective in capturing urine.8 Meanwhile, other
producers emerged across Europe. In France, for example, Peaudouce and Calines cultivated a
growing market for the two-piece disposable, while Paul Hartmann AG in Germany, Ontex in
Belgium, and Fater in Italy, among other producers, also entered the business. By the mid1960s, the product was available throughout Europe and was known familiarly as Swedish
pants (Schwedenwindel in Germany; pantolini svedese in Italy). In a few countriesin
Sweden, Finland, and France, for examplemany families used these products on a daily basis.
Elsewhere, it was more common for them to be used as supplements to traditional cotton
diapers for night-time use or when traveling or for special occasions.
The market in North America evolved in similar ways. As J&Js diapers achieved modest
success, other manufacturers appeared. By the early 1950s, Kendall Corporation, a direct
competitor to J&J in bandages and surgical dressings, and Parke-Davis, a pharmaceutical and
medical supply company, had disposable diapers or absorbent inserts on the market. They
were joined soon after by Playtex, a maker of womens undergarments and female protection
products, which imported technology and know-how from Mlnlycke. By the middle of the
decade, disposable diapers were found in 80 percent of American households with infants,
although they accounted for less than one percent of diaper changes due to the high expense.
Prices typically ran abovesometimes well aboveten cents per diaper, while cloth diapers sold
for 1-2 cents each and diaper services typically charged 3-5 cents per diaper.9
Meanwhile, other competitors and new approaches were beginning to emerge, and a dramatic
breakthrough was to come from another new entrant, consumer products giant Procter &
Gamble.
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Two alternative designs competed: the two-piece product pioneered in Sweden and
generally more popular in Europe than in North America; and a one-piece model
developed by Johnson & Johnson for a relatively small market niche in the United States.
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After considering an array of options, P&G decided to try again, this time focusing on a simple
one-piece disposable consisting of an absorbent tissue core bonded to a plastic back. The
product possessed several innovative features in addition to basic design, including a
hydrophobic top sheet made of rayon to help keep moisture in the absorbent tissue layer, and a
large plastic back sheet to help contain leakage. Like a cloth diaper of J&Js one-piece Chux,
P&Gs disposable was fastened with pins. P&G test marketed its new disposable, now branded
as Pampers, in Peoria, Illinois in 1961. Consumers rated the product highly although sales
remained disappointing due to prices still four or five times above those of cotton diapers.
P&G concluded that large demand for the product would materialize only if the company could
lower prices by 40 percent or more. During the next several years, engineers focused on a new
manufacturing process to simplify and speed up production while also redesigning the product
to use less and lower-cost material. Perfecting the new production process turned out to be
the most complex manufacturing challenge P&G had ever faced, involving developing and
debugging a massive, block-long continuous-process machine capable of producing up to 400
diapers per minute.11 In 1964, the new process was ready for another test market, this time in
Indianapolis, Indiana. Introduced at less than 6 cents per diaper, Pampers quickly sold out the
initial allocation, and consumers clamored for more.
During the next several years, the company rolled out Pampers across the United States in
small (infant), medium (daytime), and large (nighttime) sizes. By the end of the decade, the
product had become P&Gs second-largest brand.
In addition to the manufacturing
breakthrough, a key part of the companys success was clever marketing, including programs to
convert hospital maternity wards and day-care centers to disposables and free samples given to
new mothers.
Although P&G had expected Pampers initially to attract affluent consumers, it found the product
had immediate and widespread appeal across all segments of the market. The company once
received a grateful phone call from an impoverished woman who lived in a New York tenement
building. Before Pampers, the woman said, she was forced to take a pail of soiled diapers down
four floors and then walk through an unsafe neighborhood to the laundromat located two
blocks away. A similar pattern emerged later when Pampers was introduced worldwide.
Consumers in less developed countries, where household washing machines and dryers were
less common, rushed to buy disposables.12
Meanwhile, other manufacturers quickly countered the introduction of Pampers. In Europe,
Mlnlycke introduced its one-piece Combinett diaper in 1967. Featuring a tape-fastening
system, Combinett was the first complete one-piece model. In the United States, KimberlyClark, a leader in paper tissues and feminine hygiene products, had worked on disposable
diapers for years before introducing Kimbies in 1968. Kimbies featured several key innovations
that became industry standards, including a contoured shape, a new absorbent material (fluff
pulp instead of tissue pulp), a spun-bonded polypropylene liner, and adhesive tape fasteners.13
In 1971, Johnson & Johnson began to phase out the original Chux line in favor of a new
premium design with an especially soft feel and sold under the companys brand name. Several
other producers also entered, including some that manufactured store brands for leading
retailers and supermarket chains. By 1980, disposables accounted for more than 90 percent of
all diaper changes in North America.14
In Europe, low cost, one-piece models did not sweep the market quite as quickly or evenly
although the eventual outcome was the same. P&G began production of Pampers in West
Germany in 1973, and the brand soon became the domestic market leader. In Scandinavia and
France, however, the two-piece models remained popular for a time.
The Winthrop Group, Inc. on behalf of
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Mlnlycke found that consumers remained comfortable with two-piece models and did not
promote its one-piece Combinett aggressively. In France, Peaudouce and Lotus continued to
promote a T-shaped insert that was particularly effective in absorbing liquid. One-piece models
became available in 1975 through imports from Scandinavia, Germany, and the United States as
well as from local producers such as Linett and Tendresse. The one-piece models gained
between 8-10 market share points per year, eventually achieving market dominance in the mid1980s.15
Meanwhile, low-cost disposables of both types (one-piece and two-piece) hastened the
replacement of cotton diapers in most European countries. According to data compiled by the
European Disposables and Nonwovens Association (EDANA), between 1970 and 1979, the
percentage of the total market accounted for by disposables surged from 52 to 97 percent in
France; from 41 to 85 percent in Germany; and from 28 to 75 percent in Switzerland. Market
penetration already was high in Scandinavia in 1970 but surpassed 95 percent by the end of the
decade. Only in the United Kingdom and in The Netherlands did replacement proceed more
slowly, largely due to the entrenched strength of local diaper service companies.16
The ultimate and nearly complete victory of the low-cost one-piece disposable across Europe
awaited a series of technological improvements and innovations between the mid-1970s and
mid-1980s. The first was a superior fitted shape with elastic leg openings. P&G introduced
these features in 1976 in the United States on a second disposable diaper brand, Luvs.
However, P&G could not manufacture Luvs on its existing diaper machines, so the company
offered them as a premium brand for affluent consumers. Kimberly-Clark, meanwhile, was
working on a successor to Kimbies that would outperform Pampers and the Johnson &
Johnsons. Like Luvs, the new Kimberly-Clark design featured a superior fitted shape and
elastic leg openings, but it could be manufactured in high volume. Kimberly-Clark launched the
new model in 1977 as Kleenex Super Dry and renamed it the following year as Huggies. Sold
at a price point between Pampers and Luvs, Huggies became a huge hit in the United States,
passing Pampers as the leading brand in the market in the late-1980s. 17 Meanwhile, fitted
designs with elastic cuffs spread to Europe, where SCA (which bought Mlnlycke in 1975),
Peaudouce, Paul Hartmann, Ontex, and other manufacturers adopted them both for premium
and private-label brands. The new models proved extremely popular and accelerated the
replacement of cotton diapers in the United Kingdom and in the Netherlands, as well as of twopiece models in other nations.
A second major improvement in diaper design in these years involved the use of
superabsorbent polymers (SAPs), which enabled diapers to be shrunk dramaticallyby 30
percent or morein size.
The application of SAPs to diapers was patented nearly
simultaneously in 1966 in the United States by Carlyle Harmon of Johnson & Johnson and by
Billy Gene Harper of Dow Chemical. 18 The researchers found that the SAP could absorb
between thirty and sixty times their weight in liquida huge advantage over conventional
materials such as fluff pulp. European and North American diaper manufacturers began
experimenting with SAP as a partial replacement for fluff pulp in the early 1980s. Credit for
commercial demonstration, however, goes to Japanese manufacturer Uni-Charm, which
introduced its slimmed-down Moonies in 1983, with Kao, another Japanese competitor, in hot
pursuit. These innovators used 1-2 grams of SAP in each diaper and demonstrated the power
and appeal of the thin-diaper concept. Subsequently, other manufacturers increased the
amount of SAP in diapers, which permitted still more shrinkage. By the mid-1980s, ultrathin
premium disposables were about one-half the size of their predecessors. During the next ten
years, further improvements and sophistication in working with SAPs enabled another 50
percent reduction in size.19
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The thin and ultrathin models proved extremely popular around the world and, as prices came
down and the technology spread into store brands, completed the replacement of cotton
diapers and two-piece disposables.20 By the late 1980s, disposables accounted for more than
95 percent of diaper changes in Japan, North America, and most European countries. Even in
the United Kingdom and The Netherlands, thin and ultrathin models tipped the balance away
from cotton diapers and diaper services and by the mid-1990s claimed market shares
comparable to those in most other European nations.
The new models delivered the traditional advantages of disposables in a smaller package. Not
much bigger than cloth undergarments, they enabled infants and young children to move freely
and be dressed fashionably. They produced additional economic and social benefits including
savings in distribution, shipping, merchandising, and storage while also generating less waste.
Meanwhile, increasing use of disposable diapers correlated with observed clinical benefits for
individual children as well as children in group settings.
These benefits included reduced instances of diaper dermatitis and improved skin wellness from
drier skin and more stable skin pH.21
Key Lessons of the Third Period (1960s-1980s)
Low-cost manufacturing reduced the price premium for disposables relative to cloth
diapers and facilitated rapid substitution in the 1970s and 1980s in most developed
countries and in a growing number of developing nations.
Once they became affordable, disposables appealed to all segments of the market,
where consumers clearly preferred them to cloth diapers.
One-piece designs, which simplify use and cleanup, quickly won over customers in
Europe and dislodged two-piece models.
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As the focus of competition shifted from replacing cloth diapers, the pace of innovation
in disposables accelerated dramatically, resulting in improved products and more choices
for consumers in the premium segment, while the growth of the value segment exerted
downward pressure on prices.
The benefits to consumers of modern disposable diapers are diverse, extensive and
profound: ease of use; liberation of parents from time-consuming duties; happier
healthier children.
**
The disposable diaper is one of the most significant consumer product
developments of the twentieth century. In just a few years after commercialization,
disposables virtually replaced traditional cloth diapers as consumers recognized and
valued overwhelming advantages in ease of use, increased comfort, better hygiene,
and improvement in the amount and quality of time parents can have with their
children. At the same time, the industrys competitive rivalry and history of
continuous innovation and cost reduction have enabled parents from all parts of the
world and all economic circumstances to benefit socially as well as economically.
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See http://www.gpoabs.com.mx/cricher/history.htm (accessed July 2005) for an overview of the history of the
diaper.
Bengt G. Johannson narrative; U.S. Patents 19418 (1858), 318,141 (1885), 342,494 (1886), 1,694,161 (1928),
Des. 95,253 (1935).
Johannson narrative.
Chicopee Manufacturing Company, Baby Products Division, undated brochure; On Chicopee, see Lawrence G.
Foster, Robert Wood Johnson (State College, PA: Lillian Press, 1999), p. 129.
Chicopee Manufacturing Company, Baby Products Division, undated brochure; Foster, Robert Wood Johnson,
p.309; Foster, A Company That Cares: One Hundred Year Illustrated History of Johnson & Johnson (New
Brunswick, NJ, 1986), p. 116; Carlos Richer website.
The Disposable Diaper Industry in 1974 (Harvard Business School Case Services, 9-380-175), p. 2. The
Boater, a fashionable 2-piece diaper product sold in upscale department stores, sold for $1.95 each.
10
Davis Dyer, Frederick Dalzell, and Rowena Olegario, Rising Tide: Lessons from 165 Years of Brand Building at
Procter & Gamble (Boston: Harvard Business School Press, 2004), Chapters 5 and 6, esp. pp. 129-138; The
Disposable Diaper Industry in 1974, p. 2.
11
Dyer, Dalzell, and Olegario, Rising Tide, p. 132; The Disposable Diaper Industry in 1974, p. 2.
12
13
Robert Spector, Shared Values: A History of Kimberly-Clark (Lyme, Connecticut: Greenwich Publishing, 1997).
Pp. 111-112; Thomas Heinrich and Bob Batchelor, Kotex, Kleenex, Huggies: Kimberly-Clark and the Consumer
Revolution in American Business (Columbus: Ohio State University Press, 2004), pp. 184-198.
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18
Malcolm Gladwell, Smaller: The Disposable Diaper and the Meaning of Progress, New Yorker, November 26,
2001; online version http://www.gladwell.com/2001/2001_11_26_a_diaper.htm. Accessed August 2004;
19
20
La Course aux Superlatifs, Points de Vente, April 15, 1989, pp. 90-92.
21
Hygiene Products Manufacturers Group, European Disposables and Nonwovens Association, Diapers: Health
Kimberly-Clark began major investments in Europe in 1994 and acquired the Peaudouce brand from SCA two
years later. Since then, Huggies has become the number two brand across Europe after P&Gs Pampers.
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