1. Small and medium industries catering to local demand and are not able to afford advertising and sales promotion. What specific opportunity can be recognized to satisfy their need?
2. A diaper is a sponge-like garment used by individuals who are incapable of controlling their bladder or bowel movement or are unable to use a toilet facility. Once it becomes soiled, the parents or the caregiver needs to change it, as failure to do so at regular intervals may cause diaper rash. Diapers are usually composed of layers of fabric such as cotton, hemp, bamboo or microfiber and can be washed and reused multiple times. However, disposable diapers containing chemicals are thrown away after use. The decision to use cloth or disposable diapers is a controversial one, owing to issues ranging from convenience, health, cost and their effect on the environment. At present, disposable diapers with brand names such as Huggies and Pampers are commonly used. The major users of diapers are children who have not been potty trained as yet. The other market segment consists of elderly people having physical disabilities or people working in extreme conditions such as astronauts and in labs created in an environment that cannot provide for toilet facility who use diapers.
The crucial issue that is being debated is the huge waste that is getting created as a result of disposal of used diapers, which is causing environmental hazard. It is estimated that in the United States alone, around 27.4 billion disposable diapers are used every year that results in a possible 3.4 million tonnes of used diapers adding to landfills every year. Hence, a need for using technoeconomically viable cum environmental friendly reusable diapers. An American study of 6,000 new and expectant mothers last year found that 81 per cent were concerned about the environment and 70 per cent said that they planned to change their purchasing behaviour this year in order to protect the environment.
It is rightly said that money spent on disposable diapers is literally thrown in the waste basket and it is worth investing money for college education of your child. Slowly, consumers have started realizing the importance of reusable diapers. The newer, high-tech cloth diapers are userfriendly and far less harmful from an environmental impacts point of view. Although it takes time to change habit, once one gets used to them, one realizes that it is not at all difficult to use them compared to disposable diapers and that they also serve the purpose well. It has also been said by some researchers that the environmental impact that the manufacture and the washing of cloth diapers have is equal to that of disposable diapers. However, the fundamental question that remains is disposable diapers and wipes end up in landfills causing a great damage. Further, inside those plastic diapers is human waste which should not be dumped in landfills. As against this, cloth diapers can be reused, recycled, donated or even sold.
As such, cloth diapers are becoming latest craze in parenting. High-tech cloth diapers are userfriendly and easy to use. It is just a question of time that parents would change their habits, once dependable, reasonably priced and environment-friendly diapers are available.
Product development involves multi-disciplinary expertise that can result in providing a good bridge between a problem or need and a solution. Gerontology has been a neglected area of concern worldwide; however, redress of elderly issues is now a centre of social issues worldwide. Incontinence is the physiological malfunctioning of the excretory organs that result in the leakage of urine and stools from individuals. Incontinent products, which include adult diapers, incontinent garments and pads, help protect self-esteem, comfort and independence of individuals. There are a number of products on the market that can be classified under disposable and reusable products. Disposable incontinent products generally consist of a plastic outer layer, a super-absorbent polymer or chemical and an inner layer. The more recent disposables are biodegradable ones, which use a non-chemical absorption method and they are broken down over time in landfills. They are a convenience but more expensive than non-biodegradable ones and reusable ones, and their disposal adds to environmental pollution. Although some consumers say that disposable diapers are efficient on water usage, this may not be proved conclusively. This is due to increased efficiencies of toilets and washers on the amount of water needed for reusable diapers. Concerns of disposable products have ramifications on municipal solid waste management. According to Pham and Brown (2009) in an article titled Diapers and Municipal Government , disposable nappies are the third largest contributor to municipal solid waste (MSW) in the United States of America accounting for 1.5 per cent–4 per cent of the total waste. It might be initially cheaper to buy disposable nappies, but disposal costs do impact on consumers later through high municipal charges of disposal. Other countries such as Canada have instituted a disposable diaper tax or pay as you throw to mitigate the MSW and encourage consumers to recycle or use reusable products.
Reusable diapers, on the other hand, tend to have a waterproof outer layer that does not breathe, which makes them unappealing to most women who are users of the products. Otherwise, the piled 100 per cent cotton cloth that makes up a reusable diaper breathes and is comfortable to wear. If an individual is irritated by or sensitive to the nappy pile, a nappy liner is used. Contrary to the negative perceptions (Grove et al. 2002), when they looked at differences in skin temperature of boys wearing disposable and reusable diapers, found no difference in scrotal temperature. The temperature was only lower for boys who used reusable diapers without the protective plastic outer cover, which was rare to find in practice. The key benefits as stated by Pham and Brown (2009) are that reusable diapers are less expensive and healthier to use. There is no best type of product; what matters is the severity of incontinence, product quality, cost and personal preference of caregivers.
1,2
The specific choice of a product depends on several factors that include amount of urine loss, durability, ease of use, comfort, cost, pattern of urine loss and odour control ability.
3
Environmental pollution concerns have given the impetus to the utilization of eco-friendly products. The Eureka Institute (2009) reported that the smart eco nappy in the United Kingdom is a stylish solution to the billions of US disposable diapers that are thrown away every year. Furthermore, the market share of washable diapers has grown from 4 per cent of total nappy sales in 2004 to more than 15 per cent of parents using reusable nappies. Even maternity wards in the United Kingdom are being supplied with reusable nappies. Keeping the opportunity for reusable diapers in the market, various studies have been undertaken for product development in the area. The key objectives, assumption and methodological framework used in the study by Pinkie E. Zwane, Head of Consumer Sciences Department, University of Swaziland (UNISWA), are as follows:
The following objectives guided the study:
i. To design and develop a prototype for a reusable diaper for geriatrics.
ii. To determine water repellency characteristics of selected cover fabrics for the product.
iii. To evaluate the acceptance of the prototype diaper for end use by the target group.
The terry cloth made from 100 per cent cotton was selected as a suitable fabric to facilitate the absorption of body fluids towards the outer water-repellent fabric of the diaper.
Framework Methodological
A quasi-experimental design was used to assess the performance of the water-repellent fabrics for the prototype, and a qualitative approach was deemed appropriate to evaluate the product’s acceptance by end users. The creative design process was used as a methodological framework for prototype development. It involves problem identification, exploration of the problem, defining parameters or critical factors around the problem, generating design ideas, selecting the relatively best option, prototype development and prototype evaluation (Regan, Kinkade and Sheldon 1998). In exploring the problem, the aim was examined through literature search to identify crucial principles to be utilized in the product development phase. The major principles involved were absorbency, water retention within a micro-ambience and comfort in terms of moisture levels and fabric feel on the human skin. Market and garment analyses were done to determine what was on offer and to gather key garment features in the market.4
Critical factors that were considered were in terms of the target group for the product to be developed, and functional requirements needed to design and develop a quality product. Standard test methods to use in assessing fabric characteristics were identified. A decision was made on fabric types to select and test based on the generated design sketches of product, price and performance, stitch and seam types to explore, types of closure systems and colours to choose for the prototype. Selection of appropriate fabrication and colour were decided on the basis of - seam and stitch type, and closure system based on comfort and functionality of the product. Product development then ensued from the results of the tests that were conducted. During the production phase of the prototype, assessments were done to settle for the most efficient assembly methods, and suitable methods of fastenings to be used to address fit-related concerns. After the prototype development phase, the user trial appraisals were done to evaluate the aesthetics, functionality, safety, comfort and fit of the prototype on the user. On the basis of the responses received, they were incorporated in refining the prototype.5
Methods and Materials
Fabric Selection—A double-sided pile terry cloth was purposively selected to harness the absorptive property of the 100 per cent fibre content on the terry cloth. The absorbency of the terry cloth was not tested because of the established knowledge that it is highly absorbent and comfortable on the skin. The fibrefill interlining was used to aid in the wicking of absorbed excreted body fluids away from skin towards the outer layer of fabric. An outer water-repellant layer was used to stop fluid seepage to the exterior and to help keep the bedding and immediate environment of individuals dry, comfortable and sanitary.
Fabric Tests—Three water-repellent fabrics were purposively selected from the shops, on the basis of availability and fabric characteristics. They were subjected to an AATCC 2201980 waterrepellent test and an AATCC 3-1989 chlorine bleach test. Machine-washed water-repellent fabrics were later assessed for appearance. All the three were tested for water penetration and colour retention when exposed to a chlorine bleaching solution using 5 per cent of 3.5 per cent chlorine bleach concentration. After the selection of a suitable water-repellent fabric, a prototype was developed, which went through a normal washing cycle using an automatic washing machine to evaluate the product appearance qualities after washing. All the selected fabrics were white or close to white in colour for hygienic reasons and for no effect on colour change when bleached.
User Trials—Permission was sought from the Board of Directors of Hospice at Home (a non-governmental organization dealing with HIV/AIDS cases) to conduct the end user trials. Confidentiality of patients was maintained through distribution of the product by community health workers to conduct the trials. The collected data were analysed mostly qualitatively.
Discussion and Results
Fabric Tests—A comparison of tested fabrics with the standard ratings on the water repellency test showed 100, which stood for no water penetration on all the three fabric types. Hence, all the waterrepellent fabrics were suitable for end use on the basis of this test, as shown in the table that follow. The colour fastness to chlorine bleach had an effect only on fabric B that was plain white in colour but changed to a yellowish colour within two minutes. This was a clear indication that the chlorine bleach had no adverse effects on fabrics A and C but was detrimental to fabric B. Therefore, the latter was not suitable for the prototype development because the product had to be bleached in the laundering process for hygienic purposes.
The response of fabrics to a normal washing cycle using a washing machine revealed that fabric C sustained a few tears after the laundering process. On the other hand, fabrics A and B were water repellent and were not altered in appearance by the washing process.
Prototype of Description
The design was made after the consideration of the purpose of the product. It was eventually made using a double-sided pile terry cloth, half the thickness of fibrefill for sewability reasons, and using fabric A. The inner leg edges and back edge were elasticized for retention of body fluids within the diaper. Velcro fasteners were selected for easy dressing and undressing of the garment, and to achieve fit. They were sewn in the vertical direction initially. It was observed that there was no seepage of fluids to the exterior, but the fit around the legs was imperfect.
Prototype to Responses Customer
Responses received from the user trials indicated that the nappy was comfortable. This could be attributed to the use of towelling fabric, which has a soft feel on the skin. Furthermore, terry cloth was highly absorbent and facilitated the removal of fluids from the skin to the fibrefill fabric. The batting made from polyester, sandwiched between two layers of terry cloth, wicks or adsorbs the fluids from the inner layer of terry cloth to the outer layer of the same fabric, and provides a cushioning effect for comfort purposes. The outer, water-repellent fabric acted as a stopper to the seepage of fluids to the exterior. The respondents further reported that the nappy was reusable and very good if the user had only urinated.
The highlighted limitations by the end user included a lengthy period in drying the product on the line due to layers used in the construction and the water repellent layer, which may hinder rapid evaporation of the water used in the washing process. There was also staining of the nappy after being soiled with faecal material, and thus, it was referred to as ‘good if user has only urinated’. Users were later made aware that fabrics used were bleachable for hygienic and aesthetic purposes. The suggestions on improvement on the use of the product included the following: the use of durable household gloves when using the product to probably lessen the viral transmission to caregivers and the use of nappy liners for ease in discarding the stools. Emphasis was given on soaking the nappy in a chlorine bleach solution for 20 minutes to destroy any virus present in the excreted material. The cost benefit of reusable diapers was evident from the expenditure for a new born baby being $864.00 on reusable diapers as against $6,976.00 on disposable diapers over a three-month period.
A prototype was successfully designed and made for geriatrics. The developed product has long-term economic benefits, from six months to a one-year lifespan, given its serviceability for intended use. The water-repellent fabric A was best in performance when subjected to the fabric tests that were conducted. Generally, the prototype was accepted, appreciated and patented with number AP/P/2002/002613.6
1. What are the advantages and disadvantages of using disposable and reusable diapers?
2. What are the factors that have led to research in the area of coming up with reusable diapers?
3. What are the salient features and characteristics of reusable diapers produced by existing manufacturers and what are their main drawbacks?
4. What litmus test can ensure opportunity recognition in the diaper industry?
5. What are the steps involved in product development in general and diapers in particular?
6. What key inputs have been received from customers on the new reusable diapers developed? In what way can their input be further used to improvise on the product?
7. Do you think great opportunity exists for reusable diapers across the globe? If so, can it be turned into a venture? What are the key risks involved in this industry?