Designed Around the Dose: A Flexible Nonwoven Solution for On-Site Saturation
At Speciality Wipes, flexibility means more than offering different materials or formats. It means understanding how a product will be used and designing every element around the customer’s process
We recently worked with an adhesives manufacturer to develop a dry nonwoven roll that could be saturated on site by the end user. The objective was to create a convenient, reliable system that would simplify dosing while delivering the optimum level of saturation.
A roll designed for exactly one litre
Standard commercial nonwoven rolls commonly contain 50 or 100 sheets. For this application, however, a conventional sheet count would not have provided the required relationship between the roll and the adhesive liquid.
Our solution was to manufacture each roll with precisely 277 sheets. This was not an arbitrary number: testing and product development established that a 277-sheet roll required exactly one litre of liquid to achieve the optimum saturation level.
The adhesives supplier could therefore provide the liquid in matching one-litre bottles. To prepare the product, the operator simply opens the pouch and adds the entire bottle. There is no need to measure, calculate or estimate the dose, substantially reducing the opportunity for operator error and helping to ensure consistent saturation from one roll to the next.
High-integrity packaging for dosing on site
Each dry roll is supplied in a high-integrity trilaminate pouch designed to receive and contain the liquid. The end user decants the one-litre bottle directly into the pouch, allowing the nonwoven roll to absorb the formulation evenly before use.
Supplying the roll dry offers the customer a flexible product format while enabling the liquid to be introduced at the point of use. The roll, pouch and bottle work together as one carefully considered system.
Product design that simplifies the process
This project demonstrates how thoughtful product design can solve a practical manufacturing challenge. By adapting the sheet count to the liquid volume—rather than asking the operator to adapt their process to a standard roll—we created a simple and repeatable dosing method.
The result offers several practical benefits:
- Consistent and optimum saturation
- No manual liquid measurement
- Reduced risk of dosing errors
- A straightforward process for operators
- High-integrity packaging suitable for on-site saturation
- A bespoke format aligned with the customer’s existing one-litre bottles
From the unusual 277-sheet count to the matching liquid volume and trilaminate pouch, every detail was developed around the application.
It is a strong example of our ability to go beyond standard formats and engineer a nonwoven product that fits precisely into a customer’s process. Whether that requires a bespoke sheet count, specialist packaging or an entirely new product configuration, we have the flexibility and product-design expertise to turn a practical challenge into a simple, effective solution.