Coming out of the pandemic, wipes producers have gone from boom-times to a dip into leaner times, and now, forging ahead with new concepts. Many of the newest wipes developments and rollouts center around packaging. During the recent “lean” times after the empty shelves have been mostly re-stocked, many manufacturers and developers took the time to re-examine their offerings, brands and capabilities.

Among contracted manufacturers, new investments have also been part of the landscape. Companies like American Hygienics Corporation, American Custom Converting, Rebel Converting and Rockline Industries continue to invest in wet and dry wipes converting.

Packaging considerations often lead wipes development strategies. It’s what turns consumers’ heads. Whether bright branding, line extensions or sustainability considerations, the package tells the story. These are packaging and nonwovens factors developers review:

• Reducing packaging in terms of thickness/weight or square inches. Continued use of spunlace nonwovens allows for a wide range of thickness and weights. Companies continue to develop new nonwovens, such as 5K Fibres. CEO Douglas Brown says, “Recently, we started out on a new venture creating new fabrics using our 70+ combined years of experience to form the next generation of fabrics. We were focusing on our core technology and some new patents around what we trademarked with the name, ‘Spun-Blown’, since we can make really strong fibers.”
• Use of fewer materials, reducing production steps, or producing with reduced energy consumption. For example, 5K Fibres can, in some cases, eliminate the need to add “spunbond” layers to the outsides of certain fabric media for strength.
• Choosing the most efficient and runnable materials. Additives can also make materials more runnable in the manufacturing process.
• Moving to bulk packaging or increasing bulk packaging. For example, Rebel Converting produces canister wipes in high counts such as 1,200, 1,500 and 2,000, with even higher bulk options.
• Using “environmentally friendly” approaches, like source reduction with thinner materials or lower waste levels in the factory.
• Eliminating packaging-within-packaging to minimize printing, waste and improving opening/closing.
• Reducing transportation and energy usage in the supply chain. Some materials have been promoted as trendy, like bamboo, but there are long supply chain distances before manufacturing in the U.S.

It should also be noted that consumers depend on familiar packaging, such as Clorox’s traditional logo, to find these products on retailers’ shelves. Hurried consumers may miss grabbing their favorite brands. Creators balance the familiar while gaining fresh attention.

Some current trends, as reported in Nonwovens Industry, include growth of premium private labeling and increasing store brand introductions, reusable wipes, flushables, antibacterial and similar wipes such as PDI’s Sani-24 Germicidal Disposable Wipes.

Labeling and product identification in packaging are essential to consumer interest and recognition. In the canister wipes segment, Rebel Converting’s X-Treme canisters feature digital high-resolution printing which allows print of any design or graphic. Labels can be sequentially numbered, have different sets of numbers on them, or include unique images. The labels are in-molded—melted into the canister for durability.

Prototyping and product trials became difficult during the pandemic when manufacturers ran machines full out to meet market demands. In some cases, companies spent time rethinking how the future after the pandemic would unfold, especially when looking at new machine designs for enhanced and higher speed capabilities. With the approach taken by Rebel Converting to do digital printing, prototyping becomes easier. Artwork changes are quick with short lead times. Full digital technology allows Rebel to provide customers with sample canisters identical to those from a final production run. Canisters are prototyped for customers to test market new products, brands and designs.

There are many associated basic, and some complex, real-world challenges. Certain questions around multi-layered packaging, often needed to protect cosmetic or medical wipes, force producers to look for other approaches to improve their lifecycle impact. If packagers are too short sighted, they are apt to take a do-nothing view. However, economics is a key driving force where examining sustainable possibilities can lead to surprisingly innovative results. For example, more recyclable and affordable coatings may take the place of some plastic layers.

Wipes packaging confers convenience. Benefits of packaging, beyond protection, are convenience in opening/closing, ensuring freshness, one-at-a-time dispensing, package reusage and handling/ergonomics.

Top Brass Inc.’s wipes capabilities include peel-and-reseal flat packs, canisters, tubs and large count rolls in refill bags. One packaging format proprietary to Top Brass is its Flex Pack Mount technology that enables peel and reseal flat packs to be mounted vertically or horizontally onto virtually any surface. This Flex Pack Mount package benefits the user by having wipes at a desired location all the time in a smaller profile package than canisters. Disinfecting wipes in hospital rooms, food contact surface sanitizing wipes in meat processing plants, cafeteria kitchens or restaurants, laundry rooms, in the nursery, and household cleaning wipes under the sink or in the pantry are some examples of where the Flex Pack Mount can set a brand apart. The strong adhesive strips on the back of the pack attach firmly to the targeted surface, allowing for one-handed access from the pack.

The 23,000 people who went to Pack Expo in Las Vegas last year were “hungry for solutions,” according to Healthcare Packaging magazine. From RFID labeling for improved product traceability, to robotics and automation to increase efficiency, packaging innovation is a key wipes product element.