If you're a fan of our Facebook page you've probably seen the recent posts about some delamination issues with Orange You Glad and Winging It. In this post we take a few moments to explain what normal PUL looks like after being washed, and what delamination looks like:
We get a lot of questions about the lamination process and why delamination happens. First off, it's important to note that this is a material that we purchase in the raw form, on rolls and uncut. We are not laminators but we have been working with the same companies for quite a few years now, and we've developed trusted relationships with them. The raw goods we use are all produced in the US and delivered to our Montreal offices for cutting and assembly.
Lamination is a pretty straightforward concept. In the case of the fabric used in AppleCheeks™ diapers, a layer of 1mil polyurethane film is fused to a polyester interlock knit fabric using a heat activated glue. There is another type of bonding process that uses chemical solvents to bond the fabrics, and while this may be slightly less prone to delamination, it is a dirty and environmentally polluting process, which we do not support.
After you wash your diaper it probably doesn't occur to you to flip it inside out and look at the inside of the PUL (waterproof) portion, but if you take a few moments and do so now, you'll notice that there is a bit of a texture in the laminate. As per the above photo, if it looks like the photo on the left, it is normal. Any degree of variance in this texture is NORMAL, assuming there are no big bubbles or sections pulling up, and the wrinkling is quite even. The photo on the right is an example of true delamination, where the laminate is pulling up as a sheet.
In over five years of AppleCheeks™ we have had VERY few issues with delamination. However, recently there has been an issue with Orange You Glad where one batch seems to have partially not bonded very well, and this becomes apparent after a few washes. As well, some Winging Its have arrived at their destinations already delaminated, which is quite exceptional as we did not have a single problem with our previous prints from the same supplier. These are issues that we are aware of, and which are covered by our warranty. We are in constant communication with our suppliers to make sure that they are responding appropriately and correcting any issues that arise. Should you notice true delamination of either of these diapers, please send a photo and email to firstname.lastname@example.org so we see about getting you a replacement asap.
The textile industry has always been a tricky one, especially when it comes to performance fabrics such as those used in washable diapers. The PUL used in our diapers is expected to stay intact for over 300 washes, and we are so pleased to report that, with very few exceptions, this has been the case!