FORM 2
THE PATENT ACT 1970
(39 OF 1970)
&
The" Patent Rules, 2003
SPECIFICATION
(See section 10 and rule 13)
TITLE OF THE INVENTION:
Innovative large scale production of cost effective sanitary pad for hygiene of rural women.
2. APPLICANT(S)
Name Nationality Address
1. Miss Prutha P. Joshi Indian A-2/2, Siddhant, Jayshree co—op soc., Kathe
lane, Dwarka, Nashik- 422011
2, Sanj eevan Apartment,Ramanand Co-op
Hsg Soc.,Tidke Colony,Nasik-422002
A -601,Prince Castle, Near St. Joseph’s
Church, Vikhroli (VW, Mumbai 400079
2. Miss Aaloka S. Kotwal Indian
3. Mr. Prathamesh H. Borkar Indian
3. PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the nature of invention and the manner in which
it is to be performed.
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Field of Invention
Menstrual hygiene management is a very essential part of rural India. About 52% of the female
populationof India is of reproductive age and is menstruating every month. Majority of them are
a part of the rural India and do not have access to clean and hygienic sanitary products, as they
carmot afford these products and hence end up using rags, used cloths, cow dung or mud and
other such unhygienic options which have a very adverse effect on the health of women and
hence the need develops of providing the rural women with this basic need. Besides the health
problems due to unhygienic sanitary conditions, the lack or unaffordability of facilities and
appropriate sanitary products may push menstruating girls temporarily or sometimes
permanently out of school, having a negative impact on their right to education. And hence the
need develops to produce sanitary products at a low cost so that they are affordable and
awareness about them is created so that their proper utilization takes place.
Background of Invention
Sanitary napkin is a hygiene absorbent product used by women during menstrual periods. It is a
product of technical textile. We propose here that our product is cost effective as well as
innovative and therefore there are a lot of differences in the composition of the product as
compared to the conventional one. The main components of our product consist of:
-1. Core layer which was earlier made up of cotton which becomes bulky after the secretions are
absorbed and also has less absorbency than jute linters which we propose to use in our core layer
, also jute linters are treated as waste and therefore are cheap and easily available.
2. The back sheet film has to be firm and impenetrable and hence is usually made up of
polypropylene which but we have substituted it with polyethylene which has similar properties
but it is cheap than polypropylene.
3. Also to give anti bacterial finish we give coating with aloevera juice which is naturally easily
available, cheap as well as naturally antibacterial which helps the sanitary napkin hygienic. In
conventional products anti bacterial chemical finishes are given which develops rashes, allergies
etc and hence we propose to use aloevera which has a soothing effect on the skin.
Raw materials required for absorbent sanitary napkins are:
0 Top sheet in form of gauge layer
0 Absorbent core layer
0 Backsheet film for preventing leakage
0 Release paper
We have studied the properties of conventionally used brand “Stayfree” which is popular in
urban areas for comfort and hygiene. Thus we have used this as basis for comparision with our
designed product. Following is the table which describes the costs of components mostly
preferred in sanitary pads:
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Table 1: Current Costing of Individual Components
Conventional material Cost per Cost per
used Pad packet
(in rupees) (of 8 pads)
(in rupees)
Top layer (non-woven or an apertured Acetate rayon 3 24
film)
Absorbent core (cellulosic pulp with Cotton 3.50 28
SAP)
Back sheet (film) Polypropylene 0.5 4
Total cost 7 56
Summary of the Invention
We summarize that using conventional manufacturing but with innovative raw materials we have
come up with a relatively cheap sanitary pad which will be affordable to the rural women. We
have not only made it cost effective but also have tried to increase its efficiency by applying a
novel anti microbial finish like aloevera which is locally available and has been used since ages
for skincare products and using jute linters which have better properties than the conventionally
used cotton.
Also to ensure that awareness is created among rural women in case of using sanitary products
and that these products are available to them easily we propose for a wending machine to be kept
in local municipal hospitals wherein when you put about a 2 rupee coin you get a sanitary napkin
out.
Objective of the Invention
Main objective is to manufacture the low cost sanitary pad for rural areas. Thus as we have
elaborated later that our cost of 8 pads is 95:15 which is very cheap considering the different
layers of safety added. Also the antibacterial finish applied overcomes the hygiene problem of
rural women. These all benefits are not guaranteed in conventional cheap pad. This is an attempt
to resolve the major problem of women population.
Comparative study of Innovative Design of product (Refer, E1l3r.l)-RE;-J1): WWW
1. Core layer
We proposed the idea to use jute linters as they are cheap and easily available. Also jute is
one of the most affordable natural fibers. Jute fibers are composed primarily of the plant
materials cellulose and lignin. It falls into the bast fiber category. Jute fibre is 100% bio-
degradable and recyclable and thus environmentally friendly, it also has high tensile strength,
low extensibility, and ensures better breathability of fabrics. It has a very good absorbency of
about 13% which is way better than cotton thereby making it ideal for use in hygienic pads.
Further it also has better dimensional stability and good microbial resistance. These are all
advantages of jute over cotton which is used in conventional pads.
2. Top layer
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Acetate rayon is preferable as top aperture layer as this fibre has many medical applications
such as surgical packs, sanitary pads etc. where hand, absorbency are important. Cellulose
acetate is soft, smooth, cool, comfortable and absorbent with 6.5% moisture regain. It has
low sticking point of l80°F and thus can be used as a binder fibre in manufacture of
nonwovens or aperture film. Also it has property of avoiding insulation of body heat.
. Super-absorbent polymer (SAP)
Sodium polyacrylate (a type of SAP) which is sprayed on core material by SAP applicator. It
is typically used in fine granular form and the dissolved gel is sprayed on the core material. It
helps improve capacity for better retention in a disposable pad, allowing the product to be
thinner with improved performance and less usage of pine fluff pulp. The molecular structure
of the polyacrylate has sodium carboxylate groups hanging off the main chain. When it
comes in contact with water, the sodium detaches itself, leaving only carboxyl ions. Being
negatively charged, these ions repel one another so that the polymer unwinds and absorbs
water, which is attracted by the sodium atoms. The polymer also has cross-links, which
effectively leads to a three-dimensional structure. It has high molecular weight of more than
a million; thus, instead of getting dissolved, it solidifies into a gel. The hydrogen in the water
(H-O-H) is trapped by the acrylate due to the atomic bonds associated with the polarity
forces between the atoms. The superabsorbent can be designed to absorb ‘higher amounts of
liquids (with less retention) or very high retentions (but lower capacity). In addition, a
surface cross linker can be added to the superabsorbent particle to help it move liquids while
it is saturated. This helps avoid formation of “gel blocks”, the phenomenon that describes the
impossibility of moving liquids once a SAP particle gets saturated.
4. Surface add—0rz lotion for antibacterial finishing
In order to maintain hygiene and avoid skin infection and rashes, we introduce the innovative
anti—bacterial finishing. As per the recent studies, aloevera is found helpful in the treatment of
minor skin infections such as cysts and minor wounds. Its inner—leaf gel inhibits the growth
of bacteria. The two of the biologically active compounds which are providing antimicrobial
properties are: anthraquinones (entire group of phenolic compounds) and salicylic acid.
There is usage of aloe-Vera juice and is padded through padding mangle which makes better
comfort properties like anti-rash effect, antimicrobial property as well as moisture
absorbency. In conventional pad there is no use of aloevera and there the synthetic finishes
are used which can harm skin and also the are hazard to environment.
5. Back sheetfilm
The back sheet primarily prevents the exudates absorbed and contained in the absorbent
structure from wetting articles that contact the absorbent product such as underpants, pants,
pyjamas and undergarments. The back sheet is preferably impervious to liquids (e.g. menses
and/or urine) and is preferably manufactured from a thin plastic film, although other flexible
liquid impervious materials can also be used. As used herein, the term "flexible" refers to
materials that are compliant and will readily conform to the general shape and contours of the
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human body. The proposed design uses the polyethylene terephthalate (PET) for the leakage
proofing and back support of pad.
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Description
A. Machinery and Production Unit
- Antibacterial '- Heat pressing
Raw ".“‘3"“al finishing of top of all layers and
unwm er layer sealing
ll £45:
_ polycutting _ Hot melt glue
Pulp grinder . applicator and
machme release paper
Fluff d-mm Sterlization
forming Scutcher unit
system
Fluff .. , .
processing SAP applicator stacker umt
unit for packaging
Process description:
Raw material used is needed to be unwind so as to get uniformity, thus jute linters pass through
the material unwinding machine. Then the pulp grinder converts the jute linters into fine soft
pulp and then this pulp goes to the fluff processing unit to form fluff which then is sprayed with
the SAP using SAP applicator. Now we have the core absorbent layer ready with cellulosic fluff
with SAP deposited on it. Further we take the fluff and put it together and compress them and
beat up into sheets with the help of scutcher. Now we take the top layer and place it on the core
material of cellulose and then the polyester sheet is attached from backside. Thus all the layer are
put together and heat pressed. Then the cutting of pad as per the assumed size (23cm xl lcm)
mould is obtained through polycutting machine. The formed pad is lastly padded with the
aloevera juice in water (80:20) with the use of padding mangle for one dip-one nip. In this way
the antibacterial finish is applied on the pad. Then we apply gum adhesive on the backside of pad
using hot melt glue applicator. After that we attach the release paper on it. At the final stage we
stack the pads using stacker and then pack them in the form of packet of 8 pads.
Machines used are:
- Raw material un-winder
0 Pulp grinder
- Fluff drum forming system
0 Fluff processing
0 Super absorbent polymer applicator
o Padding mangle
a Hot melt glue applicator

- Compressing unit (scutcher)
- Poly-cutting system
- Sterilization system
0 Stacker
Raw material with the supplier is shortlisted in the table:
Table 2: Materials to be used in our product
1:: Material Specification Supplier
1 Jute Linters Purabi Trading (Bangladesh)
2 Acetate Rayon Fabric Daisy Trading Co-orporation (Mumbai)
3. Release Paper Double Sided Brown M. Ismail & Co (Mumbai)
Coloured 100 GSM (width-
20in)
4. Sodium Powder form Prime Laboratories (Hyderabad)
Polyacrylate
(SAP)
5. Aloe Vera Concentrated extract Be Sure Healthcare, (India)
Juice
6. Plastic bags Green Coloured Korji Damji,(Mumbai)
C. Cost effective
1. Financial analysis for large scale production unit for 8000 pads per day
We have considered the manufacturing unit for production of 8000 pads per day, so 1000 packets
each of 8 pads each. The assumption and calculations are explained as follows:
Assumptions:
0 Size of pad - 23x11 (Refer Appendix)
0 25 days per month
0 8 working hours of industry per day
0 Land & building cost is not considered in the project
0 Total land required 1200 sq m
0 Machinery expenses are considered as the investment for large scale manufacturing unit
Table 3: Plant specification
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Rated plant capacity No. of working No. of shifts
I days
8000 pieces/day ( 2400000 25 days/month = One shift: 8 hrs
pieces per armum) 300 days/armum

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Table 4: Cost per day considering 100% efficiency
Sr. M t . 1 Consumption R te 5:; day Per month
no a mm per pad a , (in rupees)
(in rupees)
1 Jute linters 8g 6.75/kg 432 10,800
2 Acetate rayon 253cm2 18.5/m 3744.5 93612.5
3 PET 253cm2 6.142/m2 124.5 31,088
4 Release paper lgm 184.26/tonne 1.45 36.25
Sodium
5 polyacrylate 0.6 gm 3 6,852/tonne 177 4425
(powder)
6 Aloevera juice 80lts 46/lt. 3680 92,000
7 Plastic bag 1 piece 0.025/piece 200 5000
Total ' 8359 208975
Hence, Total cost of single pad: Rs. 1.05/-
As the manufacturing is not fully automated thus we have to consider the wastage per item. This
makes the costing more and thus we get an idea is to what exactly will be the range of price of
one pack of 8 pads. Following is the table explaining the costing of individual components after
the losses is considered:
- Table 5: Cost per day considering production losses
Per day
Sr. no Material Consumpnon Wastage Rate c.OSt P.er month
per pad (in (in rupees)
rupees)
1 Jute linters 8 g" 1 kg 6.75/kg 439 10975
, T
2 Acetate rayon 253em2 64m 18.5/m 4930 123250
(8mx8m)
2
3 PET 253cm2 64”‘ 6.142/m2 140 34925
(8mx8m)
4 Release paper lgm 500gm 184.26/tonne 1.5 37.5
Sodium
5 polyacrylate 0.6gm 600gms 36,852/tonne 200 4975
(powder)
6 Aloevera juice 80lts 5 1t. 46/ 1t. 3910 97750
7 Plastic bag 1 piece 590 0.025/piece 212.5 5312.5
pieces
Total 9832 245800
Total cost of pad after considering production wastes: Rs 1.23/-
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Table 6: Initial Investment
Heads Cost (in INR crores)
Plant & Machinery: Total plant & machinery for pads (approx.) 6.00
Office equipment, project preparation, lab, etc. 0.025
Miscellaneous 0.01
Total 6.035
Table 7: Recurring Costs
Sr. Matierial Per Day(Rs) Per Month Per Annum
No. (Rs) (in Lacs)
1 Raw Matierial 9832 245800 24.3
2 Electricity(80units @ RSS 3200 80000 9.6
per unit)
3 Transportation cost(@Re1 1234 30850 3.7
per kg)
TOTAL 14266 356650 37.6
Cost per pad after considering electricity and transportation cost= Rs1.78/-
Therefore, cost per packet = 1.78 x 8 = Rs14.24/-
2. Profit analysis
Each packet has 8 pads in it and is produced for a maximum cost of Rs14.24/-
If we sell each packet for Rs20/- (Rs2.5/— per pad) which is very low as compared to the normal
cost of sanitary pads available.
Thus, the profit behind each packet is Rs5.76/-
For 1000 packets per day, the profit will be 5.76 x 1000= Rs5760/-Profit per month will be
5760 x 25= Rs 1, 44,000/-
And the profit per armum will be 1, 44,000 xl2= Rs 17, 28,000/-
Considering 10 workers and 1 operator working in an 8hr shift everyday:
Salary of workers = Rs 50,000/— per month
Salary of operator = Rs 18,000/- per month
Thus, Rs 68,000/- is to be deducted from monthly profit.
This will give a monthly income of Rs 78, 000/- for the factory. The armual income will be
78,000 x 12 = Rs 9, 36,000/-
The profit can further be increased by increasing the scale of production which is easily possible
with the given machineries with a few more workers. The cost of most of the raw materials was
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rounded off to the larger integer and thus the actual cost will be further reduced by a small
amount.
3. Detailed explanation of calculation
1. Jute Linters-
Rate — Rs 6.75/kg = Rs 0.00675/gm
Amt requiredper pad - 8gms
Cost of Jute required per pad = 8 x 0.00675 = Rs0.054/-
Thus cost of Jute per day = Rs 432/-
2. Acetate Rayon-
Rm—mmyfi=mommmfi
Amt required per pad - 253 cm?‘
Cost of Acetate Rayon required per pad = 253 x 0.00185 = Rs 0.468/-
Thus cost of Acetate Rayon per day = Rs 4930/-
3. PET-
Rm—mamm&=mom%mm#
Amt required per pad - 253 cm2
Cost of PET required per pad = 253 x 0.000614 = Rs 0.1554/-
Thus cost of PET per day = Rs 140/-
4. Release paper-
Rate — Rs 184.26/tonne = Rs 0.0001 84/ gm
Amt required per pad — lgm
Cost of Acetate Rayon required per pad = 1 x 0.000184 = Rs 0.0002/-
Thus cost of Acetate Rayon per day = Rs 1.45/-
5. Sodium Polyacrylate-
Rate — Rs 36.85/kg = Rs 0.036/gm
Amt required per pad — 0.6 gm
Cost of Sodium Polyacrylate required per pad = 0.6 x 0.036 = Rs 0.0216/-
Thus cost of Sodium Polyacrylate per day = Rs 177/-
6. Aloevera Juice Rate — Rs 46/lt
Amt required per day = 80lt
Thus cost of Aloevera Juice per day = 80 x 46 = Rs 3680/-
Cost of Aloevera Juice required per pad = 3680/8000 = Rs 0.46/-
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7. Plastic Bag
Rate — Rs 0.025/piece
Bags required per pad —- 1
Cost of plastic bag required per pad = 0.025 x 1 = Rs 0.025/-
Thus cost of Plastic bags per day = Rs 200/-
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Claims
We claim,fag-:
1. Core absorbent layer made up of jute linters.
2. Surface add—on of aloe-Vera juice for antibacterial finish.
3. Back-sheet consisting of polyethylene film.
4. Cost effective as compared to conventional product.
5. Large scale production set up.