How Aquapak is transforming disposable hygiene products into sustainable solutions with new dissolvable, non-toxic polymer

Aquapak has launched a water-soluble, marine-safe, and non-toxic polymer designed to "revolutionise" disposable hygiene products like wet wipes and sanitary pads by making them dissolvable, fully flushable, and free from microplastics and fatberg-causing residues.

This breakthrough is made possible by a new dissolvable nonwoven material that uses Hydropol instead of traditional plastics, significantly reducing plastic pollution and preventing waste from entering the environment.

It comes amid growing concern over the environmental impact of so-called "flushable" hygiene products that fail to break down properly.

In fact, around 11 billion wet wipes are used each year in the UK alone, and a comprehensive investigation into sewer blockages revealed that wet wipes account for 93% of the materials causing these clogs.

Meanwhile, traditional sanitary pads, made of up to 90% plastic, can take approximately 500 years to degrade, releasing microplastics that contribute to an estimated 300,000 tonnes of waste annually in Western Europe.

By replacing plastic with Hydropol in the production of soft, drapable, and durable nonwoven materials for products like wet wipes, Aquapak notes that manufacturers can maintain functionality without harming the planet.

Mark Lapping, CEO at Aquapak, said: "We have worked closely with leading nonwoven material manufacturers to develop an environmentally friendly alternative which does not rely on conventional plastic for its functionality and is set to revolutionise the nonwovens sector.

"The new material is being used to develop next generation hygiene products such as wet wipes that will not release microplastics or block sewers. This solves one of the biggest consumer pollution problems facing us today."

So, how does it work?

Unlike plastic, Hydropol is fully dissolvable and flushable due to its water solubility. When flushed, the fibres absorb water, swell, and dissolve without breaking into microplastics. They continue to biodegrade and disappear without a trace into domestic wastewater systems.

Additionally, when flushed, Hydropol does not attract toxins like fats, oils, or greases, meaning its presence in sewer and wastewater systems won't contribute to fatberg formation or blockages. In fact, studies have shown that it biodegrades effectively in effluent treatment plants.

Using this, Aquapak has developed a range of specialist polymers to support the production of a "new generation of sustainable packaging material that delivers both performance and environmental responsibility at scale".

It has partnered with Innovatec Microfibre Technology to facilitate the conversion of Hydropol pellets into meltblown nonwoven fibres in a single-step process, as well as dissolvable wipe developer KINDCLOTH - which holds a patent for dissolvable wet wipe technology - for the production of effective, sustainable wet wipe products.

The wipes are made from the nonwoven material, with KINDCLOTH-approved lotions applied to create the final product. When flushed, the wipes dissolve within seconds.

But it's not just wet wipes...

The same nonwoven technology is also suitable for a range of other applications, including insect repellent and eye makeup remover wipes, industrial wipes and face masks.

Aquapak is also collaborating with Planera to develop the Fluus flushable sanitary pad. Unlike the dissolvable wet wipe, this product uses a Hydropol coating or film applied to nonwoven materials, replacing conventional plastic. The coating dissolves when the pad is disposed of.

Since its launch, Hydropol has received recognition with two US industry awards, highlighting its innovation in the nonwoven sector.

"It is fantastic to achieve industry recognition for Hydropol’s ability to transform the nonwoven sector thanks to our partnerships with Innovatec and KINDCLOTH," added Lapping.

"By using Hydropol instead of conventional plastics, millions of tonnes of plastic pollution and the associated harmful microplastics will be prevented from entering the environment.  Furthermore, nonwovens that use Hydropol will no longer contribute to the formation of fatbergs and the damage they cause."