Billions of personal hygiene products – pads, nappies, wipes and liners – are used and discarded, many made from materials that take centuries to break down. As global demand rises for sustainable personal hygiene products, engineering has a critical role to play in rethinking how these items are designed, manufactured and disposed of. But first, we need to identify the barriers standing in the way.
Types of sustainable personal hygiene products on the market today
The personal hygiene sector is already experimenting with sustainability. Some options are widely available, others still niche. Broadly, we can divide the market into four main innovation pathways:
| 1. Disposable biodegradable products These use organic and compostable materials like cotton, plant-based films, and biopolymers. Pros: Familiar technologies to other sustainable products, reduced petroleum use Cons: Still single use; limited biodegradability without existing industrial composting infrastructure | 2. Reusable products Menstrual cups, absorbent underwear, some incontinence pessaries and washable nappies offer long-term alternatives to throwaway items. Pros: Low waste, cost-effective over time, aligns with growing interest in eco-friendly period products Cons: Requires ubiquitous access to suitable cleaning facilities, user behaviour change, and compromise on convenience |
| 3. Flushable and dissolvable items Wipes and liners designed to disintegrate after use, often made with special cellulose fibres or water-soluble polymers. Pros: Convenience and minimal disposal burden, especially for on-the-go use like sustainable baby care Cons: May still block plumbing or degrade too slowly in practice; may still be polluting the environment with microplastics | 4. More sustainable packaging Efforts to replace multilayer plastic wrappers with compostable films or recyclable materials. Pros: Reduced landfill waste Cons: Must maintain hygiene and shelf-life; few recyclable sanitary solutions |
Challenges in creating eco-friendly hygiene products
It is tempting to think that switching to sustainable hygiene products is as simple as swapping plastic for paper or throwing in a compost bin. In reality, the challenges are layered and interconnected.
Take materials, for instance. The conventional superabsorbent polymers used in nappies and sanitary pads are petroleum-derived for a reason: they work extremely well. They lock in moisture, prevent leaks, and keep users comfortable. Biodegradable or compostable alternatives – while promising – often struggle to match this performance. They can be stiff, less absorbent, or degrade too slowly unless processed in industrial composting facilities, which many communities lack.
While many consumers express strong environmental values, their actual purchase behaviour often reflects different priorities. Comfort, reliability and ease of use remain non-negotiable. Especially for products used in sensitive or time-pressured situations. If a biodegradable pad doesn’t stay in place or wipe tears too easily, even the most sustainably minded shopper is likely to return to familiar, higher-performing alternatives. The challenge goes beyond just creating greener products, it must do so without asking people to compromise on the basics they expect.
Packaging is another puzzle. It needs to protect against moisture, contamination, and damage, often leading to multilayer films that are nearly impossible to recycle. And what about adhesives? Many “green” innovations fall apart, literally, because bonding compostable materials without synthetic glue is still a major technical hurdle.
As more brands race to appear “green,” there’s a growing risk of surface-level sustainability, products labelled biodegradable or flushable that fail to deliver meaningful environmental impact. A pad wrapped in compostable plastic still ends up in landfill if there’s no composting facility. A “flushable” wipe that clogs pipes or releases microplastics only shifts the problem downstream. Looking sustainable on the surface isn’t sufficient. Products need to deliver real impact in everyday use and across a range of real-world settings. Green claims must be backed by credible performance and practical disposal pathways, or they risk doing more harm than good.
Real-world examples of sustainable hygiene brands
Despite these barriers, innovators are making progress. Brands like Natracare and Organyc offer biodegradable pads and tampons using organic cotton and bio-based films. Reusable options – from Mooncup to Thinx underwear – are growing in popularity, appealing to those willing to wash and care for their products. And wipes and pads labelled as “flushable” now feature advanced fibre technologies to break down faster, though real-world effectiveness remains mixed.
These are important steps, but they only serve part of the population. Reusables may not work for those without easy access to washing facilities. Compostables, meanwhile, rely on waste management infrastructure that often doesn’t exist. So how do we move from niche solutions to mainstream change?
Where engineering makes the difference
This is where engineering consultancies have the chance to lead. With their ability to integrate insights from materials science, manufacturing, digital systems, and user experience design, they’re uniquely positioned to solve the systemic challenges that stand in the way of progress.
Imagine absorbent cores made from next-generation biopolymers that rival petrochemical performance but break down cleanly. Picture adhesive systems made from sugar or starch-based binders that hold strong during use but disappear in compost. Or think of manufacturing lines reimagined to switch between materials quickly, cutting down on downtime and waste.
There’s also huge potential in what comes after the product is used. Engineering teams could help design in-home composting units specifically tailored to hygiene waste or even create smart disposal systems with RFID tags to guide users on how to throw items away correctly.
The commercial case is accelerating alongside the environmental one. Demand for sustainable personal care products is rising sharply, especially among younger consumers – over half of Gen Z and Millennials are willing to pay more for brands that lead on sustainability (42T’s Consumer Sustainability Report 2025). At the same time, major retailers are raising procurement standards, investors are increasingly scrutinising ESG credentials and 74% of advanced sustainability adopters now see sustainability as a source of long-term competitive advantage. As the report notes, brands that lead, not just comply, are better positioned to grow, earn loyalty, adapt to shifting market demands and stay ahead as the category continues to evolve. The engineering solutions that solve for sustainability can also unlock efficiencies, brand equity and long-term margin resilience.
Trade-offs in sustainable product design
Of course, no solution is perfect. Reusables, for example, require water and energy to clean. Biodegradable materials might have a larger land-use footprint or less durability. That’s why life cycle assessments (LCAs) are so important – and why engineers must be involved not just in building the solutions, but in measuring their true impact.
Systems thinking is essential. The hygiene product of the future isn’t just better for the planet; it has to work better for people, too. It must be comfortable, reliable, affordable, and easy to integrate into daily routines – whether you’re a teenager in London or a mother in rural Kenya. This is where circular hygiene product design becomes critical, closing the loop from raw materials through to disposal and reuse.
To break down the challenges, it helps to organise the solutions into actionable themes. Here’s where engineering can focus its energy:
| Barrier area | Engineering solution themes |
| Materials | Bio-based super absorbents, compostable adhesives, breathable plant-derived films |
| Design & function | Modular layer systems, ergonomic reusable formats, odour-neutral coatings |
| Manufacturing | Retrofittable lines for innovative materials, digital twins for process efficiency |
| Consumer use | Intuitive reusable kits (with a focus on high performance and convenience), consideration of different use cases (at home, at work, while travelling etc), packaging UX for sorting/disposal, culturally tailored designs |
| Disposal/End-of-life | In-home composters, closed loop return systems, RFID/smart labels for sorting |
This systems-led approach allows innovation across the whole product life cycle, from formulation and manufacturing to how the product is used, disposed of, and reintegrated into the environment.
What needs to happen next – An action plan for engineering sustainable hygiene products
A combination of materials with equal performance, holistic design thinking, evidence-backed environmental claims and interdisciplinary collaboration.
1. Prioritise performance parity
Don’t ask consumers to choose between sustainability and efficacy. Innovate toward biodegradable and reusable formats that match or exceed the function of existing products.
2. Solve for the whole system
Materials are just one part of the puzzle. Packaging, adhesives, manufacturing, user behaviour and disposal all need coordinated innovation to avoid shifting the problem downstream.
3. Design for reality, not just ideals
Build for real-world conditions, not ideal composting infrastructure or perfect user compliance. If a product can’t be used, cleaned or disposed of easily, it won’t scale.
4. Back claims with evidence
Green claims must be credible and verifiable. Life Cycle Assessments (LCA), biodegradability testing and transparent supply chains are more than just technical extras, they’re business essentials.
5. Collaborate across disciplines
Engineers, designers and other product development experts need to work together. The future of sustainable hygiene is interdisciplinary, not siloed.
The market is ready for transformation. What’s needed now isn’t just more innovation, but a smarter, system-led execution grounded in both engineering rigour and user empathy, with a focus on sustainable alternatives that scale.
From technical barrier to human-centred innovation
Innovation doesn’t just happen in labs or factories; it happens when diverse teams of engineers, designers and scientists work together with empathy and curiosity. Engineering firms like 42T can help manufacturers bridge the gap between sustainability goals and real-world constraints.
Whether it’s developing modular production platforms for flexible manufacturing, validating new bio-based materials, or creating robust prototypes for emerging brands, engineering consultancies bring not just ideas, but the tools to turn them into tangible, scalable solutions.
What’s next for sustainable personal care innovation?
Transitioning to sustainable personal hygiene is not a one-step fix. It’s a transformation that will take time, collaboration, and creativity. But with the right engineering mindset – curious, human-centred, and systems-savvy – we can start to chip away at the barriers and design a future where what keeps us clean doesn’t have to dirty the planet.
The challenges are real, but so is the opportunity. It’s time to engineer the change.
Want to learn more about how intentional and thoughtful engineering can accelerate your move toward sustainable hygiene solutions? Contact 42T’s innovation team today.