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Diaper Manufacturing in A Developing Country
Diaper Manufacturing in A Developing Country
http://dx.doi.org/10.1108/20450621211299547
(2012),"McDonald's breakfast launch dilemma", Emerald Emerging Markets Case Studies, Vol. 2 Iss 8 pp. 1-13 http://
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of Business, University of diapers to the market through Novatis, its baby diaper division; Novatis competes in different
St Thomas, Houston, Texas, segments of the diaper industry in Morocco. As the company continues to grow, the
USA. management of the Novatis Group debates strategies to direct growth and the positioning of
its different diaper brands as well as the possibility of offering related products to the
Moroccan market.
DOI 10.1108/20450621211295569 VOL. 2 NO. 8 2012, pp. 1-11, Q Emerald Group Publishing Limited, ISSN 2045-0621 j EMERALD EMERGING MARKETS CASE STUDIES j PAGE 1
competition with global brands, such as Pampers and Huggies, Novatis Group has
experienced more demand for their products than what they can supply. The company has
plans to increase the production capacity, yet other factors must be considered with the
increase in production. The objective of this case is to examine the current market
opportunities in Morocco, the company’s brands, production, and distribution in order to
create a strategy for the future direction of the company.
Manufacturing a diaper
The history of diapers
The use of diapers dates back further than one would probably imagine. An examination
of history reveals that diapers made of milkweed leaves, animal skins, and swaddling
cloth were used during the ancient Egyptian, Aztec, and Roman periods (Richer, 2007a).
The year 1886, marks the beginning of the mass manufacturing of cloth diapers. 62 years
later, Johnson & Johnson brought disposable diapers to the USA in 1948. In the early
1960s, Procter and Gamble began manufacturing their disposable diaper brand,
Pampers, which became a national product by 1969. Procter and Gamble’s main
competitor, Kimberly Clark, followed the diaper trend and broke into the national market
by 1977 (Richer, 2007b).
According to Richer (2005), the most critical events, that shaped the present diaper industry
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include:
1987 – the use of frontal tape and hook and loop systems.
1999 – Procter and Gamble create rash guard diapers with added petrolatum and stearate.
Source: Parry and Jones (2001), Pampers: Disposable Diaper War (A).
Diaper usage has expanded globally with current market saturation in developed countries,
and planned expansion into developing countries. Countries with the highest market
penetration for baby diapers includes the USA, Mexico, Japan, Brazil, Germany, France,
UK, Philippines, South Korea, and China (Richer, 2005). Richer (2005) also notes that the
largest future growth areas for diaper market penetration will include developing nations
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PAGE 2 EMERALD EMERGING MARKETS CASE STUDIES VOL. 2 NO. 8 2012
such as Uganda, Yemen, Afghanistan, Congo, Mali, Nigeria, Madagascar, Burkina Faso,
Niger, Malawi, and Angola. Some countries will experience a reduction in the volume of
diapers needed due to lower birth rates within the next 25 years.
diapers in Morocco. It should be noted that the profit margin is very slim in this market and
companies rely heavily on volume.
Manufacturing diapers
One diaper can contain up to 13 different components: a polyethylene or polypropylene
back sheet, tissue paper, hot melts to glue the pad/elastics/other diaper parts, hydrophobic
non-woven materials for the leg cuffs, hydrophilic non-woven top sheet, elastic cuffs made
from polyurethane, polyester foam, synthetic rubber, or Spandex, polypropylene and Velcro
adhesive tapes to fasten the diaper, polypropylene film used for the frontal tapes, a pad for
absorption made from cellulose, the acquisition and distribution layer (ADL), which is
located between the top sheet and the absorbent core, sodium polyacrylate (SAP) in the
form of fine granules that allows for retention in the diaper, additional top sheet surface
materials such as lotions to differentiate the diaper products, and decorated films or wetness
indicators that also allow for differentiation. See Figure 1 for an illustration of a diaper and
components.
The manufacturing process is made efficient through the use of technologically advanced
machinery to combine the materials, cut the different layers into the appropriate shape and
size, sort and package the diapers. With this sophisticated machinery, up to 330 diapers can
Dalaa Novatis Price, middle to lower income, Multi-tiered and streamlined 56 1.5
Tier 2 (straight to retailer)
Câlinb Novatis Distribution channel Streamlined (straight to retailer)
Winny Novatis Quality, higher income, Tier 2 Streamlined (straight to retailer) 1 1.8
Pampers Procter & Gamble Tier 2 28 2
Huggies Kimberly Clark Tier 1 Streamlined (straight to retailer) 6 3.3
Others Tier 3 Multi-tiered 9 1.5 or less
Notes: aDistribution channels are further discussed in the section on the operations of Novatis; bNovatis stopped producing and
marketing Calin in 2010
Source: http://novatis-group.com/index.php?option¼ com_content&view¼article&id¼57&Itemid¼ 81&lang¼en
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VOL. 2 NO. 8 2012 EMERALD EMERGING MARKETS CASE STUDIES PAGE 3
Figure 1 Diaper components
POLYPROPYLENE
COMPOSITE FIBER
POLYETHYLENE
POLYCRYLATE
be produced per minute; the machinery can be sourced from vendors in the USA, Europe,
and Asian markets (Richer, 2007c).
Novatis Group
Novatis Group was created in February 2003 and is comprised of seven companies:
Novatis, Norsudex, Food & Goods Distribution (FGD), Brands Communication, Eureka
Trading, Nawroz, and Jeesr Industries. The company’s offices and two production sites of
the group, Novatis and Norsudex, are located at the heart of Berrechid’s industrial zone, in a
strategic area between the kingdom’s economic capital and the rest of the country. The
following statements are from the Novatis Group web site about their mission and values
(Novatis Group web site, 2012).
Novatis Group corporate mission is ‘‘Personal hygiene and health’’. The group develops a
corporate culture with which every employee can identify. This culture relies on three
fundamental values: quality, proximity and citizenship:
Highest quality guarantee. The quality of our products is guaranteed by our choice of raw
materials, high-performance production equipment as well as the high-technical skills of our
managers.
Close proximity to the consumers. Thanks to a distribution network that covers the whole of
Morocco, Novatis remains as close as possible to the consumers’ expectations.
Taking part in the kingdom’s development. By stimulating employment and being socially
committed, Novatis contributes to our country’s development and dynamism. Novatis is also
a socially responsible player who is committed to responsible initiatives. By supporting
orphan charities, the group contributes to better living conditions for these children.
Novatis
Novatis is the diaper division of the group, and markets two brand of baby diapers: Dalaa
and Winny. Novatis serves the growing urban markets and has opportunities to service the
rural areas where there is a growing awareness of diaper use, although there are limited
disposal options. Market positioning information for these two brands is presented in Table I.
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PAGE 4 EMERALD EMERGING MARKETS CASE STUDIES VOL. 2 NO. 8 2012
Besides baby diapers, Novatis’ product line consists of adult diapers, baby wipes, and
tissues; these products constitute only a minor share of the revenue for Novatis. Novatis
markets adult diapers under the brand names Prima, Nova, and Harmonia. There are no
market share data available for this segment; however, company reports indicate that Nova
is clearly the market leader in this category through volume share.
Competition and marketing strategies. Dalaa, meaning ‘‘to pamper,’’ is Novatis largest
selling baby diaper brand and is broadly distributed across all market segments while Winny
acts as the premier brand and is distributed only to the large retail outlets targeting higher
income groups. In 2010, Novatis discontinued the production of a baby diaper that was
marketed under the brand name ‘‘Calin’’. This decision led from an ongoing examination of
the market segmentation approaches of Novatis. In the initial years, segmentation decisions
were more distribution channel-oriented than customer-focused; the company has shifted to
a more careful consideration of segmentation and market positioning for its products.
Dalaa and Winny face fierce import competitors including Procter and Gamble’s Pampers
and Kimberly Clark’s Huggies. The Moroccan Government wants to encourage the national
industry and has increased tariffs on bulk imported diapers, resulting in a decrease of
imported diapers by 5 percent.
Novatis Group combats the competition by using their limited budget to create and launch
advertising campaigns during the holy month of Ramadan. See Figure 2 containing the web
links for the different commercials that have been created.
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Distribution channels. Of the two baby diaper brands produced by Novatis, Dalaa is
considered a better value proposition; the brand is targeted towards the middle to lower
income consumers. Novatis uses two distribution channels for the diapers: the multi-tiered
distribution channel and the streamlined (straight to retailer) channel. See Figure 3 for an
illustration of the two distribution channels. The traditional multi-tiered channel places the
product in small- to mid-sized shops and retail outlets, where the traditional custom of
negotiation takes place between the seller and buyer and personal relationships are highly
valued. In order to distribute through the multi-tiered channels, the diapers must travel from
Novatis Group on Dalaa branded trucks to wholesalers; the diapers move down the chain
from distributors to semi-wholesalers to retailers. The Dalaa brand diapers are distributed to
the small and mid-sized outlets through this channel. Small stores and retail outlets tend to
sell diapers individually, since many mothers can only afford to purchase one to two diapers
per day. The downside to selling diapers individually is that it creates a perception of low
quality amongst the middle and upper middle class consumers (Novatis Group, 2011).
Overall, Novatis Group has maintained very good relationships with the wholesalers that they
serve, with the President maintaining a personal relationship with each one.
As a result of the improving economic conditions and rising standards for quality of life, large
retailers have recently started doing business in Morocco. These retailers include Marjane,
Acima (Auchan in France), and Carrefour. The diapers travel straight from the Novatis’
manufacturing facility to the large retail store locations in the Dalaa trucks. Both Winny
and Dalaa brands are distributed through this channel. While the product passes through
fewer intermediaries in this channel, all vendors struggle in this market for the limited
shelf space and settle for lower profit margins. Novatis distributes to 101 supermarkets out of
200 existing supermarkets, which can be viewed as the modern market in Morocco. With no
exclusive agreements, Novatis brands compete for shelf space at these stores with major
brands such as Pampers and Huggies. Overall, Novatis distributes 85 percent of the diapers
to the traditional small- to mid-sized retail outlets and 15 percent to the large retail outlets
(Novatis Group, 2011).
Manufacturing operations. Novatis Group has an advantage from their continuous presence
in Morocco and close relationships with the distributors, allowing the company to have a
deeper understanding of the market. Novatis Group has always had a physical presence in
the country, while Kimberly Clark does not officially exist in Morocco. Procter and Gamble
has a diaper manufacturing facility in Mohammedia, Morocco, about ten miles north of
Casablanca. However, the facility was closed from 2009 to 2011. In November 2011, the
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VOL. 2 NO. 8 2012 EMERALD EMERGING MARKETS CASE STUDIES PAGE 5
Figure 2 Advertising
http://www.youtube.com/watch?v=G57V3ESgkes
http://www.youtube.com/watch?v=ixeI_uQMZ-w
Source: Youtube.com
facility was re-opened after the company scrapped the lines and completely rebuilt (Novatis
Group, 2011). While the company may be perceived as a follower compared to Procter and
Gamble and Kimberly Clark in the diaper business, Novatis Group strives to achieve quality
control in manufacturing, and quickly adopts product and technological innovations. For
instance, Dalaa uses plastic backsheet on the diapers, allowing for a 2 percent reduction in
the per unit price compared to Pampers and Huggies who use a non-woven plastic
backsheet.
The manufacturing facilities are currently running full speed with their production lines,
using Italian made machinery. The company has 200 employees in both locations together.
A total of 2,000 diapers are produced per minute, with three shifts running each 24-hour
period. With a reputation for producing quality products, the company has captured a
considerable part of the baby diaper market share in Morocco, as shown in Table I. Novatis
sells to 450 wholesalers, 3,000 retailers, and has 100 key accounts. Overall, 60 million
diapers are produced and sold each month. Production currently meets market demand,
and there is no excess finished product for holding in inventory. A three month raw material
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PAGE 6 EMERALD EMERGING MARKETS CASE STUDIES VOL. 2 NO. 8 2012
Figure 3 Dalaa distribution channel
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supply is held in inventory, due to the long lead times for supplies sourced from countries
world-wide including the USA, Canada, France, Spain, Italy, Germany, Japan, and Saudi
Arabia. The raw materials are subject to price changes; however, with no local sources for
the materials and the bulkiness of the materials limiting amount of inventory that can be held,
Novatis is dependent on these global sources for timely supplies.
Norsudex
In October 2006, Novatis Group acquired Norsudex, a company that had been in the diaper
industry for 20 years. With some modifications, Novatis Group changed Norsudex to an
adult diaper production facility producing 120 diapers per minute. By 2012, Norsudex will
include an additional line for baby diapers, as well as a line for sanitary napkins.
Brands Communication
The new addition of Brands Communication serves to provide marketing and
communication services for all companies within Novatis Group. This company has
15 years of experience in the communication and advertising business.
Eureka Trading
Eureka Trading was the first company, founded in 1989 by the current President and CEO of
Novatis Group. The company started with the import of raw material plastics and chemical
products, and has now become a diversified trader, dealing with products ranging from
baby strollers to polyethylene.
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VOL. 2 NO. 8 2012 EMERALD EMERGING MARKETS CASE STUDIES PAGE 7
Jeesr Industries
Jeesr Industries was founded in June 2010 in order to meet the demand for hygienic
paper products; the company’s manufacturing facilities include a paper mill plant and a
converting plant. The capacity for the paper mill is 100 tons per day and for the converting
plant it is 30 tons per day. The goal for this company is to become the leader in tissue
paper products.
Economy
The Moroccan economy benefits from low labor costs as well as its close proximity to
Europe. The country has developed a diverse and market-oriented economy since 1980s.
King Mohammed VI has contributed to creating stability through lowering inflation,
improving the overall financial performance of the country, and advancing the development
of the service and industrial sectors since he became king in 1999 (CIA, 2012). The recently
constructed port (Tangier-Med) and the free trade zone near Tangier have had a favourable
economic effect on Morocco with an increase of jobs and increased foreign investment
(Kingdom of Morocco, 2010). This has encouraged foreign companies to invest in Morocco;
for example, Renault, which has had a sales presence in Morocco for the past 80 years,
recently built an industrial complex near the Tangier-Med Port. Renault manufactures cars
in Morocco, taking advantage of the lower wages and free trade agreements, and ships
the cars out to the European countries for sale (Renault, 2010). Morocco is the only
African country that has a bilateral Free Trade Agreement with the USA. In 2008, Morocco
entered into an Advanced Status Agreement with the European Union (CIA, 2012). Key
sectors of the economy include agriculture, tourism, phosphates, textiles, apparel, and
subcomponents.
Table II provides a quick snapshot of some of the key economic issues including
unemployment rate, poverty, and household income or consumption rate among the top
and the bottom ten percent in Morocco.
Demographics
Morocco is a predominantly Arab-Berber country with 99.1 percent of the population
Arab-Berber. Arabic, Berber, and French are spoken in Morocco, with the use of the French
language seen as prestigious and the preferred language for business, government,
and diplomatic communications. Of the total population, 58 percent is located in urban
areas, with an urbanization rate of 2.1 percent (see Table III for population data). The
average woman has two children, and in 2011, there were approximately 1.8 million babies’
ages zero to three (CIA, 2012). Families traditionally had four to five children, but the current
trend has moved towards having two to three children, with most women having children
during their mid to late 20s and delivered mostly in hospitals. In terms of diaper usage, the
urban residents use approximately two to three diapers per day, while rural residents use
one to two diapers per week.
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PAGE 8 EMERALD EMERGING MARKETS CASE STUDIES VOL. 2 NO. 8 2012
Table II Morocco economic data
GDP purchasing power parity (USD) 164.7 billion 157.9 billion 152.3 billion 139.9 billion
GDP – real growth rate (%) 4.3 3.7 4.9 5.6
GDP – per capita (PPP) in USD $5,100 $5,000 $4,800 $4,500
Unemployment rate 8.90% 9.10%
Inflation rate (consumer prices) 1.4% 1%
GDP – composition by sector (2011 est.)
Agriculture 16.60%
Industry 32.20%
Services 51.20%
Population below poverty line 15%
Household income or consumption by percentage share
Lowest 10% 2.7%
Highest 10% 33.2%
Morocco exports and imports
Exports $20.99 billion $17.58 billion $14.05 billion
Imports $40.39 billion $32.65 billion $30.41 billion
Industrial production growth rate (2010 est.) 4.4%
Source: www.cia.gov/library/publications/the-world-factbook/geos/mo.html
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Source: www.cia.gov/library/publications/the-world-factbook/geos/mo.html
Many opportunities have opened up to Moroccan women in recent years. This progress has
been bolstered by changes in the Family Code and the Code of Nationality (Ministry of
Justice, 2004 and 2007) to promote equality between men and women; this has also resulted
in the adoption of a new family law that includes a number of measures to advance women’s
rights. The government has also made women’s health and safe motherhood a priority and
has financed several programs to reduce maternal mortality, increase accessibility of family
planning services, upgrading of maternal health care, and provide guaranteed access to
obstetrical care (Scommegna, 2012; Semlali, 2010).
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VOL. 2 NO. 8 2012 EMERALD EMERGING MARKETS CASE STUDIES PAGE 9
Through the combined efforts of the Moroccan Government and international organizations,
programs that support the entry of women into the workforce and develop the careers of
business women have been implemented. These initiatives include programs to develop
projects led by women entrepreneurs and the allocation of funding to support
income-generating projects for rural women. These policies for economic integration of
Moroccan women are intended to fight poverty and enhance the development of women’s
potential. New legal regulations have also provided the woman the right to equal access to
commercial activity (Women Political Participation Organization, 2009).
Media
Two local television networks and a foreign broadcast available by satellite dish ensure access
to television programming for a majority of the population. The two local networks include
radio-television Marocaine, a privately owned company, and another network which is partially
owned by the state. Residents in rural areas also have access to television network
programming. In 2011, Novatis Group spent $2.0 million in television advertising including
Ramadan, according to Novatis Group private communication, allowing for brand equity
building in the rural areas and among those who are illiterate. Table IV shows communication
data in 2009. There are over 13 million internet users in 2009. It is expected that the number of
internet users will increase as literacy rates rise (See Table V for literacy and education data).
Novatis has reached the maximum production capacity with the baby diaper line and the
company is selling every produced item. An additional production line is in the plans; each
machine costs anywhere between $4 and $7 million per line and the cost of upgrades surpass
the cost of the actual line. It can take nine to ten months to install the line. While the plans to add
an additional line are in place, the company is also concerned with their marketing efforts in
Keywords:
order to be certain that increased production will be met with enough demand.
Developing countries,
Manufacturing, Now, Novatis needs to plan for the increased production of baby diapers in terms of capacity
Diaper, management and devise a marketing strategy to ensure that the demand will continue to rise.
Distribution, The development of new brands and the positioning of all brands must also be addressed. The
Advertising, company could expand further into rural markets; another option is expansion into neighbouring
Bottom of the pyramid, areas in that region of the world. These decisions have to be balanced with the strengths and
Manufacturing systems, growth opportunities for the group as a whole. The leadership of the Novatis Group is facing
Morocco challenging questions that must be addressed to continue on this growth trajectory.
Source: www.cia.gov/library/publications/the-world-factbook/geos/mo.html
Source: www.cia.gov/library/publications/the-world-factbook/geos/mo.html
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PAGE 10 EMERALD EMERGING MARKETS CASE STUDIES VOL. 2 NO. 8 2012
References
CIA (2012), The World Factbook, Central Intelligence Agency, Washington, DC.
Kingdom of Morocco (2010), Tanger Mediterranean Special Agency, available at: www.tmsa.ma/
?lang¼ en&id¼ 27 (accessed 23 March 2012).
Novatis Group (2011), Novatis Group Presentation, Novatis Group, Berrechid.
Parry, M.E. and Jones, M. (2001), Pampers: The Disposable Diaper War (A), Darden Business
Publishing, Charlottesville, VA.
Renault (2010), Renault Au Maroc, available at: www.renault.ma/decouvrez-renault/renault-maroc/
industrie/ (accessed 7 March 2012).
Richer, C. (2005), The Diaper Industry in the Next 25 Years, Diaper Consulting Services, Minneapolis, MN.
Richer, C. (2007a), Diaper Evolution Time Line, Diaper Consulting Services, Minneapolis, MN.
Richer, C. (2007b), Disposable Diaper History, Diaper Consulting Services, Minneapolis, MN.
Richer, C. (2007c), The Disposable Diaper Industry Source, available at: www.disposablediaper.net/
content.asp?6 (accessed 13 October 2011).
Scommegna, P. (2012), In Morocco, More Modern Contraceptive Use Plays Key Rule in Decreasing
Maternal Deaths, available at: www.prb.org/Articles/2012/morocco-maternal-deaths.aspx?p¼1
(accessed 23 October 2012).
Semlali, H. (2010), The Morocco Country Case Study: Health Care Environments in Morocco, Positive
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Further reading
Novatis Group (2012), available at: http://novatis-group.com/ (accessed 17 October 2012).
Participation des Femmes à la vie économique (2009), Participation des femmes à la vie économique et
insertion dans le processus de decision, available at: www.womenpoliticalparticipation.org/upload/
publication/publication17.pdf (accessed 23 October 2012).
Corresponding authors
Shahram Taj can be contacted at: Tajs@stthom.edu and Beena George can be contacted at:
GeorgeB@stthom.edu
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VOL. 2 NO. 8 2012 EMERALD EMERGING MARKETS CASE STUDIES PAGE 11