Zorb Weight Classes: LITE vs Standard vs Heavy Duty

The Decision You're Making

Once you've chosen your Zorb family—Original, 3D, 4D, or Microfiber—the next decision is how much absorbency you need. Zorb weight classes control the trade-off between absorption capacity and fabric bulk: heavier weights hold more liquid but create thicker, slower-drying products, while lighter weights offer a thinner profile with faster dry times at the cost of per-layer capacity. If you haven't chosen a family yet, start with Zorb Families Compared: Original vs 3D vs 4D vs Microfiber.

Plan for thickness in multi-layer builds. Layering Zorb for increased absorbency creates significant bulk. Each additional layer adds absorption capacity with diminishing returns — the first layer contributes the most proportional absorption, with each subsequent layer contributing less relative to the added thickness. In wearable products (diapers, pads, underwear), balance absorption needs against comfort and bulk constraints. The Zorb 4D all-in-one construction addresses this by integrating absorbent and waterproof layers into a single thinner fabric.

Understanding Your Options

LITE

LITE is the thinnest weight within a Zorb family, designed for products where a slim profile matters more than maximum single-layer capacity. LITE fabrics are easier to sew through multiple layers, dry faster, and create less bulk in finished products—best suited for panty liners, light incontinence pads, or as supplemental layers stacked for custom capacity. Available in Zorb 3D Stay Dry, Organic Cotton, and Bamboo surface styles.

Standard

Standard is the baseline weight for most Zorb families and the most versatile choice. Standard weights balance absorption capacity with manageable thickness—suitable for cloth diapers, menstrual pads, nursing pads, burp cloths, and most adult incontinence products. For the majority of projects, Standard is the right starting point unless you have a specific reason to go lighter or heavier. Available across all Zorb families and surface styles.

Heavy Duty

Heavy Duty is the maximum-capacity weight within a Zorb family, designed for high-volume liquid containment where absorption performance outweighs concerns about bulk or drying time. Heavy Duty fabrics deliver the highest per-layer absorption—often allowing single-layer construction where lighter weights would require stacking. Best for overnight diapers, heavy incontinence products, and high-volume pet training pads. Available in Zorb 3D Stay Dry, Bamboo, and Microfiber families.

Head-to-Head Comparison

Weight classes maintain the same absorption speed (under 2 seconds) and weight-to-capacity ratio (up to 10x for Original and 3D; up to 8x for 4D and Microfiber) regardless of weight tier. The difference is total capacity per layer: a heavier fabric has more absorbent fiber per square inch, so each layer holds more liquid. This means choosing between fewer thick layers or more thin layers to reach your target capacity.

Why GSM varies by family: A "Standard" weight varies significantly across Zorb families because different fiber types and constructions have different densities. Zorb Original Standard is 235 GSM while Zorb 3D Organic Cotton Dimple Standard is 550 GSM—both are the standard weight for their respective family. Always compare weight classes within the same family, not across families. For family-level comparisons, see Zorb Families Compared.

The Layering Strategy: Thin Stacks vs. Thick Singles

One of the most important decisions in absorbent product design is whether to use a single thick layer or multiple thinner layers to reach your target capacity. Both approaches use the same total amount of absorbent material, but they behave differently in finished products.

Multiple thinner layers (LITE or Standard stacked):

• Dry faster because air circulates between layers during laundering
• Allow targeted replacement of only the worn layer
• Create a more flexible finished product that conforms better to body contours
• Best for: Cloth diapers, menstrual pads, frequently laundered items where end user handles washing

Fewer thick layers (Heavy Duty, single or double):

• Simplify construction by reducing the number of pieces to cut and sew
• Create a more uniform absorption profile without gaps between layers
• Reduce total sewing time and material handling in production
• Best for: Commercial washing environments, production-scale manufacturing, pet training pads, medical underpads

Which Weight Class Is Right for Your Project?

Panty liners, light incontinence pads, or breast pads where a thin, discreet profile is essential → LITE. Single layer provides sufficient capacity for light flow applications while keeping the finished product as thin as possible.

Daytime cloth diapers, standard menstrual pads, nursing pads, or burp cloths where you need reliable absorption without excessive bulk → Standard. Use 2-3 layers for daytime cloth diapers; single or double layer for menstrual and nursing applications.

Overnight cloth diapers, heavy incontinence products, or pet training pads where maximum capacity in a single layer prevents leaks during extended use → Heavy Duty. Single-layer construction is often sufficient, simplifying both manufacturing and care.

Custom capacity targets where standard weight classes don't match your exact needs → Stack LITE or Standard layers to dial in the precise absorption level. This approach gives you more control over the finished product's thickness, flexibility, and drying characteristics than any single weight class can provide.

Weight Classes by Family

Not every Zorb family offers every weight class. Use this map to find the available options within your chosen family, then visit the individual product page for detailed specifications.