The applicator assembly delivers a cosmetic, health, or hygiene chemical composition in an active state to the user for a disposable single use. The applicator assembly includes a wrapper, and an insert. The insert holds the chemical composition, and the insert is made of a foam composition compatible with the chemical composition. The system and method for manufacturing the assembly is a web conversion process for the chemical composition and foam composition of the assembly. The insert body of the assembly is made of a foam composition compatible with the cosmetic or other hygiene or medical treatment of the chemical composition and the manufacturing process. The foam composition includes a reaction product of water, clay, polyacrylate, silane, methanol, ethylenediamine, and polyurethane prepolymer.