Hello All,
Thank you for your replies they were very useful. It has taken some time to resolve the issue but I did get there, so in summary...
My son is a heavy wetter and the PUL had gone on all the nappies (less than a year old and followed Tots Bots instructions really carefully). Even Tots Bots don't know why but they have replaced them all. I've bought some bamboo boosters too so with a mainly bamboo nappy and extra bamboo no leaks as long as a change by the 3 hour mark!
I did go and speak to the wonderful people at The Cotton Nappy Company in Leamington Spa who were also extremely helpful.
Thank you again for your replies.
Cloth Nappy Tree gives you a free, unbiased and privacy rich place to discuss and recycle your cloth nappies. Save time, money and our planet by inspiring and helping others.