condom manufacturing process

How condom is made?

Collecting the raw material-compounding-storage-dipping-tumbling-testing-packaging

See the details about condom manufacturing process:

Collecting the raw materials

Cut the bark of the mature rubber tree to extract the raw material, the sap is collected in containers. The liquid natural latex is collected in large tanks, using ammonia to make it centrifuged and stabilised for transportation by sea. The quality of raw material is checked when arrives at our site.

Latex Material Compounding

Next, in order to form a paste, some chemical additives are mixed to. Blend this paste with the liquid latex in a process called compounding.

Rubber latex Storage

After compound the latex and chemicals, then storage it in drums, for approximately seven days. During this period, vulcanization strengthens the bonds of the rubber. During the storage time, any air which might have been trapped in the mixture during compounding will escape.

Latex Dipping

Then add the compound to the dipping or condom-forming machine. We dipping 3 time to build the condom to its required thickness. Between each dip, the latex is hot air dried.

The condoms automatically roll off the mandrels after the final dipping and drying. A machine will shapes and trims the ring of latex at the base of each condom.

Condom Tumbling

Next, put the condoms in a tumbling machine, where they are coated with silica powder to prevent the rubber from sticking to itself.

The Condom Testing

After several days’ curing, the condoms are sampled by batch and tested for leaks and strength. The first such test is the burst pressure and burst volume, in which the condom is filled with air until it bursts. Condoms are required to stretch beyond 1.5 cubic feet, about the size of a watermelon, before bursting. This test is considered most important because the elasticity of the condom keeps it from tearing during inter-course.

In the water-leakage test, the condom is filled with 10 ounces (300 ml) of water and inspected for pin holes.

Condoms are also 100% tested electronically. Mounting every condom on a charged stainless steel mandrel. The mandrel is passed over by a soft, conductive brush. If pin holes are exsit, a circuit will be established with the mandrel, and the machine will automatically reject the failed condoms.

Condom Packaging

Condoms are rolled by a machine after successfully passed these tests. It is easy to pack and use the rolled condom. Lubricant is added in the packing of aluminum foiling process by the packing machine.

Condom Quality Control

Condoms are classified as Class II Medical Devices. According to the Medical Device Amendments of 1976 of the FDA, the FDA require to inspect each condom manufacturing plant at least once every two years. All electrical and mechanical equipment must be impeccably maintained. Condom-dipping line machines are designed to operate continuously; if they remain idle, their mechanisms can get clogged and rust. During any downtime, partially cured compound cannot be left in the dip tank because it could contaminate future condom production.

The FDA reviews U.S. company records and spot checks batches for cracking, molding, drying, or sticking latex. The organization also tests every lot of imported condoms. Upon sampling, lots will not pass inspection if they reveal greater than 4% failure with respect to the above dimensions, 2.5% failure with respect to tensile strength and elongation, and 0.4% failure due to leakage.

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