Receiving of pre-vulcanized latex for production used.
The production start with the preparation of latex mix by mixing the latex and water according to the strict specifications before it is transferred into the dipping tanks.
The dipping line consists of a continuous chain with 2 rows of glass formers. The process starts with the cleaning of condoms formers. The formers are first cleansed by brushing and rinsing before dipping. The formers are then dipped into the first dipping tank and withdraw slowly so that a thin, smooth and uniform film is achieved. The first dipped layer on the formers is dried in Oven 1 before it is dipped in 2nd. dipping tank. After the 2nd dipping, the condoms are dried again in oven II to ensure specifically the beading area is dried before being beaded. The condoms then move to the beading station where the open end of the condom is beaded. The condoms are then dried and fully vulcanized in a third oven. The condoms are then leached in the leaching tank containing diluted ammonia solution. A leaching process is to remove excess protein and chemicals from the condoms. The leached condoms are stripped by water before being collected in the collection baskets.
Powdering solution is prepared in the powdering tank. Condoms are transferred from the baskets to the powdering tank. Condoms in the powdering tank are stirred and drained in the draining tank.
Condoms are then put into the spinning machine to remove excess water. Condoms are then ready for the tumbling process.
Next, they are placed into a tumbler machine and tumble dry for approximately 45+/- 5 minutes at 70 +/- 20 degrees Celsius.
The dried but still hot condoms is cooled off in the tumbler machine for 15 +-5 minutes. When the condoms are cooled, they are removed and placed into poly bags for subsequent process.
The batch number, manufacturing date, time and tank number of latex are recorded for future reference.
The QA Department shall conduct dimension measurement test. This group of tests measures condoms width, thickness and length per the required condoms standard.
QA Department carry out water leak test.
The air burst test inflates the entire condom like a balloon, stretching all of the latex until it bursts. The purpose is to measure the condom strength. The test measures the maximum amount of air the condom can hold (burst volume, liters) before breaking as well as the air pressure level (kPa) inside the condoms when it breaks.
A limited number of condoms are also required to be tested after oven conditioning at 70 C degree. This test is intended to be check for major formulation or vulcanization errors.
All condoms are individually tested and rolled through electronic pinhole testing machines, which separate accepted and rejected condoms into different containers.
The condoms are lubricated by an automatic lubricant dispenser and then sealed with the aluminum foil by the sealing machines. The condoms can be foiled in rectangular shape or square shape. Normally, the inkjet information of lot no. and expiry date are conducted on online during foiling.It is limited to max 3 lines. For extra information, off line system is involved.
The foiled condoms are packed according to customers requirements and stored in a cool dry place awaiting final shipment. (e.g 3’s pack, wallet pack, bulk pack and etc.)
All condoms are finally packed in shipping carton boxes, strapped and properly labeled.
Unit container or consumer packages are designed and made of such material that the condoms are fully protected during transportation and storage and do not inflict any mechanical/physical damages when the containers and packages are opened.
Packed condoms are stored in cool and dry finished goods store. The condoms are kept on separate pallets according to lot number.
The condoms are now ready for shipment.