condom manufacturing

@HLL FACTORY, KHANAGALA PLANT, KARNATAKA

CONDOM MANUFACTURING

PROCESS

Some Facts about CondomA condom is a barrier device most commonly used

during sexual intercourse to reduce the probability of pregnancy and spreading sexually transmitted diseases.

HLL is one of the world's largest condom manufacturer.

@HLL Factory, Khanagala Plant, everyday 8 lakh pieces are produced (4 Lakh each machine)

Every 45 minutes 6000-6500 pieces come out of machine

Quality Condoms should: Need to fit penis properly Free from holes Adequate physical strength Correctly packaged to protect them during storage Correctly labeled

STEP 1- MIXING & GRINDINGLiquid Latex comes in Drums

Compounds are added (Grinding is done so that not a single granules remains intact)

This mixture is pumped to Mixing Tanks (Agitators are present for thorough mixing)

Compounding is done after mixing for 12-13 hrs at 54 degree Celsius

This mixture is then transferred to supply tanks where 18-20 degrees Celsius temperature is

maintained. Steam Jackets are present around the tanks.

(There are 2 Supply Tanks – 1 Violet (for Deleux Condom) & 1 Pink (for Moods Condom)

Temperature & Pressure is maintained

STEP 1- MIXING & GRINDING

STEP 2 – DIPPING PROCESSGlass Moulds are present in the dipping booth area

Glass Moulds are dipped in the liquid mixture to give the shape

It is a double dipping process (Latex Temperature – 28 degree C at 55.5 Pressure)

These glass moulds then go for drying and then again the dipping process starts.

STEP 2 – DIPPING PROCESS

STEP 3 – COOLING, DRYING & STRIPPING STAGEIt is then cooled down with water and then it is dried

again

Then Brushing Process is done with the help of which the Ring is formed

This mould is then dipped in the swelling tank with Ammonia

This is then passed through Silica to strip of the Condom then it is passed through dehydrator and

silicon gets separated & Liquid product gets separated (Silicon is again recycled)

Product comes in Vulcanizing Machine. Here Collection is done for 45 minutes and drying done for 30 minutes at 85 degree Celsius.

Quenching (Cooling) is done after drying at the Quenching Barrel for 15 minutes

STEP 3 – COOLING, DRYING & STRIPPING STAGE

STEP 4 – QUALITY CONTROLGoes to Quality Control for Visual Check. From each lot which arrives 30 is taken randomly for the visual

check.

Then this 100% lot goes for the Pin Hole Testing

Note: When the Quality Check crosses the Inspect Indicator of Rejection then the entire lot is rejected and goes for Salvaging where each piece is checked

manually where correct pieces are restored and rejected pieces are scrapped & recycled for the making of other latex products like slippers etc.

STEP 4 – QUALITY CONTROL

STEP 5 – PINHOLE TESTING

10 Machines Stations are present for the Check. 20 employees deputed for the work at same

time14750 condoms/employee/shift has to be

covered for the pinhole check

Correct one will go for pinhole testing and rejected ones for the water testing

STEP 5 – PINHOLE TESTING

STEP 6 – Bursting TESTNormally a condom should retain 1 Kilo Pascal Pressure and 18 litres of water. (For 49mm condom – 16 Lit & for 53mm condom – 18 Lit. Pressure remains same for both

the varieties)

10 samples are randomly taken from the approved volumes for the bursting test. Testing is done with 2.25

Kilo Pascal Pressure and 33 Lit burst Volume)

After Bursting test the sample again goes for Pressure & Volume check

Note: For the defective pieces 1 min 300 ml water testing is done.

STEP 6 – Bursting TEST

Step 7 – Lubrication &Packaging Lubrication is done before the packaging of condom.For a 49mm condom – 250mg lubricant/condom is

usedFor 53mm condom 400-450mg lubricant/condom is

used20000 pieces/operator/shift (8hr)

Packaging is done through auto feeding machine. 30000 condoms are packed in 8 hr shift.

One operator operates 2 machines in one shift so the total is 60000 per operator in a 8 hr shift.

Step 7 – Lubrication &Packaging

Thank you

For your attention

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