CONDOM MANUFACTURING PROCESS @HLL FACTORY, KHANAGALA PLANT, KARNATAKA
SOME FACTS AbOUT CONDOM A 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 worlds 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 & GRINDING Liquid 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 2 – DIPPING PROCESS Glass Moulds are present in the dipping booth area Glass Moulds are dipped in the liquid mixture to give the shapeIt 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 3 – COOLING, DRYING & STRIPPINGSTAGE It 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 AmmoniaThis 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 4 – QUALITY CONTROL Goes 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 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 6 – bURSTING TEST Normally 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 checkNote: For the defective pieces 1 min 300 ml water testing is done.
STEP 7 – LUbRICATION&PACkAGING Lubrication is done before the packaging of condom. For a 49mm condom – 250mg lubricant/condom is used For 53mm condom 400-450mg lubricant/condom is used 20000 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.