This document summarizes the 7-step process for manufacturing condoms at an HLL factory in Karnataka, India. The steps include: 1) mixing and grinding latex, 2) dipping molds in latex, 3) cooling, drying, and stripping condoms from molds, 4) quality control checks including visual inspection and pinhole testing, 5) more detailed pinhole testing, 6) bursting tests to ensure strength, and 7) lubrication and packaging prior to distribution. On average the factory produces 8 lakh (800,000) condoms per day through highly automated processes to ensure quality and safety.

1. CONDOM MANUFACTURING
PROCESS
@HLL FACTORY, KHANAGALA PLANT,
KARNATAKA

2. 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 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

3. 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

4. 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

5. STEP 1- MIXING & GRINDING

6. STEP 2 – DIPPING PROCESS
Glass 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.

7. STEP 2 – DIPPING PROCESS

8. STEP 3 – COOLING, DRYING & STRIPPING
STAGE
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 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)

9. 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

10. STEP 3 – COOLING, DRYING & STRIPPING
STAGE

11. 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.

12. STEP 4 – QUALITY CONTROL

13. STEP 5 – PINHOLE TESTING
10 Machines Stations are present for the Check. 20 employees
deputed for the work at same time
14750 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

14. STEP 5 – PINHOLE TESTING

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

16. STEP 6 – bURSTING TEST

17. 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.

18. STEP 7 – LUbRICATION
&PACkAGING

19. Thank you
For your attention
I hope you enjoyed
This Presentation