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@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
I hope you enjoyed This Presentation