CONDOM MANUFACTURING FROM LATEX

[EIRI/EDPR/3771] J.C.: 1864

INTRODUCTION

Condoms are thin sheaths worn by men during sexual intercourse to prevent
pregnancy and venereal infections. According to the 1995 National Survey of
Family Growth, conducted by the National Center for Health Statistics in
Hyattsville, Maryland, male condoms or prophylactics are the third most popular
form of birth control—proceeded only by female sterilization (29.5%) and birth
control pills (28.5%)—with usage at 17.7%. They are also one of the most effective:
research indicates that with correct use, failure rates are 2-3%. Most condoms are
made of latex rubber, but they can also be made from lamb cecum or
polyurethane.

In addition to their contraceptive value, condom use has been found effective in
preventing the spread of sexually transmitted diseases. In 1986, the U.S. Surgeon
General endorsed the use of condoms as the only currently available effective
barrier against the transmission of Acquired Immunodeficiency Syndrome (AIDS).
The spread of many other sexually transmitted diseases, such as chlamydia and
gonorrhea, can also be virtually eliminated with the use of a latex condom. With
the government touting the health benefits of condom use, manufacturers openly
advertise their products, and retailers stock condoms in visible, accessible
locations. Condoms, previously kept behind the prescription counter, are now
found on most store shelves. Today in the U.S., 450 million condoms are sold each
year.

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Despite the wide variety of styles, there are few differences among the many latex
condoms available on the market today. They can be straight-sided, contoured,
ribbed, sensitive, or smooth. They may be treated with lubricants or spermicides.
They can be blunt-ended or have a reservoir tip. Because the condoms undergo
stringent testing before they are sold, quality is generally not a marketable issue.
Hence, manufacturers attempt to build brand loyalty and market their products to
specific target consumers.

Condoms made from lamb cecums—the blind pouch in which the intestines begin
and into which the ileum opens from one side—are also available. However, they
are more expensive than latex condoms, and while they prevent pregnancy, "skin"
condoms are ineffective in preventing the transmission of sexually transmitted
diseases. In 1994, the Food and Drug Administration (FDA) approved a
polyurethane condom for sale in the U.S. The new condom has not been
extensively tested for effectiveness in preventing pregnancy and sexually
transmitted diseases.

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 CONTENTS

INTRODUCTION
RESISTANCE TO CUTTING, TEARING & ABRASION:-
DESCRIPTION OF THE PROCESS
DIPPING PROCESS:-
CLASSIFICATION OF CONDOMS
CONDOMS ARE CLASSIFIED UNDER FOUR CATEGORIES:
TIPS ON USING CONDOMS
REQUIREMENTS (PROPERTIES)
PACKING & MARKING
USES AND APPLICATION
PLASTIC CONDOMS
B.I.S. SPECIFICATIONS
INTERNATIONAL SPECIFICATION OF LATEX CONDOM
ABSTRACT:
MARKET POSITION OF LATEX CONDOM
BY PRODUCT TYPE
BY MATERIAL
BY VARIETY
BY FLAVORS
BY DISTRIBUTION CHANNEL
BY MANUFACTURING TYPE
GLOBAL MARKET OF CONDOM
TOP 10 CONDOM BRANDS LEADING THE GLOBAL CONDOM MARKET 2018
DUREX CONDOMS
TROJAN CONDOMS
LIFESTYLES SKYN CONDOMS
ASTROGLIDE LUBES
KIMONO MICROTHIN CONDOMS
LIFESTYLES SKYN CONDOMS
ASTROGLIDE LUBES
BEYOND SEVEN CONDOMS
TRUSTEX CONDOMS
CUPID’S FEMALE CONDOMS
CROWN CONDOMS
ONE PLEASURE DOME CONDOMS
MAJOR COMPANIES:
DUREX CONDOMS:
TROJAN CONDOMS:
LIFESTYLES CONDOMS:

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TABLE 1 - REGIONAL STATISTICS FOR HIV & AIDS FROM PAST YEAR
GLOBAL MANUFACTURING
CONDOM PRODUCTION BY COUNTRY
USA TRENDS
DISTRIBUTION CHANNELS FOR CONDOMS US MARKET
NICHE PRODUCTS
FEMALE CONDOMS
NON- LATEX MALE CONDOMS
DETAILED EXPORT DATA OF CONDOM
EXPORTERS LIST OF CONDOMS IN INDIA
MANUFACTURERS OF LATEX CONDOMS
SHAPING NATURAL RUBBER LATEX TO CONDOM
FROM RAW MATERIAL TO CONDOM
THE CONDOM IS CREATED
WASHED AND PACKAGED
QUALITY CHECKS IN OUR OWN LABORATORY
PROCESS OUTLINE FOR CONDOM MANUFACTURE
VARIOUS DIPPING METHODS
CIRCULATING DIPPING TANK
DIPPING METHODS:-
COAGULANT DIPPING:-
EQUIPMENTS USED
FORMERS:-
DIPPING SYSTEM:-
VULCANISATION
RAW MATERIALS AND UTILITIES
LATEX 60% DRG:
SULPHUR:
ACTIVATOR :
ACCELERATOR :
PLASTICIZERS :-
ANTI OXIDANTS:-
STABILIZERS:-
DISPERSING AGENTS:-
SALIENT FEATURE OF THE PROCESS OF MANUFACTURE:-
PREPARATION OF LATEX SOLUTION (COMPOUNDING)
FORMULATION
PROCESSING MATURING CONDITIONS-36 HOURS AT 25OC
FOR FORMULATION:-
FORMULA
FORMULATION
DIPPING PROCESS:-
DRYING OF THE LATEX COATED MOULDS - FIRTS STAGE:-
SHAPING OF THE CONDOM EDGE DPPED RUBBER CONDOMS:-

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DRYING - FINAL STAGE (VULCANISATION):-
REMOVAL OF CONDOMS FROM THE MOULD:-
WASHING SQUEEZING AND DRYING:-
TESTING AND PACKAGING
PACKING:-
TESTING OF CONDOM AS PER ISO 23409 FOR EXPORT
DURABILITY OF CONDOMS
ISO 23409 STANDARDS FOR CONDOMS
TESTING OF CONDOMS
TEST OF CONDOM SHEATH AND RETENTION MECHANISM
TEST OF LUBRICANT
TEST OF DIMENSIONS
TEST OF VOLUME AND PRESSURE
TEST FOR HOLES
TEST FOR STABILITY AND SHELF LIFE
TEST FOR BIO-COMPATIBILITY
QUALITY CONTROL AND ASSURANCE IS CONDOM MANUFACTURING
MAJOR STEPS ON VOLVED IN CONDOM MANUFACTURE
SEQUENCES IN LATEX CONDOM MANUFACTURE
COLLECTING THE RAW MATERIALS
COMPOUNDING
STORAGE
DIPPING
TUMBLING
TESTING
PACKAGING
CONDOM MANUFACTURING PROCESS
MACHINE DESCRIPTION:
CONDOM FORMING
ELECTRONIC TESTING
FOIL PACKAGING
DETAILED MANUFACTURING PROCESS OF CONDOM
COMPOUNDING
MOULDING
VULCANIZING
INSPECTION
QA
PACKING
QUALITY CONTROL AND MEASUREMENTS
CONDOM MANUFACTURING FLOW CHART
TESTING METHOD OF LATEX CONDOM
AIR BURST TEST
TESTING FOR DETERIORATION
PROPOSED CHANGES IN STANDARDS

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CONDOM PRODUCTION LINE
1. TECHNICAL PARAMETERS:
2. CONDOM DESCRIPTION:
MACHINE & PRODUCTS SHOW
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF RAW MATERIALS
COMPLETE LATEX CONDOM MAKING MACHINERY SUPPLIERS
CONDOM PACKING MACHINE
MANUFACTURERS AND SUPPLIERS OF RUBBER MACHINERY
& TESTING EQUIPMENT
RUBBER MIXER
DIPPING MACHINE
MANUFACTURERS & SUPPLIER OF RAW MATERIALS
LATEX
SULPHUR
SUPPLIER OF RAW MATERIALS (GLOBAL)

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 10,00,000 Piece/Day

Land & Building (5000 sq.mt.) Rs. 3.51 Cr
Plant & Machinery Rs. 4 Cr
Working Capital for 2 Months Rs. 1.83 Cr
Total Capital Investment Rs. 9.74 Cr
Rate of Return 47%
Break Even Point 47%

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