Dipping Systems

DIPPING PLANT

The Dipping Plant is a simple operation that only requires 4 production workers per shift. One of these workers must have good mechanical skills will the others can be general laborers. There also should be a testing person available on each shift that can test the products and document the results. There would be a general manager and a person to handle billing, purchasing and order entry, these are single shift positions.

PRODUCTION SYSTEM

At the start of each production run the dipping forms for that product are attached to the dipping racks. These racks move the forms from tank to tank, lowering the forms into the tank, raise them from the tank and move to the next tank where the process is repeated. After the last tank the forms with the latex, or plastic polymer move into the dryer where the material is cured. The next step is the pulling station where the products are automatically removed from the forms. In the step excess material is removed so the products have clean lines with no “flash” that could effect its comfort to the user. The product then moves to the packaging machinery where the products are wrapped and placed into boxes. These boxes are moved to another area where they are manually placed into larger boxes for shipping. This is a manual step.

The forms are moved back to the first tank and the process starts over.

When products are changed from size to size the pulling and packaging station only need minor adjustments. When the products are changed, for example from gloves to catheters, the pulling and packaging machines will require major adjustments or replacement of certain parts. This normally takes less then 15 minutes to accomplish.

If the plant is not used for a 3 shift operation the tanks should remain heated so that the start-up of production the next day is not delayed.

To change forms from size to size on the same product the line would be slowed and the staff would make the change in forms as the forms come out of the pulling station. When the product is changed it would be best to stop the line. When the material is changed, for example from latex to vinyl, the line would have to be stopped, the tanks drained and cleaned before the next material is added and brought up to temperature for production. This could take several hours and would best be scheduled towards the end of a shift or week.

PRODUCT TESTING

The quality person would take product from the pulling station to the laboratory, that is included in the plant, and run a series of test on the product. The test results would be documented for the Good Manufacturing Practices (GMP) or ISO 9000 requirements. Test products would be held for a period of time and then either sold or used as samples for the sales force.