presentation cotton medical textile
TRANSCRIPT
January 2012
An Overview
of
Cotton Fiber based
Medical Textile Products
& its
Manufacturing Process
CONFIDENTIALCONFIDENTIALCONFIDENTIALCONFIDENTIAL
This presentation has been produced by Onella Consulting Pvt Ltd and contains information which is protected by
Copyright & other intellectual property law, and is subject to the terms and conditions in the governing client contract.
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Brief
� This presentation covers the textile products
mostly used in medical & personal hygiene
applications
� Most of these products are used as
consumables
� This presentation is to give basic knowledge
of the products, manufacturing process and
equipments details
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Product Categories
• Products Categories covered in the presentation
– Cotton Fiber Products
– Yarn Based Products
– Synthetic Fiber Based Products
– First Aid Adhesive
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Cotton Fiber Products
• Some Cotton Nonwoven Products and their Applications
ProductProductProductProduct Type of ApplicationType of ApplicationType of ApplicationType of Application
Cotton Rolls Personal Hygiene, Medical
Cotton Pleats (Zig Zag) Personal Hygiene, Medical
Cotton Balls Personal Hygiene, Medical, Cosmetic
Cotton Pads Personal Hygiene, Medical, Cosmetic
Alcohol Swabs Medical
Dental Rolls Medical
Cotton Buds Personal Hygiene, Medical, Cosmetic
Non Adherent Pads Medical, Cosmetic
Non Adherent Alcohol Pads Medical
Tampons Personal Hygiene
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PRODUCTS AND MANUFACTURING PROCESS
Absorbent Bleached Cotton Absorbent Bleached Cotton Absorbent Bleached Cotton Absorbent Bleached Cotton
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Mixing Machine
Opening Machine
Stamping Machine
Hydro ExtractorHydro Extractor
Bleaching Machine
Cake Opener
Conveyor Dryer
Cleaning Machines
Cotton Waste Cotton Waste Comber NoilComber NoilRaw CottonRaw Cotton
Cleaning Machines
Bale PressBale Press Production Line for Semi Finish Products
Manufacturing Process- Bleached Cotton
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Bleached Cotton
• Bleached cotton for
production of final
products
• Hydrogen Peroxide
Bleached Products
• Meet all international
standard like BP, EP
and WHO
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B.P/E.P Norms for Bleached Cotton
No.No.No.No. Test ParameterTest ParameterTest ParameterTest Parameter StandardStandardStandardStandard
Expected Achievable Expected Achievable Expected Achievable Expected Achievable
Results Results Results Results
1. Physical Appearance
Bleach white, soft fibrous material free from
foreign matters <oil stain, dyes, dust, black
specks, metallic particles and cotton particles
with minimal neps>
Conforms
2. Color/Whiteness <% PV> White comparable to standard <NLT 80%> White
3. Fiber Composition 100% Cotton 100% Cotton
Fiber Length/Micronaire Not more than 27mm
20mm <2.5% Span
Length> Low Micronaire
Value <3.0 - 3.9 Ug/in>
4. Feel/Touch Scroopy & Soft Scroopy & Soft
5.Acidity/Alkalinity<Hot Extraction> No pink color developed in either solution
No change in color
developed
7. pH 6.0 - 8.0 7-8
8.Optical Brightening Agent
<Flourescence>None when examined under ultraviolet light None
9. Sinking Time in H2O 10 seconds 4-5 seconds
10. Absorbent Capacity Not less than 20 times of its weight in water 24
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B.P/E.P Norms for Bleached Cotton
11. Ether-Soluble Substances 0.50% 0.3%
12.Water-Soluble Substances
<per 5 g. Cotton>Not more than 0.60 % 0.35%
13. Alcohol Extract Colorless Conforms
14. Sulphated Ash 0.40% 0.25%
15. Microbial Requirements
Total aerobic microbial count must not
be more than 1000 cfu/g. and no
pathogens
2 cfu/ml
16. Mercury <ppm> None None
17. Odor Odorless Conforms
18. Moisture Content 8% 5.4%
No.No.No.No. Test ParameterTest ParameterTest ParameterTest Parameter StandardStandardStandardStandard
Expected Achievable Expected Achievable Expected Achievable Expected Achievable
Results Results Results Results
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Quality control measurers
• The quality control will start from selection of Raw Material.
• Complete in house testing of cotton will ensure using best
of suitable cotton for Medical application.
• The cotton cleaning line having on line control system for
foreign particle.
• Bleaching is to be done only with best of suitable chemicals
for Medical Applications.
• Cotton Drying to be done using conveyor dryer eliminating
any chances for contamination
• Complete ducting of plant to be done in Stainless Steel
• Best quality for Water treatment plant eliminating any
chances for Bacteria Growth
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PRODUCTS AND MANUFACTURING PROCESS
Absorbent Bleached Cotton Products Absorbent Bleached Cotton Products Absorbent Bleached Cotton Products Absorbent Bleached Cotton Products
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Manufacturing Processes
� For manufacturing final products, Two routes For manufacturing final products, Two routes For manufacturing final products, Two routes For manufacturing final products, Two routes
could be adoptedcould be adoptedcould be adoptedcould be adopted
– Conventional Carding Process
– Spun Lace Process
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Manufacturing Process – Semi Finish Products
Conventional Carding Process
Mixing Machine
Opening Machine with Contamination Clearing Machine
Cotton Pads
Carding Machines for
Production of Web for
Cotton Pads
Carding Machines for
Production of Thick Web for
Zig Zag and Cotton Rolls
Carding Machines for
Production of Sliver For
Cotton Balls & Buds
Embossing of Web Out Put can be Sold of
Go for Production of
Finished Products
Bleached Cotton After Dryer
Finished Products
Go to Production of
Finished Products
Out Put can be Sold of
Go for Production of
Finished Products
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Manufacturing Process- Spun Lace Process
Mixing Machine
Opening Machine with Contamination Clearing Machine
Non Woven Carding Lines with Roller and
Airlaid Cards
Water Jet for Entanglement (Spun Lace)
Raw Material
Dryer
Slitting & Winding
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Manufacturing Process- Finished Products
Thick Cotton Web SliverEmbossed Web
Cotton Pad by
Cutting
Cotton Pad By
Punching
Cotton Balls
Cotton Buds
Zig Zag
(10-20 Cm)
Cotton Rolls of
4”.6”,8”
Diameter
Cotton Rolls of
10” & 14”
Diameter
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Cotton Rolls
• Made from International
Quality Bleached cotton
• Can be with Interleaved
paper
• Different weight and sizes
should be planned
– 50 gms to 1000 gms
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Cotton Zig Zag
• Cotton Pleats folded
• With and without Pre
Cut
• Convenient is use for
Personal and Medical
Use
• Different sizes and
weights should be
planned
– 40 gms – 400 gms
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Cotton pads
• Made in all shapes like
− Round
− Rectangular
− Oval
• Can be embossed
• Used for both Medical and
Personal Care Applications
• Same can be alcohol
dipped for Medical
Applications
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Cotton Dental Roll
• Used in Dental Surgery
• Used where absorbency
and Cushioning is
required
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Cotton Balls
• Can be produced in White
or Colored
• Made from 100% cotton as
per EP, BP and WHO
standard
• Used for both Medical and
Personal care applications
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• Buds could be
made with different
tips
– Standard
– Beauty
– Saftey
Cotton Buds
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Tampons
� Used as Female Hygiene Product
� There are two type of Tampons
– Tampons with Applicator
– Tampons without Applicators
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Products Used in Cosmetic & Hygiene Textiles
Personal Wipes are used for wide
applications in wet and dry formats.
This can be made as scented,
Antibacterial, biodegradable.
These are used for Personal use,
Restaurant tables to service in
Airlines
Wipes are made from Spun Lace
Process only
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PROBLEMS FACED AND ITS SOLUTIONSPROBLEMS FACED AND ITS SOLUTIONSPROBLEMS FACED AND ITS SOLUTIONSPROBLEMS FACED AND ITS SOLUTIONS
Some Special Application Products
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Major Applications for Cotton in Cosmetic,
Hygiene & Medical Field
• Cotton is a versatile plant-derived textile suitable
for many cosmetic & Hygiene related purposes.
• For cosmetic applications cleaning skin surfaces
for removal and applying cosmetic .
• Personal Hygiene wipes for different application in
wet and dry
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Major Problem faced in these products
• While using cotton roll, zig zag, pad or cotton
balls in cleaning the wound, cotton sticks to
wound.
• Some times it increases the infection.
• This also lead to delay in healing process.
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Solution for the Problem
• Use of special cotton pads which are Non
Adherent.
• Cotton from these pads does not stick to
wound and absorb blood.
• These are made from special patented
technique.
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For more Details
To know more details of project please feel free contact:
Ravi b Arora
Onella Consulting Pvt LtdOnella Consulting Pvt LtdOnella Consulting Pvt LtdOnella Consulting Pvt Ltd
Email : [email protected]
Ph No +91-9312054022
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