Non-Woven Surgical Masks Manufacturing Process

Non- Woven SURGICAL MASKMANUFACTURING PROCESS

 

What are Surgical masks used for?

 

Surgical masks are used every day by medical professionals to provide protection against the risk of infection. Masks are used as a protective barrier in hospital for keeping germs from the mouth and nose during various medical procedure and also prevent cross contamination among patients.

There are different standards such as FFP1, FFP2 and NP5 according to the materials used and usage applications. In any case, it is essential to take note that not all masks are made equivalent, and some don't give protection by any means. Right now, by giving data on the assembling procedure of surgical masks, above all, we'll be giving some foundation data on masks to empower better-educated sourcing.

 Surgical face mask is made of non-woven material sterilizable for the single-use made of standard size, provided with elastic on both sides for holding the face mask on the mouth and nose area for protection. The face masks are easily available in various colours and sizes according to requirements. The masks are available in 2 ply and 3 ply.

 

Features of Non-Woven Face Mask

·       Hygienic

·       Protection against bacteria

·       Safety

·       Quality

·       Environment friendly

·       Breath ability

 

Various Applications of Masks

·       Hospitals

·       Home Care

·       Food Industries

·       Electronic Industries

·       General Industries

·       Pharmaceuticals

 

Various Types of Masks

N95 surgical masks

The most secure assurance against sickness. These are specific masks implied for prepared industry experts. This cover seals the zone around the face totally when appropriately fitted, however they put forth breathing a greater amount of an attempt. They additionally require the utilization of yearly preparing and fit tests to guarantee that the expert is as yet utilizing them securely.

Surgical masks

one of the most popular choices for consumers, are only mildly effective preventing the spread of illness. Because of their loose fit to the face, matter can get around the edges of the mask and still enter the nose and mouth

           Cloth masks

Surgical masks are manufactured using non-woven fabric material. The non-woven fabric has better air pass through and bacteria filtration. The materials used for non-woven masks are polypropylene (20 to 25 grams gsm), polyester or polycarbonate. The mask material is made through various process like melt blown technology and spun bond process. The tiny fibres in the material are less than a micron.

Surgical masks are bind up of multi layered of non-woven bonded fabrics. They are easily available and are easy to dispose. Various parts – bonded fabric, nose strips, ear loops,

Various test and process required for standard mask Making

·       Fixed standard

·       Various test and certification standards

·       Government Polices

·       Newer Technology

 

Materials used for manufacturing Non-Woven Face Mask

·       Ear Loop (3-5 Mm)

·       PP spun bond non-woven Fabric (Outer (Blue) and Inner (White) Layer)

·       PP Melt blown non-woven fabric (Inter Layer)

·       Elastic Band

·       Nose Wire such as plastic or aluminium wire

  

Process of manufacturing Face Masks

 The process of manufacturing mask in this type is fully automatically using ultrasonic technology for binding various 3 to 5 layers of non-woven fabric material. The ear line welding machine is used to join the rear line to the body. The material used in ear line is elastic non-woven which makes the masks to use comfortable  

Technical specification of machine

The machines have various PLC with automatic controlling the process of manufacturing the masks. The machine automatically completes the various process such as blank, trimming and folding of the masks. The main process is based on automatic fabric unwinding, automatic compounding and automatic folding and ultrasonic welding.

There are various parts in machine

·       Mask body machine

·       Nose bridge Welding machine

·       Transfer conveyor

·       Elastic Cord Welding Machine

·       Sterilization Machine

·       Ear belt machine

 

Various advance equipment is used for feeding and rewinding the masks for high stability and low failure rate. 3 different layers of masks are used in material feeding shelf. They are placed in 3 different stands one over other in various places. with the help of various seasons controlling the feeding process, the 3 layers are kept one by one over another to form one single layer with the help of roller press machine the production speed of the mask is 90~130 pieces/min

The 3-layer woven is automatically folded and wrapping using the mask body machine. The nose beam is cutting to a fixed length and join to the mask body. after that the ear belt is welded using ultrasonic technology and the mask is automatically discharge to the sanitization process. The masks are sterilized after complete making process. The equipment is simple to use for loading and unloading of the masks

The automatic machine helps reducing the waste and improves the production efficiency which helps to lower the material cost. The productivity also improves and can reach up to 150 pcs/min.

 

1 - Automatic masks machine - Rs – 30 to 40 Lakhs

(Depending on production capacity) – 100 to 150 Masks pieces per min

2 - Semi automatic masks machine - Rs 10 to 15 Lakhs

(Depending on production capacity) – 50 to 80 Masks pieces per min

3 - Manual masks machine - 5 to 7 lakhs

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