One by one, each condom is electronically tested for microscopic pinholes by means of a high-voltage scan. During the test, condoms are placed over metal forms (modules) which are sent through an electric field (there are six modules in one rotating disc, controlled by the PLC). The insulating characteristics of rubber allow this test to detect microscopic holes and thin spots in the condom. This ensures that ALL condoms are of the highest quality before being individually rolled and transferred to the wrapping unit.
Wrapping & Packaging
A Packaging Seal Machine is used for packaging. The condoms are lubricated and hermetically sealed. Each condom is enclosed in it's own foil. The machine is designed to meets the requirements of WHO standards.
The inflation test is an integral part of the international quality control standard. Field laboratories in many countries now use the inflation test to determine the degree of deterioration of condoms that have been in storage. Samples of condoms are placed over air tubes and secured. The condoms are inflated with air, measuring the bursting volume and pressure, to determine their overall strength.
Tensile Strength & Ultimate Elongation
During the first step, a sample specimen of a specific size of the condom is cut with a punch press. The condom specimen is clamped on to a Tensile-Strength Testing Unit to test the strength and elasticity of the condoms. The measurement should at least be 17MPa in strength and 700% for ultimate elongation, before and after ageing.
The Ageing Oven is used to study the degradation of plastic and rubber by subjecting it to heat in a rotational condition for a specific time. A one-week test at 70 degrees celsius in the ageing oven is theoretically equivalent to a five-year storage period under normal environmental conditions. Hot air circulation in the oven ensures even temperature distribution.
Water Leakage Test
The Visual Leak Tester for condoms is a compact device complying with international quality control standards. It consists of a carousel of ten condom holders mounted on an ergonomic stainless steel stand with an integral water reservoir. Filling each condom with 300ml of treated water (Reverse Osmosis) for 1 minute and examination for water leakage through the walls of the suspended condoms. The condoms are then removed from the mount, the open end closed and the condoms rolled back and forth once. After this, the condoms are yet again inspected for signs of water leakage.
Length: The length of the condom is determined by it being suspended over a Condom Length Madrel, graduated in millimetres. The length of the condom measures 180mm.
Width: The unrolled condom is placed over a Steel Width Ruler with a scale graduated in millimetres and allowed to hang freely.
Thickness: The double wall thickness of the condom is determined by a Microdial Guage.
Vacuum Leak Test
Package Seal Testing is determined to comply with WHO international quality standards. It provides a visual check when the integrity of the foiled condoms are tested under a vacuum. A defined vacuum is generated in the vacuum chamber to evaluate the integrity and to ensure the seals are intact. The testing process is successful if the foiled condom pack inflates. This is basically the last test before storage and warehousing.