industrial nitrile gloves Production Processes

Coagulant Dipping

After the glove former is cleaned, it will be coated with coagulant (eg. calcium nitrate) and be dipped into the coagulant bath to help the latex mixture adhere to the formers and to help ensure the latex is distributed evenly. The glove formers are dipped into the coagulant tank under workers’ control to extract the protein from the previous glove dipping and this dipping is done once for every production cycle.

Drying

Drying is one of the stations in production process of latex gloves manufacturing whereby the coagulant converts the liquid latex film into a wet-gel on the glove formers and will eventually travel through a series of ovens to dry the gloves and end the coagulation process. In brief, it is a process of drying the gloves from wet to readymade gloves.

Latex Dipping

Latex dipping is one of the stations in the production process of latex gloves manufacturing and the tank is filled with compounded latex. A latex layer will be formed on the glove former after it goes through this tank. The thickness of the latex glove is determined at the coagulating and dipping stage. The longer the time the glove former travels in the coagulant tank, the thicker the latex gloves will be formed. 

Leaching

This leaching stage can called as the pre-vulcanization leaching. It also known as “wet gel leaching”. Residual chemicals and proteins on the surface of the gloves are put into the leaching process to be removed after the drying of latex mixture. A longer leaching line can wash out latex proteins more effectively. Besides that, the water must be hot and fresh enough to make the proteins dissolve better. This step is a critical step to minimize the occurrence of latex sensitivity. The water temperature, process duration, and water exchange rate will affect the effectiveness of the process. Good leaching line can result in a good and quality latex glove.

Beading

Beading is a process whereby up to a dozen chemicals are added to help in next manufacturing process of latex gloves. The chemicals added are antioxidant that prevents deterioration of the rubber molecules in the final product by heat, moisture, and ozone. Chemical accelerators are also added to help control the next vulcanization process.

Vulcanization

One of the discovery key in manufacturing rubber is the vulcanization process. It is a curing process in the production process of latex gloves whereby the latex particles are modified by adding in accelerator chemicals to it. When all the materials are heated, sulfur atoms are chained with the rubber molecules to form a cross-link that gives strengths and elasticity to the physical properties of the rubber. This process ensures the rubber will not be torn and melt easily.

Post Leaching

This process is similar to the wet-film leaching previously, but it is a little different whereby it is carried out on the dry/vulcanized latex film. Therefore, it is also known as “dry-film” leaching. Time and temperature is the most important element to ensure effectiveness in the process of water extractives reduction. Latex gloves may be leached up to 24 hours to ensure its effectiveness.

Slurry Dipping

This stage is also known as “wet even powdering”. The slurry tank containing the cornstarch solution can prevent latex gloves from sticking in the tank. The slurry is also referred to as wet powder. The benefit of this powder is acting as preservation of the latex gloves and to assist in the latex gloves donning process.

Stripping

At this stage, the latex gloves are stripping from the glove formers. There are two types of methods, which are manually or automatically stripping the latex gloves from the glove formers. 

Tumbling

The tumbling process at latex gloves manufacturing process is to remove excessive powder on the gloves. The latex gloves are putting into the commercial dryers to ensure that the powder is more evenly distributed and excess powder can be removed.

Powder-Free Gloves

Powder-free gloves stage is a technology to prevent stickiness of gloves by avoiding powder usage completely by going through chlorination or polymer coating process. This is one of the important technology processes in manufacturing latex glove nowadays because most of the glove makers are producing the latex gloves with powder-free. Basically, the powder-free latex gloves are transformed from powdered gloves when the powder is removed. Before the latex gloves dried, the powder helps the latex gloves give uniformity as well as to prevent the latex gloves from molding together. The tackiness on the glove surface can be removed by rinsing the latex gloves in water. Then it is placed into a chlorine bath to transform the powdered latex gloves to powder-free latex gloves. The glove is turned inside out and the process is repeated. The powder-free gloves are placed back into the dryers when the bathing process is completed.

Quality Control

carries out its quality control in total quality management system. In total quality management system, the process includes regular testing of raw materials, close monitoring the manufacturing process, continuous improvement on quality control, maintain regular quality control, complying with stringent quality standard, target for zero defects, good instructional labeling, efficient work standardization, continuous improvements in packing and loading, close monitoring of production process, tensile strength machine, innovative auto-stripping system, visual air pump test, water tight test, physical dimension test, protein test and powder test in their manufacturing process of latex gloves. The visual air pump test, water tight test and physical dimension test will be carried out in this quality control stage while the other test will be carry out during each manufacturing process of the latex gloves. The air pump test serves to check for holes and visual defects in gloves while the watertight test serves to check for pinholes rate on the latex gloves. Each country will have their own acceptable quality level (AQL) in allowing the company to export product to their country. For example, the companies that want export their gloves to United States, a 2.5 AQL in the watertight test or better. The physical dimension test is used to measure the dimension of the gloves whether to know the measurement does meet the inspection level of 4.0 that set in AQL.

Packing

Packing is the final stage in the manufacturing process of latex gloves. Packs latex gloves in flat and efficient layer-by-layer to ease the dispensing of gloves in order to avoid latex gloves difficult to dispense from each gloves later. This type of packing method can reduces waste and makes latex gloves easier to take out from the box. For example, we can dispense tissue from a tissue box easily and the idea is applied to the latex gloves’ box dispensers. This layered technique is often use by all glove manufacturers.

Lastly, when all production processes are completely carried, the latex gloves will be keep in TG warehouse for labeling and then send to their particular customers. In addition, the latex gloves are also being exported to other countries. The production processes of Top Glove are repeated for all the production lines and to ensure the latex gloves that are produced are in high quality and safe for use.