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Automatic Rubber Latex Dipping Plant

 

1 Introduction
This automatic latex dipping plant was designed and invented for manufacturing latex products. The latex dipping machine can produce a variety of items such as gloves, swimming caps, balloons and condoms by different types of dipping equipment with particular types of moulds. Many countries throughout Southeast Asia and South America are abundant in natural rubber latex. All these countries are fully utilized their facilities for latex products, but the maximum outputs of dipped products are Malaysia & Thailand. However, apart from natural latex, the synthetic latex, such as nitrile, neoprem and PVC are also being developed for making different types of gloves but different types of chemical additives are also needed. Besides natural rubber latex or synthetic rubber, other auxiliary ingredients, such as vulcanizing agents, vulcanization accelerators, activators, retarders, auto-oxidants, stabilizers, thickeners, and coagulants are also required to mix with latex for appropriate quality products.
The result of the chemical reaction brought about by mixing these natural and synthetic products together is a very high quality rubber latex which can be used to produce the various products commonly used for medical and industrial purposes as well as for everyday purposes.
The machinery used in the plant outlined in this proposal is of the latest design. The ease with which this high performance, low power consumption, automated machinery can be used make the need for operators minimal.
The plant itself was designed by companies with 30 years of experience in mechanical engineering for companies with vast reservoirs of knowledge and experience selecting to the use of rubber, chemicals, and their effects on one another. Though other countries may offer plants of a similar nature, none can match the quality or price of a Taiwan made rubber latex dipping plant. Moreover, the service offered by companies in the Republic of China make the establishment of this plant an ideal investment

2 General Processing Information
2.1 Flow Chart

2.1.1 Automatic latex dipping products (surgical/examination glove)


2.2 Process Description
2.2.1 The rubber or rubber latex is mixed with the organic and inorganic materials needed. However, before mixing, the chemicals are ground, finished and dissolved in water.
2.2.2 After the latex solution has been mixed, it is placed into the barrel of the automatic dipping machine. The dipping process is completely controlled by a microcomputer. Different products are made simply by changing the molds of machine models.
2.2.3 After edge rolling and spray flocking, the product is vulcanized in a high temperature oven.
2.2.4 After vulcanization, the product is placed in water, which separates it from the mold. The empty mold is then cleaned, cooled, and reused in the cyclical operation.
2.2.5 The product is then chlorinated and cleaned to enhance its appearance.
2.2.6 The product is then vulcanized for a second time to increase its quality and durability.
2.2.7 Each product is then inspected by the quality control machine, which rejects any defective merchandise.
2.2.8 Products passing quality control inspection are forwarded the edge-trimming machine, which removes any excess material caused during the dipping process.
2.2.9 The products are then automatically packaged and sealed in bags.
2.2.10 The finished products are then either stored or shipped to their final destination.
Remark: for more details please refer to the attached sheet.


3 Plant Description
3.1 Production capacity:

From 3,000pcs~10,000pcs/hr depends the investor’s market requirement and available of plant space.

3.2 Raw materials:
Natural rubber latex or synthetic rubber is the main ingredient used for making rubber latex dipped products. Other ingredients such as vulcanizing agents, vulcanization accelerators, activators, readers, auto oxidants, stabilizers, thickeners, and coagulatants are also required to make high quality latex dipped products.

3.3 Machines and Equipments

Items
Sets
Grinding Machine
1
Auto Dipping Machine
1
Auto Beading Machine
1
Automatic Spray Flocking Machine (for household glove)
1
Vulcanizing Drying
1
Automatic Stripping Machine
1
Cleaning & Chiller Machine
1
Surface Treatment Machine (Chlorination for household glove)
1
Chemical Compounding
1
Quality Control Examining Machine
1
Automatic Testing Machine
1
Packaging Machine
1
Bag Sealing Machine
1

3.4 Manpower Requirement

Job Classification
ManpowerMember
Plant manager
1
Mechanical/electrical maintenance
2
Foreman
1
Dipping operator
6
Testing/packing
18
General worker
2
Total
30


3.5 Utilities:
Water consumption: 4,000L/day
Electricity consumption: 300Kw
Gas consumption: 120kgs/day

3.6 Plant Layout
3.6.1 Plant site planning
The factors relating to the choice of a site for latex dipping production plant may vary considerably. Among these considerations are factors such as the price of real estate, availability of reliable transportation, the size of the market and an available supply of raw materials. The main concerns are good transportation, available of water.
3.6.2 Minimum land and plant site required
80M(L) x 20M(W) x 8M(H)
3.6.3 Plant layout


4 Total Budget
4.1 Capital availability for the production line (ranging from USD330, 000 ~ 800, 000 depends on the capacity, types of products required)
4.2  Investor / buyer’s required conditions:
Ability to import raw materials


5 Suppliers Information
Company Name: Asian Success Machinery Co., Ltd.
Address: No.733, HO-PIN Road, PATE City, TAOYUAN HSIEN, Taiwan, R.O.C.
Tel: 886-3-3613456
Fax: 886-3-3660228
E-mail: asuccess@ms16.hinet.net
URL: Http://www.glovemachine.com.tw
The typical machines are:
5.1 Chain type dipping line for gloves, balloons, condom
5.2 Batch type of dipping line for cotton glove dipped with nitrile, PVC
5.3 Dotted gloves: cotton gloves implanted with PVC dots
5.4 Special function for critical latex products such as latex boots, swimming caps etc.
5.5 Special dipping line for PVC dipping lines and also supply the moulds for gloves and condoms in ceramic, glass and aluminum materials
5.6 The supplier also provides process know-how and material.

6 Appendix
6.1 EXPLANATION OF GLOVES DISPENSATION ROOM
6.1.1 Outline:
Latex Gloves are produced by the following method:
First combine latex with other additives which was ground before to be solution, then put them into the dipping tank. Use the same method of dipping to get a layer of the latex materials after the hand former putting in the dipping tank, and then via drying and vulcanizing processes to get a certain shape.
The skill for making latex gloves is higher than for plastic ones. And it depends on the skill of mixing the Raw Material, controlling the thickness and vulcanizing evenly. The technique in mixing the raw material is the main criterion in getting production of perfect gloves.
6.1.2 Mixing The Raw Material:
6.1.2.1 Ball Grinding Machine:
It must mix some organic and inorganic chemical before making Latex Product.
Before mixing with Latex, all of chemicals must go through ball grinding machine for being the solute in water.
6.1.2.2 Mixing Barrel:
Mixing the solution of chemical with latex before the dipping work.
6.1.2.3 Coagulants Agents Mixing:
Before dipping in the emulsion, the moulds need to dip in the coagulants agents, which can be stirred by the workers. If there are powdery materials in the coagulants agents then the sedimentation phenomenon must be prevented.

6.2 PRODUCTION TECHNIQUES OF THE AUTO GLOVES DIPPING MACHINE
6.2.1 Brief Introduction:
This device is specially designed for examination and surgical latex gloves. It moves on a conveyor chain, a pair of moulds tools is set each 180mm on the chain, following the conveyor chain movement the molds make their rotations. Via the movement of the machine, a serial of auto processing operation is achieved: Auto Washing, Coagulants Agents Dipping, Latex Dipping, Drying, Beading, Fore-Leaching, Vulcanizing, Post-Leaching, Wet Powdering, Cooling, Stripping, and then a complete finished product. Except the stripping, the others processes are performed by auto operation.
6.2.2 Dipping Techniques:
6.2.2.1 Manufacturing process: Please refer to the flow chart.
6.2.2.2 Conveyor system and mould tools:
●The conveyor chain is made of special abrasive steel. The VS Motor transmission is adjustable within 6-9 meter per minute in accordance with practical production condition.
●Conveyor chain orbit is made of abrasive and lasting steel.
●Mould orbit is made of stainless steel, it will be lasting used and not make air-pollution.
●The mould holder is designed in an excellent manner, and made of the special steel; there is high heat resisting bearing in the internal moulds. As a result, the movement is smooth; it is easy to load and unload for moulds.
●Depended on guide rail, the mould holders can rotate by themselves to make the stripping materials dry evenly. Guide rail usually designed by the need of processing, it can help to fix the obliquity, balance, descending or other necessary angles of the hand moulds.
●Tension of conveyor chain is adjusted by auto gravity regulating stand.
●Hand moulds is made of lasting, high quality ceramics and it is fixed easily and quickly.
6.2.2.3 Dipping In Coagulants Agents And Drying Operation:
●The coagulants agents tank is made of stainless steel and have adding- temperature equipment.
●After washing, the hand moulds go downward to this tank for dipping and then go upward for drying. Using hot wind age to drying them, it has quick and even drying effect.
6.2.2.4 Latex Materials Dipping And Dripping Engineering:
●Stainless Steel Dipping Tank is equipped with cold and hot water jacking (able to bear water pressure over 1.5 kg/cm2). The temperature of the dipping materials can be kept at a certain degreeand a constant temperature device is also included.
●Furnished with auto cycling system, so latex in the dipping tank can be stirred automatically. As a result, the Latex Solution keeps running, and the film on the surface of the emulsion is prevented; film phenomenon always happens due to the latex contacts with the air too long.
●The tank is divided into main and sub tanks by a partition, which is as high as the Latex Solution. The Raw Materials after agitator are passed to the main tank and flow over the partition into the sub one. Keeping this kind of circulation, Latex Solution will be kept at a certain level.
●After dipping in the coagulants agents, the hand moulds move smoothly into the emulsion tank for dipping and processing.
●Of the whole production process, this step is the most important one for it can decide whether it has met the requirements of evenness and thickness of the gloves and the production speed. It is the main point for making a good quality and stability gloves.
6.2.2.5 Beading:
●After dipping and drying at the lip part of the hand mould, the mould will be curled by the beading machine.
●There is an adjuster in Beading unit. It will depend on product requirement to make different length of products.
●The Beading wheel is suitable for all sizes hand moulds: and it will not damage the moulds but will get nice Beading.
6.2.2.6 Fore Leaching:
●Tank is made of stainless steel, and there are keep warm and heating device. The water in leaching tank must over flow to keep water clean and be sure to get the result of leaching.
6.2.2.7 Vulcanizing Process:
●Energy of vulcanizing oven is heated by steam, electricity or gas. There also is a auto leaching for temperature requirement in the oven. It will be able to control the temperature degree until setting degree. Mould moves in the oven horizontally and be heated evenly; so it can promote goods quality.
6.2.2.8 Hot Water Tank (Leaching and vulcanizing Assistance):
●Furnished with heating pipe, the leaching tank of stainless steel is able to keep the temperature of water between60 - 100 ℃ which Can achieve leaching reaction as well as vulcanizing assistance.
6.2.2.9 Water Powder Tank:
●Two ways of powdering: wet and dry. The former production is less pollution than the latter. However the wet powdering method only uses cornstarch, will become paste after mixing with water. And the dipping machine is equipped with a water powder tank.
●The water powder tank of stainless steel is designed with circulation system in order to avoid sedimentation phenomenon.
●First mix cornstarch with water, after the post leaching process, the hand mould will be passed to the tank and then be dried. So the mould will be covered with the cornstarch evenly. This kind of powdering way will not scatter the powder but will save money.
6.2.2.10 Cooling Engineering:
●Fan-Type cooling design.
●After vulcanizing, the temperatures of the moulds and the products reach about 100℃ which makes "stripping" difficulty. So cooling fan must be needed.
6.2.2.11 Stripping:
●Stripping is operated by workers; it needs about 3 workers each side. But it will also need another one worker for replacement.
So 7 persons x 3 shifts = 21 persons.
●The stripping room is furnished with air condition, which will make the workers feel comfortable. And the working efficiency is promoted too.
●Aluminum stripping room also can prevent air-pollution.
6.2.2.12 Mould Washing And Drying:
●It is an auto washing operation device; after stripping, the moulds are moved into this section.
●After soaking in detergent, the moulds will be moved into ultrasonic washing tank, then pass to the hot water tank.
●After washing, water on the moulds will be get rid off by the air-curtain. And then the moulds will be moved to the coagulants agents.
●By this washing and drying method, the moulds can be kept clean for a long time.

Sponsored by the Bureau of Foreign Trade (BOFT)   Administered by the Taiwan External Trade Development Council (TAITRA)
333 Keelung Rd., Section 1, 5-7 Fl., Taipei 11003, Taiwan ROC
Tel: +886 (2) 2725-5200     Fax: +886 (2) 2757-6245     E-mail: taitra@taitra.org.tw
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