Process Flowchart Steps:
Raw Material Selection:
Select appropriate fibers based on product requirements:
Cotton: For high absorbency.
Polyester: For durability.
Spandex: For elasticity.
Fiber Preparation:
Washing, bleaching, and sterilizing the raw fibers to ensure purity.
Drying the fibers before further processing.
Spinning:
Converting the prepared fibers into yarn.
Adjust yarn thickness and quality as per product specifications.
Weaving/Knitting:
Weaving: For producing gauze or flat fabrics.
Knitting: For elastic bandages.
Sterilization:
Apply sterilization processes like:
Ethylene Oxide (ETO).
Gamma Radiation.
Autoclaving.
Cutting and Packaging:
Cut the fabric to required dimensions.
Ensure the cutting process is sterile.
Use surgical-grade sterile packaging.
Quality Control:
Test tensile strength, elasticity, and microbial resistance.
Check absorbency levels for gauze bandages.
Final Packaging and Distribution:
Seal the bandages in final medical-grade packaging.
Prepare for distribution to hospitals, pharmacies, or clinics.
Detailed Process Steps:
1. Raw Material Selection:
Natural fibers like cotton are highly absorbent, while synthetic fibers like polypropylene or polyester add durability and moisture resistance.
Elastic components like spandex or latex-free elastic ensure flexibility.
2. Fiber Preparation:
Raw cotton or synthetic fibers are cleaned and bleached to remove impurities.
Sterilization ensures that the fibers meet medical-grade cleanliness standards.
3. Spinning:
Prepared fibers are converted into yarn using spinning machines.
The thickness of the yarn is adjusted depending on whether the bandage is elastic or gauze-type.
4. Weaving/Knitting:
Weaving machines create gauze-like fabrics with open spaces for air permeability.
Knitting machines are used for elastic bandages, integrating spandex or similar materials.
5. Sterilization:
Sterilize the fabric to remove microbial contamination using:
Ethylene Oxide (ETO): Effective for medical-grade textiles.
Gamma Radiation: Common for medical equipment and textiles.
Autoclaving: Steam sterilization under pressure.
6. Cutting and Packaging:
Fabric is cut into standardized sizes using automatic or manual cutting machines.
Packaging occurs in a sterile environment to ensure no contamination.
7. Quality Control:
Conduct tests such as:
Tensile strength tests to ensure durability.
Absorbency tests for gauze bandages.
Elasticity tests for stretchable bandages.
Verify compliance with ISO 13485 and EN 13795 standards.
8. Final Packaging and Distribution:
Use vacuum-sealed or sterile pouches for each bandage.
Labels should include sterilization date, product type, and usage instructions.
Flowchart Representation:
Raw Material Selection ➔ 2. Fiber Preparation ➔ 3. Spinning ➔ 4. Weaving/Knitting ➔ 5. Sterilization ➔ 6. Cutting & Packaging ➔ 7. Quality Control ➔ 8. Final Packaging & Distribution
