ORTHOPEDIC CASTING TAPES

PRODUCTION PLANT.

 

INTRODUCTION

 

As one of the leading medical products manufacturers and exporters in Korea, SNF, specializes in synthetic

orthopedic casting tapes, fiberglass or polyester fabric coated with water-activated polyurethane resin and orthopedic splint.  

Our R&D efforts for the past few years have resulted in highly successful development of essential features such as strength,

lightweight, moldability and comfort, etc. The newly developed soft type of casting tapes shortens the  rehabilitation periods and

enjoy massive popularity in the market as a leading brand in Korea.  As a result, all ROBO products are CE marked and

registered at FDA in USA.

 

Considering their high quality, more than a million pieces of casting tapes  particularly hard and

soft types available and splints-pre-cut and roll types are supplied domestically as well as over

30 countries including U.S.A, France, Germany,  Turkey,  Iran, China for the last five years. Thanks to such proven quality and competitive price, we succeeded in replacing old-fashioned plaster bandages

with synthetic orthopedic casting tapes which boast of several advantages compared to plaster bandages.  

 

Boasted by the technical confidence of quality products we proudly unveil the complete production facilities for orthopedic casting tapes alongside production technology transfer.

 

In 2007 the similar facilities were exported to Iran, with a few more that are currently under construction. Moreover, reliability and quality are guaranteed by supplying customized machines designed in-house and upgraded based on valuable production experiences accumulated through the years.  Although small in scale, the proposed production plant are easily expandable; thus ensuring of high return on your investment.

 

PRODUCTS AND SPECIFICATION

 The proposed facilities can manufacture ROBOCast™/Poly products that have advantages such as lightness, strength, radiolucency, and

 porosity unlike the traditional plaster cast.  In addition, cast removal generates less and larger dust than that generated upon the removal 

 of  plaster cast. Exposure to moisture or water also triggers a chemical reaction that causes the tape to become rigid.  

 The following are major characteristics:

 1. Excellent X-ray radiolucency
 2. Superior end lamination and mouldability  
 3.
Good air permeability
 4. Easy removal
 5.
Environment- friendly material

 

 The following are specifications for quality products:

 

PRODUCT DESCRIPTIONS

TYPES

SIZE (wide * long)

ROBO Cast Fiberglass

Hard and Soft Available

1”~5”  * 360cm

ROBO Cast Polyester

Hard and Soft Available

1”~5”  * 60cm

ROBO Splint Fiberglass

Pre-cut

1”~6”  * 10”~45”

ROBO Splint Polyester 

Pre-cut

1”~15” * 10”~45”

ROBO Splint Fiberglass

Roll

1”~6”  * 2.0m to 4.5m

ROBO Splint Polyester

Roll

1”~6”  * 2.0m to 4.5m

 

        

 

PRODUCTION PROCESS AND MACHINES

  

PRODUCTION PROCESS

PROCESS DESCRIPTION

  

텍스트 상자: Reacted
Polyurethane Resins
텍스트 상자: Knitted Fabric 
Drying
텍스트 상자: Raw Materials
Preparation
 

 

  

 

 

 

 

 

  

 

 

 

 

 

 

 

 

텍스트 상자: Coating/Winding
on Fabric
텍스트 상자: Sealing and Packing

 

 


               

 

 Pre-mixed raw materials are weighed and put into the reactor. Raw material handling area should be dehumidified and kept dry.

 

 

Polyurethane resin may be substituted for water activated pre-polymer in the reactor.

 

 

 

 Knitted-fabric (fiberglass or polyester) is dried in the drying room and transported into the coating machine. Polyurethane is then impregnated into dried fabric.

 

 

Resin-impregnated fabric is wound on a bobbin at a specified tension or cut into the specified standard length.

 

 

After conducting quality inspection, the finished products are sealed and packed. The sealing process is critical for long-term storage. All the necessary information are printed on the sealed pack.

 

 

 

  Notes:

  1. Casting tapes production facility should be operated in a properly dehumidified area to ensure the quality of the products.

  2. The processes described above are based on ROBO cast production

      (may vary slightly depending on the types of the product to be manufactured).

 

  PRODUCTION MACHINES AND INSTRUMENT

  Most of the production machines have been designed in-house and upgraded in order to produce high quality products. In particular,

  the casting production facilities  requires enclosing specific parts with glass and proper dehumidification for the purpose of quality assurance.

  Therefore, accurately controlling humidity and temperature inside the machine requires sensitive parameters and practical experience

  accumulated from long-term operation.  The exclusive technology of resin mixing and sealing of products also help enhance product quality.

 

  To protect production Know-how and related technology the detailed technical specification of each machine and related pictures are

  not fully introduced in this proposal (to be provided during in-depth discussions when drawing up contract).

   1.   Casting tapes coating facilities

   2.   Air compressor and dehumidifying system (dry air generation)

3.    Raw material drying/heating system

4.    Heating oven for resin

5.    Sealing machine/Bobbin cutter

6.    Printing machine

7.    Electric control panel

8.    Weighing instrument

.  Laboratory equipment

 

PROPOSED STANDARD PLANT

 

  PRODUCTION CAPACITY

   2,000 pieces/day (10 working hours a day) based on ROBO cast 

   50,000 pieces/month (25 working days a month) based on ROBO cast

 

  UTILITY CONSUMPTION

   Electricity           :  50 kw except air conditioning facilities

   Water                :  0.5 ton/day

 

  BUILDING SPACES REQUIRED

   Raw Material Storage                  : 150

   Production Area                          : 100

   Products Storage                         : 100
  

   * Additional spaces for office , laboratory, etc. should be considered.

   * All interiors of the building should be equipped with HVAC and each room housing the installed machine,

      de-humidified for the purpose of quality assurance.

  

   OPERATIONAL WORKERS

WORK

GRADE

NUMBERS

Manager

Management

1

Raw Material Handling

Skilled

1

Fabric Drying

Unskilled

(1)*

Coating & Winding

Skilled

2

Sealing & Packing

Unskilled

1

   Note :

   1)  Numbers marked with ( * ) indicates concurrent position.

   2)  The necessary workers indicated above should be regarded as forecast data based on skill grade of operational workers.

 

  PRODUCTION TECHNOLOGY TRANSFER

   To enable the reliable production of quality products, the transfer of  production know-how to Client is important

   including machinery supply. S N F provides Client with all necessary technologies for the production of quality products.

  

  We continue with our R&D effort particularly the creation of new technologies and products to meet the needs of customers

   and for sharing with them in pursuit of mutual growth.

 1.    property right of creativity

 2.    property right of intellect

 3.    protective rule of trial and errors

 4.    formula for technical production

 5.    others as necessary

 

  SCOPE OF SUPPLY

   In general SNF is responsible for the following machines and technical services (note, however, that detailed work scope are adjusted

   depending on the contract conditions.

 

SUPPLY AND WORKS

CLIENT

SNF

Production machinery

 

O

Core raw materials supply(*)

 

O

Site erection

O

 

Site supervision(*)

 

O

Production technology transfer

 

O

Building work and HVAC

O

 

   Note:

   The types of core raw materials and their supply for the purpose of quality assurance should be determined based on contract condition.

   Site supervision service is provided   upon Client’s request.

 

  PROPOSED FACTORY LAYOUT

   The factory layout is proposed for planning purpose only ; rearrange as necessary to accommodate the optimized production scheme,

   which should be determined considering various design parameters such as production capacity, product types, HVAC,

   necessary utility facilities, etc.