Disposable syringe manufacturing is perfect for people who have years of experience in the medical product market. Disposable Syringes are primarily made of plastic material. They are used in the field of medical and veterinary science. They are used for intramuscular and intravenous injections and are disposed of immediately after usage.
Previously most syringes were made of glasses. Due to their availability in sterilized condition, ready-to-use, and cost-effectiveness, disposable syringes are fast replacing the glass syringes. The advancement of AIDS and related fatal diseases worldwide has added of not using reuse of syringes and the demand for disposable syringes has increased phenomenally. Disposable syringes are mainly injection molded from polypropylene.
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Syringes are available in sizes of 1 ml, 2ml, 5 ml, and 10 ml, in a variety of designs and consist of either two or three components construction. The number and size of injection molding machines required to depend upon syringe construction, number of mold cavities, annual production. The major advantages of using disposable plastic syringes are that no infection is transmitted since the injection is disposed of immediately after use
Market Potential of Disposable Syringe
Firstly, the disposable plastic syringe has big market potential. Besides the growing domestic market for the product, there is also great potential for export to nearby countries. For sustained exports on a durable basis, accreditation under ISO:14000 or ISP 9000 is mandatory.
The glass syringes are very fast becoming redundant. There are many manufacturers of disposable plastic syringes in the country. Out of which about 5-6 units are under the small-scale sector. The total installed capacity is to be about 400 million and the actual production is about 350 million.
Only one unit in Haryana with a capacity of 50 million disposable plastic syringes. Production in the small-scale industry has not been considered because it is quite insignificant as compared to organized units and may eventually of cheaper and quality products from the organized sector. Some of these units are 100% export-oriented units. At present, there is no manufacturing unit in Eastern India.
Equipment Required to Manufacture Disposable Syringes
Some of the basic machines and equipment needed to make disposable syringes are the following:
- Injection Moulding Machine
- Sterilization Plant
- Scrap Grinding Machine
- Air Compressor
- Bilster Packing Machine
- Water Pump
- Chilling Plant
- Different types of Moulds
- Vacuum Dust Cleaner
- Rubber-tip Washing Machine.
- Foil stamping or screen printing equipment.
- Lab Equipment
- Weighing Devices
- Packing Materials
Manufacturing Process and Source of Technology of Disposable Syringe
The cylinder and pistons are produced by injection molding machines. They are fed by individual granule feeding systems in different parts to be molded. This determines the relevant types and Quantities of raw material to be supplied by the feeding lines. Clamping force, Temperature, Dosing and injection pressure of raw material, and clamping time of the machine are automatically controlled so that disturbance or faults in production should occur very rarely and wastes are kept at the lowest possible rate.
The Scrapes are then separated from the molded parts, which are then transported, to a control channel. A conveyor belt situated below the machine removes the scrapes. For shrinking to their required dimensions. The molded parts are packed into plastic containers or bags and are deposited in an air-conditioned interim storage room for at least one or two days.
After the shrinking is completed, the scales and the product logo are printed on the syringe cylinders by a semi-automatic embossing machine. The feeding is performed manually while printing and discharging are done automatically. The cylinders and the pistons are conveyed to the assembling by means of vibrating feeders. The piston is automatically fitted into the cylinder and is immediately tested for tightness.
The complete syringe is placed by hand into the deep drawing cavities of the blister packing machine for sealing up the single units automatically with the plastic foil. Between 50-250 sealed units (according to delivery demands) are packed into a cardboard box by hand. The boxes are closed, labeled, and subsequently pelletized. After in-process storage over a few days, sterilization is carried out. The autoclave sterilization with ethylene oxide allows the previous packing of the final products ready to be delivered ex-works.
Therefore the cardboard boxes can be placed into the autoclave on pallets but only after being stored under normal conditions for two to three days in order to insured the sterilization effect. This minimum period is a presupposition for the bacteria to reach with the blister foil a certain to reach within the blister foil a certain degree of growth necessary for rendering them innocuous. It is recommended to design the autoclave chamber for one daily production in order to minimize quality controls because bacteriological tests are done batch-wise.
Due to the fact that ethylene oxide is inflammable, the sterilization equipment must be explosion-proof and installed in a separate room. Sterilization of one batch takes about 8 hours. Syringe shall be manufactured in accordance with recognized codes of good manufacturing practice for medical devices and shall be substantially free from defects affecting appearance, safety, and serviceability for the intended use.
Estimated Project Cost of Disposable Syringe Manufacturing Plant
|Plant capacity: 45,000 Nos./Day||Plant & machinery: .70 CR|
|Working capital: 1.5 CR||T.C.I: 2.5 CR|
|Return: 40.00%||Break-even: 35.00%|
The actual cost of the disposable syringe manufacturing project may deviate from a change of any of the assumptions. You can modify the project capacity and project cost as per your requirement.