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Specifications For Wound Care Manufacturing

Author: Robert Smith
by Robert Smith
Posted: Jul 02, 2015
wound care

There are literally hundreds of wound care products on the market. These products may be used by individuals, in medical treatment facilities, hospitals, nursing homes and many other places. The high volume of use has made wound care a billion-dollar industry in the U.S. alone. Due to an increasing population and an increase in aging population, the demand for wound care products is booming. Wounds vary in seriousness and the type of products needed to care for them. There are six basic causes of wounds including:

  1. Surgical
  2. Diabetic
  3. Arterial
  4. Trauma
  5. Venous
  6. Pressure

Wounds also vary in type according to tears, punctures and cuts. Regardless of the type and severity of the wound, one thing that remains constant is the need for sterile treatments that will not contaminate the wound. This is where the process of wound care manufacturing comes into play.

How Wound Care Products Are Manufactured

Die cutting is a manufacturing process using dies to cut shapes out of different types of materials when the same shape is used time after time. The dies are actually blades that are made in the desired shape and then mounted to a strong, solid backing. As the material us run through the die cutting machine, the die cuts the shape out of the material by pressing it between the blade and the flat surface beneath. The blade may be used to cut through a single layer or multiple layers. After cutting, the materials are shaped and/or put together to create the final product. Die cutting is performed with specially designed machines like those at Baril Corporationt.

The Issue of Waste

The design of the dies should take the best possible use of the materials into consideration. Ideally, there should be as little waste as possible. Most companies that use die cutting as part of their process or which perform die cutting services for other businesses will make arrangements for the disposal or recycling of excess materials with the latter being the preferable option.

Clean Room Die Cutting

Wound care manufacturing is performed using clean room die cutting. The goal of this manufacturing process is to create a sanitary environment that is detrimental to the production of safe, secure products that can be used on all types of wounds. The clean room also offers humidity and temperature control. Different ISO ratings have different specifications in determining how a clean room should be designed and maintained for specific uses. Ideally, a clean room that is used in wound care manufacturing should be designed for the following operations:

  • Sterile packaging
  • Assembly and inspection
  • Rotary die cutting
  • Flatbed die cutting
  • Multi-layer laminating
  • Ultrasonic part cleaning

The area of wound care has advanced significantly from the bandages and tape of old. Today, products are designed and created with various properties such as antimicrobial action, moist products or those which exudate absorption. This diversity of characteristics provides challenges to the companies involved in wound care manufacturing. Wound care products and those used in various areas of the medical industry require uncompromising precision and environment control. The quality of the product and its ability to serve its use according to specification relies on the ability of the manufacturer to create a precise procedure in a clean environment.

The development of new wound care products often comes on the heels of new discoveries through observation or research. For example, it was discovered late in the 20th century that wounds heal faster when they are kept moist instead of being exposed to air. As a result, occlusive wound dressings began to be manufactured that would maintain a moist environment conducive to healing. Today, these dressings have advanced to increase the speed of re-epithelialization, boost collagen synthesis, and create an environment that discourages the growth of bacteria. In addition to better healing, this style of dressing is also less likely to result in scarring.

Even the simplest wound care products require special care during the manufacturing and packaging process. Bandages that contain an anti-microbial agent can help minor wounds heal faster and reduce the potential for infection that could result in a much more serious condition.

The Part of ISO in the Process of Wound Care Manufacturing

The International Organization for Standardization (ISO) is an independent developer of voluntary international standards, and the largest organization of its kind. It consists of 163 countries and produces standards that make things work. Implementing ISO standards into any manufacturing process results in processes and products that are of higher quality, safer, and more efficient. ISO is at the heart of international trade, creating a consistent set of variables that make it easy to recognize and implement new products in almost any industry.

The Importance of the Die Cutting Process in Wound Care

The die cutter performs the same job in a clean room that it does in any other manufacturing process with the exception that it does so in a carefully controlled environment. Equipment such as the cutting die may be identical except that there will need to be considerations in how contaminants are avoided. Some situations incorporate the use of an autoclave to produce high pressure steam to kill any bacteria that may be present on the machine. Stainless steel blades should always be used because of their ability to withstand constant exposure to high temperature steam without producing rust that can contaminate the products. Unlike the cutting surface in a regular die cutting process, wood cannot be used and should be limited only to those made of stainless steel. The room also needs to be controlled for temperature and humidity to discourage the growth of bacteria. Minute particles are kept out through a controlled air system which also incorporates filters for optimal air quality.

One of the most significant considerations in wound care manufacturing is employing an experienced staff who understands the process and the steps required to keep the clean room sanitized. Their actions, such as entering and exiting the clean room, will affect the condition of the room and the end result of the products they are working on. A top quality die cutting company that specializes in clean room die cutting should be your first choice for any type of wound care manufacturing.

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Author: Robert Smith
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Robert Smith

Member since: Mar 26, 2014
Published articles: 313

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