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How Are Condoms Made?

Air Burst Test Dipping Pinhole Testing
1. Tapping of Rubber Latex
Natural latex comes from the rubber tree (Hevea Brasiliensis). Special cells in the tree, called laticifers, produce latex, a milky substance that drips from scores made on the tree. Rubber trees are cut at night when humidity is high, so the flow lasts longer before the cut dries. One rubber tree yields 1/2 to 3/4 of a cup of latex each night before the cut stops dripping. The latex is collected in the early morning.
2. Latex Tank
After collection, the raw latex is stored in a latex tank. Here the temperature can be carefully controlled to maintain the proper characteristics. Latex tanks are also used for transporting and storing latex before processing begins.
3. Ensuring Latex Quality
Before the latex is used to produce condoms it undergoes many critical tests. Technicians test and analyze latex for quality and purity before it is used to make condoms. The quality of latex determines the elasticity and strength of the condom. Only the highest grades of latex can meet the specifications for manufacturing Kimono condoms.
Compounding Dipping Pinhole Testing
4. Latex Compounding Process
Compounding is a process in which our special formulations are added to the latex to strengthen, preserve, and make Kimono condoms ultra thin and strong. Several unique and secret compounds are used to make Kimono condoms. Shown here is one of several mixers in which latex compounding takes place.
5. Latex Dipping Process
After the latex is compounded, it is dispersed in a dipping tank. Shafts called "mandrills" create the shape of the condom. The mandrill is dipped into the latex which picks up a thin layer of latex. After dipping, the mandrill passes through special temperature controlled drying and curing ovens that help strengthen the condom. In addition, there are several other special technologies employed during the dipping process to create the distinctive quality of Kimono condoms.
6. Individual Condom Testing
After production, the condoms are tested. One by one, each and every condom is electronically tested. In this test, condoms are placed over metal forms that are sent through an electrical field. The insulating characteristic of rubber allows this test to find microscopic pinholes and weak spots, through which electricity can pass and be detected. Pinhole testing ensures that all Kimono condoms are of the highest quality before wrapping.
Wrapping Packaging Packaging
7. Wrapping Condoms
Condoms are lubricated and hermetically sealed. Each condom is enclosed in its distinctive Kimono wrapper.
8. Packaging Condoms
Packaging is the final step in the production of Kimono brand condoms. Foil wrappers are collected and boxed into their elegant Kimono package.
9. The Final Product
Kimono condoms are now complete. This combination of sophisticated Japanese engineering, and  premium natural rubber latex processed with state of the art technology results in a more reliable, and incredibly thin condom.

Additional Condom Testing

Even though the condoms are complete they are not yet ready for shipping. Because safety is essential for every Kimono condom user, before Kimono condoms are shipped, they must undergo a series of strength and quality tests. Kimono condoms must not only meet all US and International safety standards, but exceed them as well. Below are a series of stringent tests preformed on Kimono condoms to ensure only the most reliable condoms make it into stores.

Air Burst Test Water Burst Test Tensile Test
Condom Air Burst Test
Condoms are placed over air tubes, secured, and placed under air pressure. The amount of air the condoms can hold and the air pressure they can withstand before bursting help to determine their overall strength. The results are recorded and weighed against national and international standards. Latex condoms can expand to hold 18 liters (5 gallons).
Condom Water Burst Test
In this test, a condom is tested to see that it is able to hold water. Water stretches the front of the condom and weighs it down. Its ability to contain the water and withstand the forces on it is evaluated. The results are judged against national and international standards to ensure the highest quality.
Condom Tensile Test
Clamps grip segments of the condom and pull it apart. The point at which the condom snaps is recorded and reviewed to make sure that it surpasses both national and international standards. Latex condoms can stretch up to seven times their normal length. Such testing ensures the condom has the necessary elasticity and strength.
Aging Test Water Leak Test Kimono MicroThin 12ct
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Condom Aging Test
Through special oven chambers simulation is created to mimic the effect of time on the condom. The photo shows a special oven used to control temperature and environment during this test. The results help ensure that latex condoms, when stored properly, will perform reliably.
Condom Water Leakage Test
Condoms are randomly selected from production lots and tested to ensure that there are no holes. They are filled with water and blotted to make sure no water leaks out.
     

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