Critical Components Of A Surgical Face Mask-Making Machine

With the heightened levels of risk of infection by the COVID-19 virus that has become a global pandemic and the ultimate source of fear, you must find meaningful ways to stay safe and protected. Medical professionals, especially surgeons, need a way to protect themselves and their patients during surgeries and other clinical operations.

face mask machine structure   

Surgical face masks are created to catch and retain any aerosols and liquid droplets that contain bacteria released from the mouth or nose of the medical personnel. The best surgical face mask making machines are a critical component of good mask design, weaving, and finishing. In this way, surgical masks prevent contamination of wounds during surgeries, and sterile rooms containing critical patients who may die from the slightest infection or illness.

An important point to note about surgical face masks is that they are not designed to catch any viruses and bacteria before the wearer of the cover can inhale the pathogens. It has been shown that when it comes to protecting the surgical mask wearer from infection from airborne contaminants and pathogens, surgical face masks offer zero protection.

The more viable solution in this instance would be N95 masks. These are manufactured specifically to keep out viruses, smoke, smog, pollen, and bacterial pathogens from the respiratory system of the mask wearer because of their tight sealing, enhanced material, and well-designed shape. FFP masks are also an excellent alternative to N95 covers. A melt blowing technique is used to create surgical face masks. A majority of the materials that are utilized in making surgical face masks consist of non-woven fabrics. Let’s focus on the vital elements of a surgical face mask-making machine.

mask making machine 3ply face mask

Materials required in bulk production of surgical face masks

The majority of surgical masks consist of three carefully laid-on layers. The three layers are obtained from the placement of melt-blown material inside the layers of non-woven fabrics; the melt-blown content is the active filtering component. It works to block airborne microbes from either going into the wearer’s system from the environment or going into the environment from the wearer’s respiratory system.

The pleating design of masks allows the wearer the option of extending the hood down to cover the area from the nose down to the chin. Accommodating surgical face mask designs will allow the wearer to secure the mask in three different ways:

  • Headbands – these are elastic straps that are fastened behind the wearer’s head.
  • Earloop – a string attached to the outer edges of the mask is placed discreetly behind the ears to support the cover on the face.
  • Tie-on strapping – these are usually non-woven straps (two or four) that are tied behind the head of the person wearing the mask.
blank mask machine
blank mask machine

Popular materials used to craft surgical face masks include:

  • Melt blown materials such as polypropylene act as the filtration components of surgical face masks, blocking the entry or exit of airborne microbes through the cover.
  • Non-woven fabric

In these types of fabric, there is no dependence on yarn interlacing to produce internal cohesion. Non-woven fabrics also lack an organized geometrical formation. Every single fiber joins to another in a relationship that forms the overall material.

 

Properties of non-woven fabrics used to produce surgical face masks

  1. A majority of non-woven fabrics are considered disposable products.
  2. These fabrics are usually either bonded or felted together to create the finished product.
  3. Products manufactured from non-woven fabrics are considered disposable in many cases.
  4. In the textile industry, non-woven fabrics are used to strengthen other materials and assisting in sewing and interfacing with foreign substances.
  5. If the fabric is laminated, it is usually bonded with heat and glue instead of being non-woven.

The most outstanding properties of non-woven fabrics that allow them to be used in surgical face masks include:

  • Softness
  • Absorbent qualities
  • Ability to be sealed by heat
  • Lint-free
  • Easy to breathe through
  • Flame resistance
  • Durable, stiff, and moldable
  • Drapable and water repellent

Bonded fabrics used in making surgical face masks are created through direct spinning, dry laying, and wet laying.

For the felted non-woven fabrics, wool is a great option and is made using short fibers from animal hairs.

Vital elements of a surgical face mask-making machine

Given the fragile state of the global medical scenario, it is imperative for as many people as possible to own high-quality face masks. The surgical mask making industry is experiencing never before seen profitability levels. As a mask maker, you can choose one of two routes: using an automated surgical face mask making machine, or you can create the face masks by hand.

Opting to make masks by hand will cost you a lot of time and effort spent laboring away to cut fabric, add layering of non-woven material, and finally seal the covers. On top of that, there are quality checks that determine the efficacy and reliability of every mask before you sell them off to unsuspecting members of the public. Selling substandard covers to people may warrant jail time or steep fines. The more natural way is to use an automated surgical face mask making machine.

Making masks using machines is capital intensive. Fewer people are required, so it saves you time and money in the long run. All you need to start producing masks on machines is the device itself and space on which to put the machine. As for raw materials, non-woven fabrics and other components of surgical masks can be obtained throughout the year. The mask-making industry is attractive to new entrepreneurs due to minimal labor, resource, and operational costs.

You can now obtain face mask machines that are highly customized to produce different surgical mask designs. The most efficient devices and tools are standard machinery, automatic, or semi-automatic options. A majority of these machines also come equipped with precision blades for cutting fabric into neat pieces.

Adjustable components allow the designer to fabricate masks of any size. In addition to this, top of the line machines such as the Deqi machine from deqimachine.com also includes ear loop welding devices. The Deqi machines can also carry out automated material feeding, blank mask cutting and folding, nose clip welding, and earloop binding.

3ply disposable face mask

Conclusion

Face masks have become an essential tool for survival in the age of the Corona epidemic. For the discerning entrepreneur, a high-quality, excellent surgical face mask making machine is required to produce superior face masks in bulk. Always ensure that the device you select has the correct components to allow for fast mask production.

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