CATHETER MANUFACTURING
[EIRI/EDPR/4527] J.C.: 2744XL
INTRODUCTION
A catheter is a flexible tube made of latex, silicone, or Teflon that can be inserted into the body creating a channel for the passage of fluid or the entry of a medical device. For many years, the epidermal catheters used were plain tubes made of available industrial compounds, and design was largely based on current need. In the 1950s and early 1960s, a very common practice was to cut a suitable length of industrial polyvinyl chloride (PVC) or nylon tubing and have it sterilized with the other surgical equipment. Nowadays, there are many specialized catheter designs. For example, specific catheter designs allow catheters to be used in pulmonary, cardiac (vascular), neonatal, central nervous system, and epidural tissues. Catheters are designed to perform tissue ablation (tissue removal) and even serve as conduits for thermal, optics, and various medical devices.
The three major types of catheters are coronary, renal, and infusion. Coronary catheters are used for angiography (x-ray of blood vessels after injection of radiopaque substance), angioplasty (altering the structure of a vessel), and ultrasound procedures in the heart or in peripheral veins and arteries. The best-known renal catheters are Foley catheters, which have been commercially available since the 1930s. These catheters are equipped with an inflatable balloon at the tip and are used for urine incontinence, dying patients, and bladder drainage following surgery or an incapacitating injury or illness. The Foley catheter is relatively easy to use and used throughout the world in hospitals, nursing homes, and home-care settings.
Catheters are flexible, hollow tubes which allow blood to flow in and out of your body. They are most commonly used as a temporary access for up to three weeks. This is often done when a patient needs dialysis immediately and is waiting for a fistula or graft to mature. They are also used when a permanent access fails and a patient is too unstable to delay treatment. Several different types of catheters exist. Or we can say that a catheter is a tube put into the body, usually by a medical person, to let fluids drain out. It is often used when the person cannot urinate, as during and right after surgery.
It can also be used to drain pus or blood out of a wound. It is very bad to reuse one as it can have germs on it from the first use. It must be inserted in a very sanitary method so as not to introduce germs into the person. Many folks that have illnesses that makes it difficult to urinate must have them in all the time and sometimes get urinary tract infections if they are not changed often and in a safe manner.
COST ESTIMATION
Plant Capacity 7500 Nos./Day
Land & Building (4000 sq.mt.) Rs. 2.78 Cr
Plant & Machinery Rs. 3.25 Cr
Working Capital for 2 Months Rs. 1.70 Cr
Total Capital Investment Rs. 8.18 Cr
Rate of Return 27%
Break Even Point 61%
CONTENTS
INTRODUCTION
CATHETER LENGTH, SIZES & TYPES
CATHETER LENGTH
BALLOON SIZE
TYPES
DIAMETERS:
STRAIGHT-SINGLE USE CATHETERS
2-WAY FOLEY CATHETERS (RETENTION CATHETERS)
CURVED OR COUDE
3-WAY FOLEY CATHETER
BRIEF DESCRIPTION OF CATHETER
DIALYSIS CATHETER
THE LINE CAN BE USED FOR:
PERIPHERALLY INSERTED CENTRAL CATHETER (PICC)
TUNNELED CATHETERS
UROLOGY CATHETER
CENTRAL VENOUS CATHETER
RAW MATERIALS
DESIGN
SILICONES
POLYVINYL CHLORIDE
LATEX RUBBER
CHEMICAL COMPOSITION OF LATEX
USES, ADVANTAGES & DISADVANTAGES
ADVANTAGES OF CVC FOR DIALYSIS:
SHORT TERM OPEN ENDED CATHETER
PERIPHERALLY INSERTED CENTRAL CATHETER
TUNNELED CATHETERS
IMPLANTABLE VENOUS ACCESS DEVICES
CENTRAL VENOUS CATHETER
TYPES OF CENTRAL VENOUS CATHETERS
THE TYPE OF CVC INSERTED DEPENDS ON THE:
CENTER VENOUS CATHETERS: OPEN-ENDED OR CLOSED-ENDED
OPEN–ENDED
CLOSED-ENDED
SHORT-TERM CATHETERS
IMPLANTABLE VENOUS ACCESS DEVICE (IVAD)
INDIAN DISPOSABLE CATHETER MARKET
THE MAJOR PRODUCTS OF DISPOSABLE CATHETERS ARE:
THE MARKET CAN BE BROADLY CATEGORISED ON THE BASIS OF ITS END USES INTO:
BY DISTRIBUTION CHANNEL, THE MARKET IS DIVIDED INTO:
KEY INDUSTRY PLAYERS IN THE INDIA DISPOSABLE CATHETERS MARKET
GLOBAL MARKET OF CATHETER
CATHETERS INDUSTRY SEGMENTS
CATHETERS MARKET TRENDS
CATHETERS MARKET COMPETITOR ANALYSIS
CATHETERS MARKET TOP PLAYERS
LSR (LIQUID SILICONE RUBBER)
PROCESS OF LIQUID SILICONE FOLEY CATHETER
TECHNOLOGY OF CATHETER
PROCESSING COATED CATHETERS
PROCESSING STEP OF FOLEY CATHETER
A FOLEY CATHETER
PHOTOGRAPHS
MELT PUMPS
MELT PUMPS WITH MULTI-LAYER DIE
OPEN CALIBRATION TANK
BALLOON FORMING MACHINE
DUAL FLUTING AND WRAPPING MACHINE
TWO-LAYER HIGH-PRECISION STRAND LINE
WINDER, HAUL-OFF WITH DIAMETER CONTROL & VACUUM CALIBRATION
DIE & CARRIAGE, PREHEATING SYSTEM & UNWINDER FOR SUPPORTING WIRE
CONTROL SYSTEM
CATHETER DESIGN AND MATERIALS
MATERIAL DIFFERENCES
CATHETER DESIGN
TIP DESIGN
FIGURE: LEFT: PREFORMED TIP OF GROSCHONG CATHETER, MIDDLE: DOUBLE LUMEN (9.5 FR) HICKMAN CATHETER WHICH IS CUT TO LENGTH BY OPERATOR; RIGHT: CUT END OF SILICONE PORT CATHETER. NOTE RELATIVELY THICK WALLS DUE TO LOW TENSILE STRENGTH OF SILICONE. ALL ARE INSERTED THROUGH A PEEL AWAY SHEATH.
LEFT: PREFORMED SOFT TIP OF MULTIPLE LUMEN CATHETER
CATHETER OVER NEEDLE DEVICES
CATHETER THROUGH NEEDLE/CANNULA
NEEDLE DESIGN
CATHETER SIZE
FIGURE: CROSS SECTION OF TWO DOUBLE LUMEN CATHETERS (A AND B), AND TWO TRIPLE LUMEN CATHETERS (C AND D) SHOWING DIFFERENT ARRANGEMENTS OF LUMENS
MULTILUMEN CATHETERS
HUB OPTIMIZATION AND INTEGRATION OF HIGH-PERFORMANCE CATHETERS
TUBING ASSEMBLY
HUB-CATHETER
STANDARD HUB SPECIFICATIONS
BOND STRENGTH
HUB DESIGN AND MANUFACTURING OPTIMIZATION
LIQUID SILICONE FOLEY CATHETER MANUFACTURING EQUIPMENTS AND CATHETER MOULD
VERTICAL LIQUID SILICONE RUBBER (LSR) INJECTION MOLDING MACHINE
ABOUT MACHINE
OTHER MACHINE STYLE:
THE MAIN FEATURE OF THE VERTICAL LSR MOLDING MACHINE:
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
SUPPLIERS OF OPEN CALIBRATION TANK
SUPPLIERS OF TWO-LAYER HIGH-PRECISION STRAND LINE
SUPPLIERS OF WINDER
SUPPLIERS OF HAUL-OFF WITH DIAMETER CONTROL
SUPPLIERS OF VACUUM CALIBRATION
LIST OF EQUIPMENTS (MACHINERIES) FOR CATHETER THROUGH EXTRUSION PROCESS
MAIN COMPONENTS OF A CATHETER EXTRUSION LINE
EXTRUDER
MELT PUMPS
GRAVIMETRIC FEEDING
DIES
VACUUM CALIBRATION AND COOLING
DIAMETER CONTROL
WINDERS
CUTTING UNITS
ALTERNATIVELY, CUTTING SYSTEMS PROVIDE THE FOLLOWING:
UNWINDER FOR SUPPORTING WIRE
PREHEATING SYSTEMS
PROCESS CONTROL WITH PROTOCOL LING
CLEAN-ROOM CONDITIONS
TWO-LAYER HIGH-PRECISION STRAND LINE
CONTROL SYSTEM
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
