DISPOSABLE SYRINGE MANUFACTURING [3531]
Disposable Plastic Syringes are being used by doctors to inject medicines through Intravenous or intramuscular ways for the treatment of diseases & also by research & development personnel. Disposable syringes are made of plastic material and are used in the field of medical and veterinary science. Due to their availability in sterilized condition, ready to use, and cost effectiveness, disposable syringes are fast replacing the age old glass syringes. Moreover, the horror of AIDS worldwide has almost dispensed with the reuse of syringes and the demand of disposable syringes has increased phenomenally. Disposable syringes are mostly injection moulded from polypropylene. Syringes are available in sizes of 1 ml, 2 ml, 5ml and 10ml, 50ml in a variety of designs and consist of either two or three components construction. The number and size of injection moulding machines required depend upon syringe construction, number of mould cavities, annual production. These are made of plastic material have been successfully used in the medical and Pharmaceutical Practice for many years The constantly increasing use of this type syringe Indicates its importance which is based mainly on the advantages it offers regarding cost and hygienic applications. The manufacture of plastic syringes has been developed to such a degree that the products now satisfy the requirements and standards set by the hospitals and physicians. At the same time they offer the best possible technique of applications to the physician and highest possible degree of safety to the patient. Disposable needle is widely used by doctors for injection purpose with the help of syringes. With the increase in population in our country, requirement of medicine and injections has increased. For more strength of people more number of needles are required with syringes. Tablets or capsules also pay a great role in the life of human beings but injections are also a must to some extent. For quick relief, needles are used by surgeons, dental surgeons, Veterinary Surgeons and by the breeders in the poultry farm, where the farm birds are periodically injected against epidemics. During epidemics for better control, disposable needles are of much use. Veterinary Surgeons and doctors find it more useful to use needles as tablets or syrup shall not be helpful. To avoid wastage and to reduce cost by quantity of syrup, needles find a wide scope with the veterinary surgeons/doctors. With the development of pharmaceutical industries the use of syringes and disposable needles will also develop. About 70% pharmaceutical industries are in small scale sector. The output of small scale sector covers a wide spectrum, anti T.B. Drugs, ant dysentery drugs, unit rhenemsties, haematirines, hormonal preparations, tranquilizers, analagesties and anti-Ryrities. Disposable needles are becoming more popular in the medical world due to its lower cost and higher accuracy. Plastic can be used in place of metal without any problem. The procedure is also relatively easy and cheaper. Only one disadvantage is that there is not so much heat resistance as compared to hypodermic needle. Even then the disposable needle has widely replaced hypodermic needle because of lower cost, easy compatibility and higher sterilizations. Whenever a suture is required to close a wound. needles to arm the suture material are necessary. The number of sizes and the variety of different shapes of needles run into many thousands. The range supplied by manufacturers is usually classified into types for specific surgery, as for example. arterial. general purpose. intestinal. obstetric ophthalmic. plastic. retention. Shapes are designated as straight, curved, 1/2 circle, 5/8 circle etc. and the sections as round bodied, triangular cutting edge, triangular reverse cutting point, tracer point. In addition the length of the needle from point to hilt is specified in millimeters and the hilts are designed to take the various diameters of suture material employed. Needles are chosen by the surgeon to suit his operating technique and it is largely because of the surgeons interest in improving suture efficiency that the development of surgical needles has taken place. In very many cases the surgeon himself has caused needles to be made to his own design and a large number of commonly used needles are referred to by the name of the inventing surgeon. Surgical needles are of two types : those which have an eye through which the suture is threaded and eyeless needles where the suture is inserted into the hollow hilt and held in position by swaging the metal around it. The first patent on an eyeless needle was obtained by the late Sir Henry Souttar in 1921. but in the U.K. their use has only increased appreciably in the past few years. In the U.S.A. 70 percent of the suture needles are of the cycle’s type. The needles themselves are made either of stainless steel or of carbon steel, the latter usually being plated to resist corrosion. At one time the carbon steel needle had a better resistance to bending than its counterpart in stainless steel but recent technological advance hare is proved stainless steel needles and they now compete in strength with carbon steel and have added advantage that they will not corrode and do not present the surgeon with the dreaded emergency of having to locate and extract the broken point of a needle embedded somewhere in the tissues of an unfortunate patient.
COST ESTIMATION
Plant Capacity 30000 Nos/Day
Land & Building (1000 sq.mt) Rented
Plant & Machinery Rs. 1 Cr
Working Capital for 1 Month Rs. 11.30 Cr
Total Capital Investment Rs. 1.20 Cr
Rate of Return 33%
Break Even Point 64%
INTRODUCTION
DISPOSABLE SYRINGE
DISPOSABLE NEEDLE
USES AND APPLICATION
B.I.S. SPECIFICATION
MARKET POSITION
60% OF SYRINGES IN INDIA UNSAFE STUDY
EXIM SCENARIO IN INDIAN SYRINGES AND NEEDLES MARKET
PRODUCTION OF SYRINGES AND NEEDLES
APPROACHING AD SYRINGES
THE DEMAND
THE BIG PROBLEM
NEW KIDS
THE UNEXPLORED TERRITORY
STATE WATCH
CHINA IS HERE TOO!
TACKLING COST ISSUES
NEED A DESPERATE CHANGE
NEED FOR EDUCATION
INTO THE FUTURE
MARKET SURVEY (GLOBAL)
INDUSTRY INSIGHTS
U.S. DISPOSABLE SYRINGES MARKET SHARE, BY TYPE,
2013 - 2024 (USD MILLION)
PRODUCT INSIGHTS
APPLICATION INSIGHTS
REGIONAL INSIGHTS
COMPETITIVE INSIGHTS
BASIS AND PRESUMPTION
MANUFACTURERS/SUPPLIERS OF DISPOSABLE SYRINGE
PROPERTIES
SHAPE AND DIMENSIONS OF NEEDLE
UNION BETWEEN THE HUB AND THE NEEDLE
SAMPLING PROCEDURE AND CRITERIA FOR CONFORMITY
SAMPLE SIZE AND CRITERIA FOR CONFORMITY
DISPOSABLE SYRINGE TECHNCAL ANALYSIS
PRODUCTS
MATERIAL
STANDARDS (IN ACCORDANCE WITH ISO7886)
STERILIZATION
INDIVIDUAL PACKAGE
LABELING
ADVANTAGE OF I KM DISPOSABLE SYRINGE
STEPS IN DISPOSABLE SYRINGE MANUFACTURE
MANUFACTURING PROCESS
FREEDOM FROM PYROGENIC MATERIAL
TEST FOR ABNORMAL TOXICITY
FREEDOM FROM EXTRANEOUS MATTER
LIMIT FOR EXTRACTABLE MATTER
LIMIT OF ACIDITY AND ALKALINITY
LIMIT FOR EXTRACTABLE MATERIAL
LUBRICANTS
SIZE AND DIMENSION OF THE SYRINGE
NOZZLE
GRADUATION POSITION OF SCALE NUMBERING
FLANGE OF BARREL OR FINGER GRIPS
PISTON
DEAD SPACE VOLUME
MAXMUM DEAD SPACE
LEAKAGE TEST
LEAKAGE TEST BETWEEN BARREL AND PISTON
STERILITY”
PACKING
OUTER CONTAINER
MARKING OF CONTAINER
MARKING OF OUTER CONTAINERS
LEAKAGE TESTING
ACCEPTANCE CRITERIA
PROCEDURE
ACCEPTANCE CRITERIA
THE TEST SHALL BE FOLLOWED AS BELOW
PROCESS FLOW DIAGRAM OF DISPOSABLE PLASTIC SYRINGE
DETAILS OF PLASTIC PART PROCESSING AND STERILIZATION
GASEOUS STERILIZATIONS WITH ETHYLENE OXIDE
MIXTURES
FACTORS INFLUENCING ETHYLENE OXIDE STERILIZATION
TEMPERATURE
CONCENTRATION
MOISTURE
STERILIZATION CONCEPTS
TEST FOR STERILITY
CAUTION
MEDIUM FOR AEROBIC ORGANISM
MEDIUM FOR AEROBIC ORGANISM
METHOD
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
POLYPROPYLENE
SUPPLIERS OF STAMPINGS
SUPPLIERS OF ETHYLENE OXIDE
SUPPLIERS OF PACKING PAPER
SUPPLIERS OF PACKING BOXES
SUPPLIERS OF PVC PLASTICS
NEEDLE
SUPPLIERS OF PLANT & MACHINERY
MOULDING MACHINE
SUPPLIERS OF PRINTING MACHINE
SUPPLIERS OF STERILIZING PLANT
SUPPLIERS OF PACKAGING MACHINE
SUPPLIERS OF WEIGHING MACHINE
SUPPLIERS OF INJECTION MOULDING MACHINE FOR DISPOSABLE
PLASTIC SYRINGE
SUPPLIERS OF PLANT AND EQUIPMENTS
FOR DISPOSABLE SYRINGE/TURNKEY CONSULTANTS
SUPPLIERS OF MOULDS FOR DISPOSABLE SYRINGE
SOURCE OF TECHNOLOGY
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)