Surgical face masks are made with non-woven fabric, which has better bacteria filtration and air permeability while remaining less slippery than woven cloth. The material most commonly used to make them is polypropylene, 25 grams per square meter (gsm) in density.
25 gsm mask material is made in a spunbond process, which involves extruding the melted plastic onto a conveyor. The material is extruded in a web, in which strands bond with each other as they cool. The 25 gsmhigh-filtration fabric is made through melt-blown technology, which is a similar process where plastic is extruded through a die with hundreds of small nozzles and blown by hot air to become tiny fibers, again cooling and binding on a conveyor. These fibers are less than a micron in diameter and provide the high level (95% or 99%) of Bacteria and Particle filtration required in medical procedures.
Masks are manufactured in a complete automatic machine. The three layers (inner spun-bond non-woven layer, middle melt-blown high filtration layer & outer spun-bond non-woven layer) are folded and ultrasonically welded together to provide a consistent, pleated & sealed design to ensure the designed filtration. The nose-pin is layered and sealed in between the fabrics automatically during the welding process.
Thereafter, the welded masks enter the next machine in process, wherein they are ultrasonically stamped with elastic ear loops. This is followed by a manual Quality Check procedure which is carried out on every mask that is manufactured. Once approved, the same enters the final stage of the process – wherein the masks are UV sterilized without any human contact. Thereafter, the masks are packed in sterilized packets of 50 and sealed in their respective inner & outer boxes.
The production facility is a state-of-the-art setup wherein hygiene, quality & safety are of the essence. All employees employed in the factory are women who are trained and highly-skilled in executing their respective jobs. Admission is only allowed in the premises with prior permission and upon meeting the hygiene guidelines laid out, which include wear of Personal Protective Equipment like hair-nets, gloves, sterilized and static-free coats, safety shoes and safety glasses. These steps are taken to ensure Quality & Reliability resonate in the products that bear the HUNT mark on them.