How Are Condoms Really Made?
Photo by Dainis Graveris on SexualAlpha
Every year, 450 million condoms are sold in the United States. They represent a significant market in the entire world, especially because they're so essential to our sexual health.
And yet, how many of you actually know how male condoms are made?
Tales from Antiquity already talk about devices made of animal bladders used as protection against venereal diseases…
Nowadays, condoms are still the only way to protect you fully from STIs, viruses and bacteria, but also unwanted pregnancy.
How are condoms made?
What materials are used to make condoms?
Condoms are class II medical device, meaning that the companies which produce them have no obligation to list the ingredients used for their fabrication. It makes it very hard to know what really contains a condom...
The little information appearing on condom packages merely mentions their principal ingredient. In fact, most condoms are either made of latex (hevea sap), lamb intestines, polyurethane (a type of plastic), or polyisoprene (a synthetic material).
Then, starting from this base, other ingredients are added. It has been proved that mainstream condoms contain detergents to prevent bacteria from thriving, preservatives that extend shelf-life, anesthetics to decrease sensitivity, other agents that make them smoother…
Alternatively, some brands embrace transparency while choosing to create products free of harmful chemicals. Check out the list of ingredients used to make Green Condom Club condoms. It'll give you an idea of what an eco-friendly condom contains!
Condom manufacturing process: step by step
Let's examine the manufacturing process of latex condoms, from the tree to the finished product.
First, an incision is made in the bark of a rubber tree to collect the milky sap, called latex.
Once stored in tanks, the latex is transformed by adding other ingredients and additives.
After that, glass molds (in the shape of penises) are suspended and dipped inside a tank containing the latex mix.
Once the molds are withdrawn, a fine layer of latex remains on the glass. This film will be the actual condom!
The molds are generally dipped twice, some even three times, to create a strong and thick condom. Between each dip, they go through an oven to be heated (cf. step 7)
Next, the rolled edge of the condom is formed to create a secure fit.
Now, the rubber film is set at a high temperature to dry up. We call this process vulcanization, allowing condoms to be elastic and leak-proof!
After being brushed and cleaned with soap, condoms are taken out of their molds and collected in containers.
They are then rewashed in big washing machines, to rinse out any soap deposits and other residues.
At that point, coating agents are added to improve condoms' smoothness.
Finally, the whole batch of condoms is dried in hot air.
After an electronic test, condoms are inserted in air-tight and light-proof packaging. A drop of lubricant is added before being sealed.
How are condoms tested?
Depending on the manufacturers, different condom testing techniques are performed:
Electronic test for holes
Just before being packaged, the whole batch of condoms is subject to a first electronic test: a high voltage is applied to metallic molds (with the condoms) while rotating on carbon fibers. If the electrical current passes, there is a hole.
After that, only some samples are randomly checked for further inspections. In general, condoms are tested to guarantee a 5-year shelf-life.
Stretching test for strength
This test consists of stretching a condom up to its breaking point: condoms need to be able to extend several times their length.
Some other companies stretch the width of a condom to see how much it can expand. It normally can stretch up to 750% of its original width!
Water test for defects detection
It's an electrical leak test in which condoms are dipped into an electrically conductive liquid.
Air inflation test for elasticity and strength
In this test, condoms are filled with air. To give you an idea, condoms can contain 25 liters of air!
Electronic microscopy testing
This additional test allows spotting defects that are not visible to the naked eye.
Bacterial load measurement
This test makes sure the bacteria on the condom surface are below a certain threshold to guarantee no overgrowth during the shelf life.
Biocompatibility testing
Being a medical device, most condoms are tested on animals after fabrication. To do so, parts of condoms are placed into rabbits' wombs, which are then extracted to observe any vaginal irritation.
How are vegan condoms made?
Well, vegan condoms have a similar process than the one explained above, except that:
Vegan condoms producers don't add casein, which is a protein derived from cow or goat's milk used to make the latex softer. But by using this ingredient, the condom market contributes to the controversial dairy industry.
Vegan condoms are also cruelty-free. Some manufacturers have formulations that do not need to be tested on animals or have found an alternative test to guarantee biocompatibility.
However, it takes a few simple steps to avoid these practices!
To make condoms both vegan and cruelty-free, Green Condom Club uses a higher temperature than other manufacturers, as well as specific formulations and ingredients. Glyde, a company that makes ethical vegan condoms, uses thistle extract to replace casein!
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