Scaling respiratory device production for the medical industry with KraussMaffei injection moulding technology

Intersurgical, a globally recognised leader in the medical industry, specialised in the design, manufacture, and supply of an extensive range of respiratory support devices. During the global health crisis, they encountered a pressing challenge: the need to rapidly scale up production to meet an unexpected surge in demand for crucial respiratory products. Items such as oxygen masks and respiratory filters became essential for protecting both patients and healthcare workers. 

Following the closure of its primary factory in early 2020, Intersurgical faced the daunting task of significantly increasing its production capacity. This had to be achieved while maintaining high standards of precision, product quality, and rapid cycle times, all within the constraints of a cleanroom manufacturing environment. To overcome this challenge, Intersurgical turned to KraussMaffei, seeking their expertise and solutions to meet these demanding requirements. 

About Intersurgical: Founded in 1982, Intersurgical has grown from a small family business in the UK to a global leader in respiratory care solutions. With over four decades of experience, they have established themselves as an essential partner for healthcare providers worldwide, now serving more than 100 countries. 

Their journey began with a vision to meet the growing demand for innovative, high-quality respiratory products. From their initial focus on the UK market with a limited product range, they have expanded through continuous innovation and market development. Today, Intersurgical is proud to offer an extensive portfolio of respiratory care products, positioning them at the forefront of the hospital sector globally. More about Intersurgical https://www.intersurgical.com/

Challenge 

As the global health crisis spread, the demand for critical respiratory products, such as oxygen masks and respiratory filters, surged dramatically. These products have been essential in protecting patients and healthcare providers, and preventing cross-contamination during ventilation and anaesthesia. With the closure of the first factory in February 2020 due to the pandemic, Intersurgical urgently needed to boost its production capacity significantly. The challenge had been multifaceted: maintaining excellent product quality, ensuring high precision, achieving fast cycle times, and doing so within a cleanroom manufacturing environment—all while adhering to extremely tight delivery schedules amidst global travel restrictions. 

Solution 

To address these challenges, Intersurgical had turned to KraussMaffei, a trusted partner known for its high-tech injection moulding solutions. KraussMaffei had provided an ideal mix of machines, including the CX, CX ClassiX, and PX series, equipped with multicomponent technology. This combination offered the precision, efficiency, and reliability needed to meet Intersurgical’s stringent requirements. 

One of the key machines delivered was the CX 200 with an electric turntable, capable of producing high-quality oxygen masks with exceptional speed and accuracy. The CX 200 featured a clamping force of 2,000 kN, screw diameters of 35 mm and 30 mm, and a cycle time of just 18 seconds, ensuring rapid production without compromising on quality. The machine’s design had been perfectly suited for cleanroom manufacturing, an essential requirement for producing medical-grade products. 

Implementation 

Despite the logistical challenges posed by the global health crisis, KraussMaffei demonstrated exceptional agility by delivering and commissioning the equipment in record time. The CX 200 had been swiftly installed at Intersurgical’s facility in Lithuania, where it had begun producing oxygen masks using a four-cavity mould. The mould produced two halves of the oxygen mask from polypropylene (PP) and thermoplastic elastomer (TPE) materials, ensuring durability and comfort for the end users. 

The implementation process had been smooth and efficient, enabling Intersurgical to rapidly scale up production. The increased capacity had allowed the company to meet the heightened demand for respiratory products, ensuring that hospitals and governments worldwide received the necessary equipment promptly. The collaboration between Intersurgical and KraussMaffei had not only enhanced production capabilities but also improved cost-efficiency, helping Intersurgical navigate the uncertainties of the pandemic. 

Conclusion 

Intersurgical’s partnership with KraussMaffei during the global health crisis exemplified the power of collaboration and innovation in overcoming extraordinary challenges. By leveraging advanced injection moulding technology, Intersurgical had significantly increased its production of life-saving respiratory devices, ensuring that healthcare providers could continue to deliver critical care to patients worldwide. The rapid response and effective solutions provided by KraussMaffei played a pivotal role in helping Intersurgical maintain its commitment to quality and precision, even in the face of a global health emergency. 

Are you looking to enhance your production capabilities with cutting-edge injection moulding technology? 

Contact Headland to discuss how KraussMaffei’s solutions can meet your medical manufacturing needs and speak with our injection moulding experts.