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How Condoms Are Made And Tested - ONE®

How Condoms Are Made And Tested

If you have read some of our other blog posts you may remember that condoms, in one form or another, have been around millennia. And that over time, they have been made out of all kinds of materials. But have you ever given thought to how a modern latex condom is made?

We at ONE® give a lot of thought to the premium quality of our condoms, and thought it might be interesting to explain just how they’re made. We promise that by the end of this, you will be just as excited about these processes as we are.

For the purpose of this discussion, we’ll focus on external condoms (previously referred to as male condoms) because they are the most widely manufactured. Come on, let’s go!


A Note on Ingredients and Sustainability

Before we talk about the manufacturing process, let’s talk about what goes into our condoms. We at ONE® are committed to using only the most premium, sustainable and quality ingredients out there. Every ONE® Condom that you wear is made with our own proprietary soft and silky smooth latex called Sensatex®. Get it, because of the amazing sensation?

When we make condoms, we’re not only thinking about you as the customer, but we also think critically about our impact on our planet and everyone/everything that shares it with us. When you buy ONE® Condoms, you can be confident that they are non-GMO and vegan-friendly, that the packaging tube itself is actually made completely out of recycled cardboard and that our production facilities are more energy efficient than ever.

All of this is done to make sure that you feel comfortable and protected in using our products. After all, when you use condoms correctly, condoms work to reduce the risk for transmitting sexually transmitted infections (also known as sexually transmitted diseases) and to prevent pregnancy.

To read more about our commitment to creating one-of-a-kind condoms, as well as our commitment to sustainability, please check out more about our sustainability efforts here.

Dipping, Heating, Cooling

Believe it or not, the first step in manufacturing condoms actually involves glass. That’s right! To shape the condoms, cylindrical shaped glass “formers” are dipped in our soft and silky Sensatex® liquid latex.

Fun fact: this is where we can create fun and pleasurable styles of condoms, unique to ONE® Condoms, like the Pleasure Plus® or Super Studs™ condoms. By using special glass formers with special grooves, ribs or studs, we can mold how the condoms are shaped throughout the manufacturing process. This is also the point where you could add a dash of color if you wanted to – which gives certain condoms a different color. Cool, right?

This process is repeated at least two to three times, depending on the style, to ensure that the liquid latex is evenly distributed across the entire surface of the glass and is the proper thickness and strength. Now you know why we discourage using two condoms at once – you’re already getting two powerful layers of latex protection! Between each dip, the condoms are cycled through an industrial oven, and then cooled before being dipped again for good measure.

Drying, Leeching and Tumbling

After the dipping and heating process has been completed, these fledgling condoms are then dried by industrial fans and then pushed through to the leeching process. This process is critical, especially for people who have a latex allergy. Through the leeching process, excess chemical products and proteins formed during the dipping and heating process are removed.

Generally speaking, most people experiencing a latex allergy are actually allergic to the proteins found in latex – leeching removes many of these proteins. (Note: There is also another option besides latex condoms for those with a latex allergy: consider a polyurethane condom!) We use a series of small but mighty water jets to wash the condom, inside and out (quite literally rinse and repeat). This process is also repeated a few times to ensure the condom has been thoroughly cleaned.

Now you have a bunch of very clean, but very wet condoms, now what?! Well, just like a drying machine you might find in your garage or at the local laundromat, the condoms are actually tumbled dry. And voila, you have what we call in the business the “raw” condom! Because the latex is a little sticky in this form, it is powdered and dried (to make sure it doesn’t stick to itself inside the wrapper) within large industrial dryers. We told you it was kind of like laundry!

Testing and Quality Control

No premium product like ONE® Condoms would be complete without rigorous testing and quality control! As a medical device, there are international standards for production that must be upheld, and we at ONE® like to exceed those standards.

Condoms are manufactured in batches. The condoms from each batch are sampled and tested two times during the manufacturing process and a third time once the batch is complete. These tests include the airburst test, freedom-from-holes test, tensile test, dimensional test, and package integrity test. In addition, every condom goes through an individual electronic pinhole test.

  • The electronic tests are simple but rigorous. Condoms are pulled over metal cylinders (called mandrels), placed within an intense electrical field to determine whether there is electric conduction. Because rubber does not conduct electricity, there is no reason any electricity should register for these mandrels. If electricity reaches these mandrels, there is a pinhole or thin spot in the latex and the condom is automatically discarded by the machine.
  • Airburst testing is very aptly named. There is an internationally regulated amount of air pressure and volume that condoms must withstand without breaking. A sampling of condoms from each batch is filled with air (much like a balloon at a party store) until they break. The level of volume and pressure at which each sample breaks are then recorded. If the condoms don’t meet the established acceptance criteria, the entire batch is discarded.
  • There are two types of freedom-from-holes testing. Both include filling the sampling of condoms with water, and testing to see if they leak.
    • The first is an automated test where the condom is filled with salt-water solution and submerged in the same solution. An electrode is applied to the outside and inside of the condom. If a current is detected between the two electrodes, the condom fails.
    • The second is a visual test, where the water-filled condom hangs and is squeezed and visually inspected for leaks by an operator.
  • Tensile testing is done by laying the condoms flat, cutting out a band of latex and using equipment to pull and stretch the band of latex until it breaks. The batch must meet the requirements for tensile strength.
  • Dimensional testing. Condoms are required to meet their established dimensional specifications for length, nominal width and thickness. If the sampling of condoms from the batch is found to be out of specification, the batch is discarded.
  • Package integrity testing happens once the condoms are rolled up and in the wrapper. Using vacuum technology, the sampling of condoms in wrappers is inspected for any packaging holes or leaks. If the sampling of condoms fails the test, the batch is discarded.

See videos and images of the different types of testing here. 

Lubricating and Packaging

Each condom is rolled, and then before inserting into the wrapper, a small drop of lube is placed at the top of the condom. Over time, that one drop slowly disperses down the full length of the condom. But this lubrication process may vary based on the amount of time between the condom’s manufacturing and when the customer uses it.

We decided to innovate! In some of our newer condoms, like MyONE® Custom Fit® and UltraFeel®, we have tapped into our new proprietary technology called TotalGlide®. Wwith TotalGlide®, we use a machine to add lube along the entire length of the condom before it is rolled up, which guarantees that it is smooth and silky from tip to base.

Pretty cool, huh? And don’t worry, if you want to add more you can always check out our great selection of hybrid, water and silicone-based lubricants here and apply as liberally as needed. (Note: We strongly recommend adding extra lubricant during sex, as lube significantly helps reduce condom failure. *Wink*)

From there each lubricated condom is placed within one of our snazzy wrappers (check out some of the condom wrapper designs here), and packaged up for your pleasure in one of our sustainable recycled cardboard tubes!

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