Patient care

Roll-to-roll converting is a highly efficient and automated process for the conversion of flexible materials like paper, film, and foil. This method involves the continuous unwinding of a large roll of material, which then undergoes various operations such as printing, coating, laminating, cutting, and slitting, before being rewound into smaller rolls of the desired width or length.

Roll-to-roll converting offers several key benefits that make it a preferred method in various industries. Some of these advantages include:

1. Efficiency: The continuous process allows for high-speed production with minimal downtime, maximizing output and reducing manufacturing costs.
2. Precision: Roll-to-roll converting ensures consistent and accurate results, maintaining product quality and meeting specific dimensional requirements.
3. Customization: The method allows for easy integration of various operations such as printing, coating, and laminating, enabling the customization of products to meet specific needs and preferences.
4. Reduced Waste: By minimizing material waste during the converting process, roll-to-roll operations contribute to cost-effectiveness and environmental sustainability.
5. Scalability: The technique is easily scalable, making it suitable for both small-scale and large-scale production, providing flexibility for businesses to adjust production volumes as needed.

PolarSeal possesses the capacity to fulfill various demands in the healthcare sector, catering to a broad spectrum of applications. Our expertise enables us to offer cost-effective solutions tailored to your specific product requirements. The consumer demand for personal care products spans a wide array, including:

• Blister Dressings 
• Foot Care Products 
• First Aid Dressings
• Podiatry Applications
• Cosmetic Patches
• Transdermal Patches
• Hydrocolloid and Hydrogel Blister Pads
• Aromatherapy Patches
• Eye Patches
• Hydrogel Dressings

PolarSeal leverages a diverse range of in-house capabilities to offer comprehensive service solutions for our clients. Our streamlined approach to manufacturing large quantities of consumer healthcare products is enhanced through the following techniques:

1. Precision Material Slitting: We expertly slit master rolls to exact specifications, ensuring optimal material efficiency and minimizing waste.
2. Precision Cutting: Our cutting tools maximize material use, crafting components precisely according to your specifications.
3. Expert Laminating: Utilizing specialized processes and our industry knowledge, we proficiently laminate multiple layers of materials for your product.
4. In-House Printing: With our internal printing capabilities, we can imprint your brand on the product itself or the packaging, making it easily recognizable as yours.
5. Efficient Packing and Pouching: By integrating our manufacturing lines, finalized products seamlessly transition to our pouching line for packing, palletizing, and subsequent distribution to your preferred location.

• Lamination of multiple layers
• Precision die cutting of intricate component parts
• Flexographic and product marking for instructions and branding
• Full assembly of devices
• ISO 7 cleanroom converting
• Packing of devices into pouches or cartons

PolarSeal works with you through the design and product testing process to confirm the correct adhesives to use on a wearable device from Silicone Gels to Low Trauma Hydrocolloids. We ensure the adhesive and material are:

1. Skin-friendly
2. Breathable (requirement dependent)
3. Absorbent
4. Repositionable
5. Sterile
6. Cooling

PolarSeal specializes in delivering affordable adhesive solutions tailored for the efficient mass production of everyday consumer healthcare items, ranging from blister dressings and first-aid components to hydrogel dressings, regardless of specific product intricacies. With extensive industry expertise spanning decades, we possess a keen understanding of consumer demands, allowing us to collaborate in crafting premium-grade components.

By comprehensively grasping market dynamics and client requisites, PolarSeal facilitates the manufacturing process, including parts production, packaging and pouching, as well as providing labeling and printing services for easy product identification. Our comprehensive capabilities extend to supporting the development and production of various items, from cosmetic tube filling to standard plasters and dressings. We manage the entire product lifecycle, from initial concept to final delivery, thereby streamlining the time-to-market process for your essential products.