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DESIGN AND MANUFACTURING OF PERSONAL PROTECTIVE EQUIPMENT (PPE)

IN NEPAL

Technical Report · May 2020

DOI: 10.13140/RG.2.2.31658.03523

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 DESIGN AND MANUFACTURING OF PERSONAL
PROTECTIVE EQUIPMENT (PPE) IN NEPAL

PREPARED BY

SARVESH PANDEY
ME (HYDROPOWER)
21162

A REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE CREDIT

REQUIREMENT IN PANDEMIC FOR MEEG 213

PREPARED FOR

SURENDRA SUJAKHU, PhD

DEPARTMENT OF MECHANICAL ENGINEERING
KATHMANDU UNIVERSITY
DHULIKHEL, NEPAL

MAY 24, 2020

TO: SURENDRA SUJAKHU, PhD
FROM: SARVESH PANDEY (21162)
DATE: MAY 23, 2020
SUBJECT: DESIGN AND MANUFACTURING OF (PPE) IN NEPAL.

Here is the report on design and manufacturing of Personal Protective Equipment in

Nepal that you authorized on May 10, 2020.

PPE is equipment that will protect the user against health or safety risks at work. It can
include items such as safety helmets, gloves, eye protection, high-visibility clothing,
safety footwear and masks. The equipment is personal because it is used individually
and not shared with others. Most of them are thrown away after being used one time.
They are protective because the equipment works as a barrier between the body and
the germs.

This report manifests the possibilities of forming PPE sets in Nepal along with the raw
materials needed to manufacture it and the design procedure that are in practice all
over the world to protect the medical personnel from COVID-19 Corona virus and
other influenzas as well.

Thank you for allowing me the opportunity to participate in this worthwhile study.
And I will be very happy to discuss its finding with you.
 TABLE OF CONTENT

List of tables…………………………………………………………………………….i
List of figures…………………………………………………………………………..ii
CHAPTER 1 INTRODUCTION………………………………………………………1
1.1 Background………………………………………………………………………...1
1.1.1 Components of PPE........................................................................................2
1.2 Objective………………………………………………………………………...…6
1.3 Scope……………………………………………………………………………….6
CHAPTER 2 DISCUSSION…………………………………………………………...7
2.1 Purpose……………………………………………………………………………..7
2.2 Design of PPE……………………………………………………………………...7
2.3 Gloves designing process…………………………………………………………..7
2.3.1 Decision matrix for material selection of Gloves……………………….…...8
2.4 Mask designing process……………………………………………………...….…8
2.4.1 Decision matrix for material selection of Mask……………………………...9
2.5 Gown designing process…………………………………………………………...9
2.5.1 Decision matrix for material selection of Gown……………………………10
2.6 Face shield designing process…………………………………………………….10
2.6.1 Decision matrix for material selection of Face Shield…………………......10
2.7 Goggles designing process………………………………………………………..11
2.7.1 Decision matrix for material selection of Goggles…………………...…….11
2.8 Shoe Cover designing process……………………………………………………12
2.8.1 Decision matrix for material selection of Shoe Cover……………………..12
2.9 Head cover designing process…………………………………………………….12
2.9.1 Decision matrix for material selection of Head Cover……………………..12
CHAPTER 3 CONCLUSION………………………………………………………..13
.
LIST OF TABLES

Table 1 Decision matrix for material selection of medical gloves……………………..8

Table 2 Decision matrix for material selection of Mask……………………………….9

Table 3 Decision matrix for material selection of Gown………………………….….10

Table 4 Decision matrix for material selection of Face shield………………………..10

Table 5 Decision matrix for material selection of Goggle......……………………..…11

Table 6 Decision matrix for material selection of Shoe cover………………………..12

Table 7 Decision matrix for material selection of Head cover…………………….…12

 LIST OF FIGURES

Figure 1 Complete PPE Set…………………………………………………………….1

Figure 2 Protective face shield…………………………………………………………2

Figure 3 Triple layer disposable mask…………………………………………............3

Figure 4 N-95 Respiratory mask……………………………………………………….3

Figure 5 Types of gloves…………………………………………………………….…3

Figure 6 Disposable isolation gown……………………………………………………4

Figure 7 Reusable gown………………………………………………………………..4

Figure 8 Shoe cover………………………………………………………………....…5

Figure 9 Disposable head covers……………………………………………….……...5

Figure 10 Safety goggles….……………………………………………………………5

Figure a Spun bonding process………………………………………………………...9

Figure b Melt blown process…………………………………………………………...9

Figure c Pad-Dry-Cure process…………………………………………………….…..9

 CHAPTER 1 INTRODUCTION
1.1 Background
PPE was thought to be originated during World War I as a mean to prevent the
soldiers from chemical intoxications. The use of chemicals shifted the mode of war
and to overcome it, PPE was originated. The use of respirators allowed the troops
to escape the effects of harmful toxins and gas. Similarly, the use of masks and
gloves assisted the scientists and researchers to work in a safe environment. In the
middle ages blacksmiths used to wear Apron and hand gears to prevent them from
being burned and to stop the equipment from falling on their body [1]. The modern
industry has drastically evolved since then, with greater focus on protective work
wear for a wide range of trade industries. PPE now extends to clothing, footwear,
goggles and other garments that are all designed to protect an individual from
injury. Early PPE like body armor, boots and gloves focused on protecting the
wearer's body from physical injury. The doctors of sixteenth-century of Europe
also wore protective uniforms which consisted of a full-length gown, helmet, glass
eye coverings, gloves and boots to prevent contamination when dealing
with affected victims. These were made of thick material which was then covered
in wax to make it water-proof. A mask with a beak-like structure which was filled
with pleasant-smelling flowers, herbs and spices to prevent the spread of bad
smells which spread disease through the air[2].

Fig 1: Complete PPE set

(RSS, 2020)

1
1.1.1 COMPONENTS OF PPE
PPE or personal protective equipment is defined by the Occupational Safety
and Health Administration (OSHA) as “specialized clothing or equipment
worn by an employee for protection against infectious materials” [3]. It is very
important to select the correct PPE. Just as important, the PPE must be
working correctly every time we use it, either alone or in combination with
other PPE. The components of PPE are listed below with short description:

a) Face shield
b) Mask
I. Triple layer medical mask
II. N-95 respiratory mask
c) Gloves
d) Gowns
e) Shoe covers
f) Head covers
g) Goggles

A brief introduction of each component is given below:

a) Face shield:
A face shield is an item of Personal Protective equipment that aims to protect
the wearer’s entire face from chemical splashes or potentially infectious
materials. A face shield provides splatter protection to facial skin, eyes, nose,
and mouth. Visors can be made up of plastics such as polycarbonate,
propionate, acetate, polyvinyl chloride, and polyethylene terephthalate
glycol (also known as PETG). The plastic is often given anti-glare, anti-fog,
anti-static, or other coatings. The attached suspension systems can include
elastic straps, Velcro, headbands, glasses-type temple bars, pin-lock, or ratchet
systems [4].

Fig 2: Protective face shield

2
b) Mask:
Masks are designed to keep operating rooms sterile, preventing germs from the
mouth and nose of a wearer from contaminating a patient during surgery.
Although masks have seen a rise in popularity among consumers during
outbreaks such as the coronavirus, surgical masks are not designed to filter out
viruses, which are smaller than germs. Masks are made using specialized
machinery, and then sterilized. Nonwoven polypropylene and textile material
is fed from bobbins into machinery that cuts and ultrasonically welds it
together [5]. Surgical masks typically have one layer of textile material
surrounded by other layers of nonwoven material on both sides, making for 3-4
layers total depending on the mask. The machine attaches other parts like ear
loops or metal strips before the masks are sterilized and packaged.

Fig 3: Triple layer face mask Fig 4: N-95 respiratory mask

c) Gloves:
Gloves are disposable/non-disposable PPE set used during medical
examinations and procedures to help prevent cross-contamination between
caregivers and patients. Medical gloves are made of different polymers
including latex, nitrile rubber, polyvinyl chloride and neoprene; they come
unpowdered or powdered with corn starch to lubricate the gloves, making them
easier to put on the hand [5].

Fig 5: Various types of gloves

3
d) Gowns:
Gowns are medical safety suits worn by professionals as Personal Protective
Equipment (PPE) in order to provide a barrier between patient and
professional. They may also be used to help prevent the gown wearer from
transferring microorganisms that could harm patients. They are classified as
disposable and reusable isolation gowns.
 Disposable (single-use) isolation gowns are designed to be discarded
after a single use and are typically constructed of nonwoven materials
alone or in combination with materials that offer increased protection
from liquid penetration, such as plastic films [6]. The basic raw
materials used for disposable isolation gowns are various forms of
synthetic fibers (e.g. polypropylene, polyester, polyethylene). Fabrics
can be engineered to achieve desired properties by using particular
fiber types, bonding processes, and fabric finishes (chemical or
physical treatments).

 Reusable (multi-use) gowns are laundered after each use. Reusable

isolation gowns are typically made of 100% cotton, 100% polyester,
or polyester/cotton blends. These fabrics are tightly woven plain
weave fabrics that are chemically finished and may be pressed through
rollers to enhance the liquid barrier properties. Reusable gowns
generally can be used for 50 or more washing and drying cycles [6].

Fig 6: Disposable isolation gown Fig 7: Reusable gown

4
e) Shoe covers:
Shoe cover provides a barrier against possible exposure to airborne organism
or contact with a contaminated environment. It reduces the spread of
contaminations and helps to maintain a cleaner room environment [7].

Fig 8: Shoe cover

f) Head covers:
Head covers protect the hair and scalp from possible contamination when
sprays or airborne exposure is anticipated [8].

Fig 9: Disposable head covers

g) Goggles:
Goggles are forms of protective eyewear that usually protects or encloses the
area around the eye in order to prevent particulates, droplets or chemicals from
striking the eyes. They are designed to provide eye protection from splashed or
sprayed body fluids [9].

Fig 10: Safety goggles

5
1.2 Objective
1. To adopt a system approach for design and manufacture PPE set in Nepal.
2. To establish the measures to access and compare the effectiveness of PPE.

1.3 Scope
1. It can be used by medical personnel to treat COVID-19 patients safely.
2. It can be utilized to treat patients from several pandemics that are to come
in future.

6
 CHAPTER 2 DISCUSSIONS
2.1 Purpose
Personal protective equipment is special equipment you wear to create a barrier
between you and germs. This barrier reduces the chance of touching, being exposed
to, and spreading germs. Personal protective equipment (PPE) helps prevent the spread
of germs in the hospital. This can protect people and health care workers from
infections. All hospital staff, patients, and visitors should use PPE when there will be
contact with blood or other bodily fluids. Due to pandemic spread all over the world
there has been shortage of PPE set all over the world. Personal Protective Equipment
(PPE) is most important in preventing transmission of the COVID-19 Corona virus not
only in treatment centers but also various activities, e.g. cleaning, waste management
and safe burials, and community care related to the outbreak. The purpose of this
report is to overcome the lack of PPE set in Nepal by designing and manufacturing it
within Nepal.

2.2 Design of PPE

In present context, lack of PPE has become a burning problem for healthcare workers
all over the world. Especially developing countries like Nepal are facing this problem
because of lack of infrastructures and raw materials. Also, lack of skilled man power
is a major cause of it. The number of COVID-19cases are continuing to grow in the
world, Health care facilities worldwide is contending with an increasing crush of
patient, and growing more and more desperate for the tools they need to protect
themselves from catching and spreading the virus that causes infections.

2.3 Gloves designing process:

Gloves designing are quite a complex job in the sense, it is a lengthy process. The
gloves have to pass through a number of steps, namely former cleaning, coagulant
dipping, drying, latex dipping, leaching, beading, vulcanizing, post leaching, slurry
dipping, stripping, tumbling, and quality control [10].

7
2.3.1 Decision matrix for material selection of gloves

The decision matrix for various materials that can be used in making gloves is shown
below:

Material Chemical Comfort Tensile Puncture Cost Durability score

Resistance Strength Resistance
Latex 2 4 2 2 3 3 16

Nitrile 5 3 5 5 4 5 27

Vinyl 1 2 3 1 5 3 15

Table 1: Decision matrix for material selection of medical gloves

From the above table it can be seen that the chemical resistance, Tensile strength,
Puncture resistance, Durability is very good for Nitrile gloves. The cost of latex glove
is low as compared to the other two. From the table it can be concluded that Nitrile
gloves is best among all and it is generally preferred by health personnel.

2.4 Mask designing process:

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, either 20 or 25 grams
per square meter (gsm) in density. Masks can also be made of polystyrene,
polycarbonate, polyethylene, or polyester.20 gsm mask material is made in a spun
bond 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. 25
gsm 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 [5].

8
2.4.1Decision matrix for material selection of mask

Materials Impact Durability Chemical Density Cost Score

Resistance Resistance

Polyethylene 4 4 4.5 5 4 21.5

Polystyrene 2 3.5 3 4 3 15.5

Polycarbonate 3 3 2 3 2 13

Table 2: Decision matrix for material selection of mask

From the above table, the score of polyethylene is highest among all. Polyethylene has
good chemical resistivity and high density. Similarly, it is more durable and long
lasting. So, for efficient mask production, Polyethylene is used most.

2.5 Gown designing process:

A surgical gown is a class 2 medical textile used to reduce the transfer of bacteria
from the skin of surgical staff to air of operating room as well as protect the surgical
staff from contact with bodily fluids. Gowns are most often constructed from fibers
such as polypropylene and polyester, by using a nonwoven technique. These fibers are
relatively too cheap to make but produce a high quality product [6]. Typically, a gown
uses the nonwoven technique known as SMS which stands for spun bond, melt blown,
spun bond. In some cases the SMS process can include more than one melt blown
layer between the outer spun bond layers.

Fig a: spun bonding process fig b: melt blowing process fig c: pad-dry-cure process

9
2.5.1 Decision matrix for material selection of gowns

materials elongations Density Melting Chemical strength score

point resistance
Polypropylene 4 2 3 4 2 15

polyester 2 4 4 2 4 16

Table 3: Decision matrix for material selection for gowns

From the above table, the score of polyester is highest among all. It has good
elongation, and good chemical resistance. It seems to be the winner for making
medical gowns.

2.6 Face shield designing process:

Two methods are used to manufacture face shields: They are extrusion and injection
molding. Face shields cut from extrusion sheets provide better impact resistance than
injection molded face shields because extrusion sheets are made of high molecular
weight plastic pellets while injection molding must use lower molecular weight plastic
pellets, which provide better melt flowing property needed by injection molding [4].

2.6.1 Decision matrix for material selection of face shield

Materials Impact Optical Material Chemical Elongation Score

Resistance Quality Cost Resistance

Polycarbonate 4 5 3 4 4 20

Cellular 3 3 5 5 3 19
acetate

PETG 5 4 3 3 2 16

Table 4: Decision matrix for material selection for face shield

From the above table, it can be seen that the score of Polycarbonate is higher than
cellular acetate and PETG. The winner is Polycarbonate for making face shield. It is
also cost effective

10
2.7 Goggles designing process:

Goggles and safety glasses are typically created using an injection molding process
that injects a polymer material into a metal mold that has been fabricated to reproduce
the desired shape of the lenses and frames. The exact steps used to make goggles and
safety glasses will depend on the particular type of product being fabricated [9]. The
steps for fabricating medical goggles are:

a) Mold creation
b) Injection molding
c) Surface treatment
d) Inspection and final production
e) Packaging

2.7.1 Decision matrix for material selection of goggles

Materials Hypo Light Strength Flexible Corrosion Score

allergic Weight Resistance

Cellulose 3 4 2 2 3 14
acetate

Cellulose 5 5 3 3 4 20
propionate

Nylon 3 3 5 4 3.5 18.5

Table 5: Decision matrix for material selection of goggles

Beside them, Polycarbonate is also used which is also a good material. But, while
talking about effective material, Cellulose Propionate is used widely to make goggles
for medical persons.

11
2.8 Shoe covers designing process:

Shoe covers are designed by various textile companies. Polypropylene or plastic is

used to make disposable shoe covers that prevent the germs and bacteria from entering
into the operation room [7].

2.8.1 Decision matrix for material selection of shoe cover

Materials Cleanliness Cost Durability Anti-skid Score

Polypropylene 2 4 3 3 12

Plastic 4 2 4 4 14

Polyethylene 2 3 3.5 4 12.5

Table 6: Decision matrix for material selection of shoe cover

Generally, plastic is used as raw material for manufacturing shoe covers because of its
various good properties. It gives good cleanliness and it is cheap as well. Also, it is
durable and has good anti-skid property.

2.9 Head covers designing process:

Head covers are designed with the same materials that are used to design Shoe covers.
It includes materials like Polypropylene, Plastics and Polyethylene [8].

2.9.1 Decision matrix for material selection of Head covers

Materials Cleanliness Cost Durability Anti-skid Score

Polypropylene 2 4 3 3 12

Plastic 4 2 4 4 14

Polyethylene 2 3 3.5 4 12.5

Table 7: Decision matrix for material selection of head cover

12
 CHAPTER 3 CONCLUSIONS
The above mentioned materials in the decision matrix are the best suitable materials to
manufacture PPE kits in Nepal. Using these raw materials, PPE kit can be
manufactured in Nepal and we can learn about PPE designing from this report. The
designed PPE set can help the medical personnel to be safe from COVID 19 corona
virus and other influenzas as well.

13
 References:
[1]. Cheung, G. k. (2013, November 03). PPE from the beginning. Retrieved may 14,
2020, from Health and safety middle east.

[2]. Mitchell, A. H. (2014, october 11). MH life sciences. Retrieved may 14, 2020,
from Infection control today.

[3]. OSHA. (2003, january 4). freedom and information act. Retrieved may 15, 2020,
from united states department of labor.

[4]. Mundell, E. (2020, april 29). Face shields a more effective deterrent to COVID?
Newyork, United states of America.

[5]. kosecki, D. (2020). The right way to wear a mask and gloves. Elemental.

[6]. kilinc, F. s. (2015). A Review of Isolation Gowns in Healthcare: Fabric and Gown
Properties. 14-19.

[7]. admin, T. e. (2020, march 13). Retrieved may 16, 2020, from [Link]

[8]. KEVIN J. GIBBONS, M. F. (2017). The surgical cap: Symbol, science, argument,
and evidence. Chicago: Bulletin of the american college of surgeon.

[9]. association, A. o. (2007, march 11). American optometric association. Retrieved

may 17, 2020, from Think about your eyes.

14

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