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The Madoors USA Automatic Surgical Mask Production Line Machine is a fully automatic PLC-controlled folded face mask production system — also known as the C-type face mask machine — using ultrasonic bonding technology to produce 3 to 5-layer PP non-woven, activated carbon, and filter material folded masks to FFP1, FFP2, and NP5 standards, including 3M 9001 and 9002 mask body processing, with automatic blanking, trimming, folding, welding, nose clip attachment, UV-C sterilization, and ear loop welding in a completely hands-free production sequence. Built with first-class industrial components — Siemens and Schneider automation, MS Ultraschall and Weber ultrasonic systems, Festo and SMC pneumatics, SICK and IFM sensors, and Panasonic electromotors — CE certified, with 24/7 remote online monitoring and troubleshooting, 3-day maximum spare part lead time guarantee, and free commissioning and user training, the Madoors USA Surgical Mask Production Machine provides the superior quality, reliability, and efficiency required for mass production line operation.
TECHNICAL SPECIFICATIONS
The Madoors USA Folded Face Mask Machine produces C-type folded face masks from 3 to 5 layers of PP non-woven fabric, activated carbon filter material, and melt-blown filter layers — the layer combination and specific raw materials determine the filtration standard achieved, with different raw material combinations producing FFP1, FFP2, and NP5 certified masks. The ultrasonic bonding technology joins the multiple fabric layers without adhesives or stitching — the ultrasonic energy creates molecular-level bonds between the thermoplastic non-woven layers that provide structural integrity equivalent to or exceeding sewn construction while completely eliminating the needle holes, thread ends, and adhesive contamination of alternative joining methods.
The PLC automatic control system manages the complete production sequence — automatic material feeding and rewinding, blanking of the mask body from the material rolls, trimming to the mask body dimensions, folding of the C-type profile, ultrasonic welding of the folded body, nose clip attachment, and UV-C sterilization — with automatic counting of completed masks throughout the production run. The mold extraction rapid replacement system allows different mask body shapes and sizes to be produced by changing the mold set without extended machine downtime.
The mask body and ear loop welding units can operate independently — in the event of a partial failure in one unit, the other unit continues production, directly maintaining production continuity and reducing the impact of any single component failure on overall production output. The industrial PC with touch screen provides the operator interface for all machine functions, parameter adjustment, and production counting.
The complete machine structure uses aluminum alloy construction with plating-treated parts — the aluminum alloy provides the lightweight, high-rigidity machine frame required for precise mask dimension consistency across high-speed production cycling, and the plating treatment provides corrosion resistance and the clean-room compatible surface quality required for medical product manufacturing.
The elastic non-woven ear loop material is welded to the mask body by the re-use ear line welding machine — the elastic material provides comfortable fit without pressure on the wearer's ears for extended wear periods. The mask's filtration fabric provides good filter efficiency with perfect fit to the human face for use in high-pollution industrial environments including building and construction, mining, and any application requiring respiratory protection to the specified filtration standard.
KEY FEATURES
Fully Automatic Hands-Free Production — CE Certified
The completely hands-free production sequence — from raw material roll feeding through complete finished mask output — provides the hygienic manufacturing standard required for medical mask production, where hand contact with mask materials during production would compromise the sterility and contamination-free quality of the finished product. CE certification confirms compliance with European machine safety and medical product manufacturing standards — the certification documentation required for production of masks to European market requirements.
Ultrasonic Bonding — No Adhesives, No Needles, No Thread
The ultrasonic bonding technology that joins mask layers without adhesives, needle holes, or thread provides three simultaneous production quality advantages — the bond strength is consistent across the entire bonded area without the adhesive distribution variation and cure time dependence of adhesive bonding, the absence of needle holes eliminates the potential filtration bypass paths that needle-punched seam holes create, and the absence of thread ends eliminates the contamination risk of thread particle shedding into the mask interior. These three quality advantages directly contribute to the consistent filtration performance and hygienic quality of the finished masks.
FFP1, FFP2 & NP5 Standard Compliance — Multi-Standard Capability
The ability to produce masks to FFP1, FFP2, and NP5 filtration standards through different raw material combinations from the same machine directly provides the production flexibility required for manufacturers supplying multiple market segments — FFP2 for the healthcare and high-filtration industrial market, FFP1 for the standard dust and pollution protection market, and NP5 for specific standard requirements — from a single machine investment.
Rapid Mold Exchange — Multi-Product Flexibility
The mold extraction rapid replacement system that allows different mask body shapes and sizes to be produced by mold change eliminates the need for separate machines for each mask size or shape — the same machine produces the complete range of folded mask geometries through mold exchange. This rapid mold exchange directly maximizes the utilization of the machine investment by covering the complete folded mask product range.
Independent Mask Body & Ear Loop Units — Production Continuity
The independent operation capability of the mask body and ear loop welding units directly maintains production continuity during partial failure events — if the ear loop welding unit requires maintenance, the mask body unit continues producing mask bodies that can be completed when the ear loop unit returns to service, and vice versa. This production continuity architecture directly reduces the total production loss from any single component failure event.
First-Class International Components — Long-Term Reliability
The specification of first-class international industrial components throughout the machine — Siemens and Schneider automation, MS Ultraschall, Weber, and Sonikks ultrasonic systems, Festo and SMC pneumatics, SICK, IFM, and Turck sensors, and Panasonic, Gamak, and Volt electromotors — provides the long-term reliability and service life required for continuous mass production operation. These component brands are recognized globally as the highest-quality available in their respective product categories, and their specification directly minimizes the component failure rate and maintenance frequency throughout the machine service life.
24/7 Remote Online Monitoring & Troubleshooting
The 24/7 remote online connection for machine status monitoring and troubleshooting provides the most responsive technical support available for production line equipment — issues that would otherwise require waiting for an engineer visit can be diagnosed and resolved remotely at any time of day or night. This remote support capability directly minimizes production downtime from technical issues, maintaining the production output required for mask supply commitments.
3-Day Maximum Spare Part Guarantee
The maximum 3-day lead time guarantee for spare parts directly minimizes the production downtime from component replacement requirements — the worst-case parts delivery time of 3 days provides a defined maximum downtime scenario for production planning, allowing the manufacturer to manage production schedules with confidence in the parts supply responsiveness.
MASK TYPES PRODUCIBLE
FFP2 Folded Mask
3M 9001/9002 equivalent. 5-layer construction with melt-blown filter. High-filtration healthcare and industrial application. Elastic non-woven ear loops. Nose clip.
FFP1 Folded Mask
3 to 4-layer construction. Standard dust and pollution filtration. Industrial and general protection application.
NP5 Folded Mask
Specific standard configuration. Alternative layer and material combination for NP5 standard compliance.
C-Type Folded Mask
Multiple fold configurations from mold exchange. Different body shapes for different market and anatomical fit requirements.
ASSEMBLY & INSTALLATION SEQUENCE
Production Space Assessment
Machine footprint, material roll storage positions, finished mask collection positions, electrical supply — voltage, phase, and power — compressed air supply, and ventilation for ultrasonic and UV-C systems are confirmed.
Machine Installation & Leveling
The aluminum alloy machine structure is installed at the confirmed production position. Machine level and alignment for consistent material feed are confirmed. All electrical and pneumatic supply connections are made.
Siemens/Schneider PLC & Touch Screen Commissioning
The PLC control system is powered up. All Siemens and Schneider automation modules are confirmed operational. Industrial PC touch screen interface functions are tested.
Ultrasonic System Calibration
MS Ultraschall, Weber, or Sonikks ultrasonic welding heads are calibrated for the specified mask material layer combination and bonding parameters. Bond quality on test material is confirmed.
Mold Installation & Mask Body Test
The mask body mold for the primary production mask type is installed. Test production run of mask body blanking, trimming, folding, and ultrasonic welding is completed. Mask body dimensions and bond quality are confirmed to the specified standard.
Ear Loop & Nose Clip Integration
Ear loop welding unit calibration and elastic non-woven attachment quality are confirmed. Nose clip attachment mechanism is confirmed operational. Complete mask assembly test is completed.
UV-C Sterilization & Counting Verification
UV-C sterilization system is confirmed operational on the completed mask output. Automatic mask counting accuracy is verified.
Remote Connection & Free Training
Remote online monitoring connection is established and 24/7 access is confirmed. Free commissioning and user training for all operating personnel is completed.
DEPLOYMENT SCENARIOS & USE CASES
Madoors USA Automatic Surgical Mask Production Machines are specified for any mask manufacturing facility requiring fully automatic folded mask production.