Benefits of Silicone Dressings in Wound Care – Continued

How Can Silicone Dressings Be Used For Pressure Ulcers?

The most common type of pressure ulcer is the sacral pressure ulcer which can be hard to treat due to its location and its risk of infection from faecal matter and increased exudate production. This means that using the right wound dressings is critical in patient recovery.

Studies have shown that the use of a soft silicone wound dressing for these types of pressure ulcers can lessen the risk of damage to the surrounding skin and reduce the amount of dressing changes needed, both of which result in less discomfort for the patients.

Furthermore, for those at risk of developing pressure ulcers, the use of soft silicone bordered foam dressing can help to protect vulnerable areas of skin and prevent pressure ulcers from occurring by reducing friction and sheer when turning patients or to prevent footwear from rubbing.

How Can Silicone Dressings Be Used For Skin Tears?

Unlike pressure ulcers, skin tears are acute wounds that can be closed with primary intention. These types of wounds typically occur in elderly patients as their skin is more fragile and, therefore, more prone to tears.

To manage skin tears, whether they are minor or severe, the flap of skin must be realigned as soon as possible to prevent further damage. Once precise alignment of the skin flap has been carried out, a silicone-coated net dressing can be applied to secure the skin flap in place.

The dressing should be kept in place for a minimum of 5 days to allow the flap to fully adhere to the underlying skin tissue and to avoid further pain or discomfort.

The benefits of silicone dressings for skin tears include:

  • Ensures secure placement of the skin flap
  • Provides an atraumatic method of fixation
  • Offers low allergy potential
  • Allows exudate to pass through a secondary dressing

When choosing a silicone dressing for the treatment of skin tears, make sure that you look for one that provides maximum tack strength to ensure that the dressing stays in place for the total recommended length of time.

What Are the Cost Implications of Using Silicone Dressings?

If you are worried about the cost of implications of using soft silicone dressings, you should know that in recent trials, where both silicone dressings and other commonly used dressings for burns and split-skin grafting were applied, the soft silicone dressing significantly reduced the time required for dressing changes, the number of dressings used and the cost of pain management. Furthermore, healing rates were quicker, and the soft silicone dressings needed to be changed less frequently, resulting in even more savings.


Soft silicone dressings can be used to aid the healing process of many different wounds types by helping to prevent trauma to the wound bed and the periwound skin. They can be used on both low and highly exuding wounds and are particularly beneficial to patients with fragile skin and those who suffer pain during dressing changes.

Benefits of Silicone Dressings in Wound Care

Improvements to wound care and recovery have led to new research and materials being used in dressings. Dressings in the past were rudimentary and required ongoing changes to keep the wound in question clean. Today, combined with a variety of additional features like antibacterial agents, debriding agents, and proteolytic activity, and pH balancers, wounds have a better ability to heal and recover properly without undue stress through the recovery process.

The dressing itself also matters. In recent years, silicone dressings have taken precedence in wound care due to their various benefits.

How Do Silicone Dressings Work?

Silicones are long-chain polymers that contain repeating chains of silicone, oxygen, and other elements. They have a hydrophobic soft silicone layer that is tacky to touch, preventing the dressing from sticking to the wound but still enabling it to adhere to the surrounding skin. This helps to minimise patient trauma during dressing changing.

Silicone dressings are used to assist wound healing for a wide range of conditions, including diabetic ulcers, skin grafts, blisters, skin abrasions, and skin tears. They can be used either as a wound contact layer with a secondary dressing or as a highly absorbent dressing for more exuding wounds. In fact, soft silicone dressings are suitable for almost all indications where it is necessary to prevent trauma to a wound and the surrounding skin and pain to the patient.

Although anyone can use silicone dressings, they are particularly suitable for patients:

  • With fragile skin, including young children and the elderly.
  • Those who experience pain at dressing changes.
  • Those who need to protect at-risk periwound skin.

What Are the Different Types of Silicone Dressings?

Primary wound contact layers

These soft silicone wound dressings are not designed to be absorbent but to allow exudate to pass through into a secondary dressing. These are usually thin and consist of a flexible polyamide net that is non-adherent to the wound bed. This type of silicone dressing is useful for superficial wounds such as skin tears, skin abrasions, surgical wounds, and pressure sores.

Foam dressings with silicone adhesive

You can find many absorbent dressings that have a soft silicone wound contact layer. This layer forms a gentle seal between the dressing and the wound and makes sure that any fluid is absorbed by the dressing and does not escape to the surface of the skin.

Silicone gel sheets

Silicone gel sheets are thicker and do not need a secondary dressing. They should only be used on healed wounds to reduce or prevent scarring. It can be used for both hypertrophic and keloid scars and closed wounds as prophylaxis against both new and old scar development.

Benefits of Silicone Dressings in Wound Care

The patient and the wound itself both benefit from silicone dressings. We have compiled some of the best benefits below; keep reading to find out more.

Reduction in Pain During Redressing

Pain experienced during dressing change can cause trauma to the patient and can exacerbate wounds. In fact, according to the World Union of Wound Healing Societies, changing the dressing is one of the most difficult and painful parts of wound recovery. Traditional dressings tend to pull at the periwound skin, damaging the healing process and even resulting in longer recovery times.

Silicone dressings actively reduce pain and trauma of epidermal stripping during dressing changes as they are easily removed and do not interact chemically with the wound or affect the cells responsible for the healing process. Furthermore, soft silicone cannot enter the circulatory system as it is insoluble in wound exudate, and its molecules are too big to penetrate through cell membranes or pass through the skin into blood vessels. This means that it cannot produce any undesirable systemic effects in the body.

Scar Reduction

Silicone dressings have a long history of being used in instances where scar reduction was a priority. Silicone dressings promote a healthy environment for the wound to heal and prevent excess damage from occurring. Silicone sheets work specifically to reduce or, in certain situations, entirely prevent hypertrophic and keloid scarring.

Improved Comfort

Soft silicone dressings are ideal for those with sensitive or fragile skin. Children and the elderly alike are both well suited to the silicone dressing. Of course, the benefits are for everyone. If patients find that dressing changes cause pain and stress, silicone dressings are a great alternative. The same applies to wounds where protecting the periwound skin is paramount to recovery.

Silicone dressings can be worn for longer, meaning fewer dressing changes are required. They also pull less at the skin during dressing change and are overall more comfortable for the patient to wear during their full recovery period.


Silicone wound dressings are transparent, which means that wounds can be inspected with ease, both during application and during wear. This reduces the frequency of changes needed to the wound, resulting in less trauma for the patient and lower costs over the duration of treatment.

Other key benefits:

  • Flexible and conform well to body contours.
  • Low toxicity, so safe to use.
  • Low thermal conductivity.
  • Low chemical reactivity.
  • Repels water and creates a watertight seal.
  • Does not support microbial growth.
  • High gas permeability.
  • Adhesive to dry skin.
  • Do not leave a residue upon removal.

How Do Silicone Dressings Provide These Benefits?

Traditional dressings use skin adhesive to secure them into position. Though the adhesives do not come into the wound itself, pulling on the surrounding skin can cause damage to the stratum corneum. On the other hand, Silicone dressings remove far less of the stratum corneum compared to other options.

Traditional dressings, especially gauze dressings, also tend to dry out, during which time they tend to adhere to the wound and periwound skin. Though removal in these instances is essential, removing such adhered dressings cause damage and result in serious pain. If soaking the dressing to remove it occurs, it is recommended that a new dressing type be considered immediately.

By choosing the right silicone dressing, the dressing will stay intact, be worn for longer, and improve patient comfort and recovery. It vastly improves the patient experience and is also ideal for more serious wounds, abrasions, and even burns.

Wound Care: Selecting the Right Dressings for Optimal Results

The correct dressing is a critical component to any successful wound care management strategy. Buying basic dressings can cause a lot of problems down the line, particularly when it comes to traditional gauze dressings. These dressings and their adhesives tend to pull at the skin and become adhered to the wound itself. Improving the dressing material and stocking up on the right recovery materials to help promote healing in a variety of wound types is a must for all medical professionals.

Features Needed in Dressings

There are a few features that dressings need in order to help promote healing in wounds and chronic wounds. To help you understand what you need, it is vital that you learn about these features. They include:


Bacteria can cause severe complications in wound recovery and is a common contributing factor when wounds become chronic. Bacteria can also cause the wound to become malodorous. Antimicrobial dressings can work to prevent these issues.

Debriding Agents

In instances where bacteria cultures have already been detected in the wound, debriding agents are essential. Debriding agents are one of the oldest forms of medicine, though modern medicine has moved far away from using maggots to debride wounds. 

Debriding agents are essential in dressings when dead tissue or bacteria colonies need to be removed from the wound as a part of the healing process and wound management. While the most common type of debridement occurs manually by medical professionals, there are certain types of dressings that can do this. Hydrogels and antibacterial dressings, as well as specialist designs, can work to debride the wound and promote healing.

Proteolytic Activity and pH

These types of dressings work to reduce bacteria and the inflammatory response during the healing process. By balancing pH in the wound, the dressing can easily promote healing. An imbalance in pH often results in longer recovery times and, in some instances, complications. Improving pH back to a balanced level helps the patient significantly.

Types of Dressing to Choose

We are one of the sector’s most trusted coatings manufacturers and can create custom and medical-grade dressings. Our team is capable of producing complex medical coatings that suit a variety of wound types and needs.

Silicone Gel and Acrylic PSA Coating Dressing

Silicone dressings are more gentle and can be worn longer. They are the latest dressing to hit the medical community and are ideal for those with fragile skin or complex wound recovery treatments.

Silicone gel wound dressings offer many great benefits thanks to the perforation in the dressing itself. This means that the wound is immobilised, and it is less likely to become contaminated or to suffer from a bacterial infection. These dressings also tend to absorb wound drainage and allow for oxygen entry and escape.

Specialist and Medical Dressings

We can work with you to create specialist dressings based on patient needs. We create and manufacture specialist and medical dressings for wound recovery and work commonly with your suppliers or with your needs to create the perfect wound dressing for your medical institution’s individual needs.

How Wound Care is Adapting to COVID Medical Care

The healthcare sector has faced unprecedented challenges since early 2019. From the first wave of COVID to mutations and a disrupted medical system, wound care has changed quickly and perhaps permanently. Even post-pandemic, the previous wound care model may well be a thing of the past. If there’s one thing that COVID has transformed, it’s the move to a more case-specific management model that is helping individual patients move through the medical system more intuitively. That’s changing the wound care sector in some surprising and even positive ways. Wound care suppliers and the industry itself have already started making the shift.

How Covid-19 Has Impacted the Wound Care Industry

While the primary focus has been on the treatment and management of COVID patients, one of the key side effects highlights the need for wound care away from the front lines of the healthcare sector. That’s because, even though wound care isn’t often an emergent front line, it’s become more critical as it serves those with chronic illnesses. That means that there was the risk of overtaxing the healthcare system via inpatient stays and emergency room attendance. With the risk of COVID higher in those environments, it immediately became clear that wound care would have to be less site-specific.

The Rise of Telemedicine

While there are limitations with telemedicine models, it has proven to be a valuable option for those in the wound care sector. However, it has less value than other remote medical treatment areas because it does not allow for procedure-based medicine, and practitioners cannot effect change on wounds themselves. What telemedicine has allowed for is an effective wound maintenance approach, further easing the strain on a struggling healthcare system. Wound monitoring can be almost as effective via remote appointments, and because of the reduced time constraints, those monitoring sessions can be inserted into weekly visits. The result could be a reduction in healing time for wounds.

Shifting Responsibilities and Increased Cross-Collaboration

One of the COVID crisis’s defining aspects has been the explosion of collaboration, innovation, and cooperation in the wound care sector. Big names in wound care, academics, and clinical teams have been communicating on social media throughout the pandemic and providing guidance and help for medical teams working in Tissue Viability. Twitter was especially valuable for those separate organisations that started to work together, with academics getting involved by opening access to journals and databases. Established organisations and associations like Legs Matter and the National Wound Care Strategy Programme were incredibly rapid with their creation and dissemination of guidance protocols, including Lower Limb Amputation Prevention and in-depth guides on self-care for wounds and leg ulcers. As clinical workloads were reduced to help cope with the demands of COVID, resources became more easily deployed and were delivered where they would be most effective.

COVID is changing the wound care industry and its applications at a very rapid pace. It seems increasingly likely that the industry post-pandemic will be a very different landscape that benefits patients and frontline workers alike. Easing the strain on emergency rooms and clinics has been the priority, but the positives that have come out of the disaster could change wound care for the better long into the future.

Raleigh Coatings acquired by Advanced Medical Solutions in £22million deal

Raleigh Coatings has been acquired by Advanced Medical Solutions Group plc (AMS) in a £22million deal that will be a major boost for both companies.

As a surgical and advanced wound care specialist company, AMS is a perfect fit as a parent company for Raleigh Coatings and the businesses are looking forward to an exciting future together.

Raleigh is the only independent UK company that offers acrylic and silicone gel contract coating for the wound care market, and one of very few companies offering this specialism in the world. We provide tailor-made solutions for our blue-chip customer base, which includes many of the major wound care and specialist manufacturers in the healthcare sector.

We have a pipeline of innovative developments which will ensure our continued growth as a leading player in wound care and bio-diagnostics.

The acquisition strengthens AMS’s position in the wound care sector by enabling the company to bring specialist services such as acrylic and silicone coating, perforation processing and other capabilities which are currently outsourced, in-house.

Bringing new projects to the medical space

Already a key supplier to AMS, Raleigh’s expertise will allow AMS to enter the bio-diagnostic testing sector and help it to increase efficiency of wound care manufacturing operations and bring new projects to the medical market.

Chris Meredith, CEO of AMS, said: “We are delighted to add Raleigh to the Group. We have been looking for synergistic technologies that add value to our wound care business and this acquisition strengthens our position and product offering in that sector significantly.

“Having outsourced silicone coating and perforation for some time, we are pleased to bring this capability in-house. Raleigh has also played an important part in improving the design of our LiquiBand® XL mesh which we see as an important part of our continued US growth strategy. Raleigh’s expertise in other sectors, such as bio-diagnostic strips, also opens up further new commercial opportunities for the Group. We look forward to welcoming the Raleigh team to the Group to build on their commercial success and leverage their development pipeline.”

Julian Watkins, business development manager at Raleigh Coatings, said: “The acquisition of Raleigh Coatings by Advanced Medical Solutions from Apollo Chemicals Group Ltd, is great news for all concerned. It will enable us to continue with our innovative work, while providing enhanced product offerings and creating new opportunities for growth.

“No jobs are affected by the acquisition and we continue to operate from our recently upgraded manufacturing facility in Eccleshall. It will be business as usual for all of our clients, who we thank for their continued custom.

There are clear synergies between the two companies and we’re looking forward to working with AMS and going from strength to strength in our new partnership.”

Who Can Provide Wound Dressing Coatings?

When you’re a provider of wound dressings, you need to know that you’re only selling the highest quality products at all times. That means choosing only the best manufacturers for your wound dressing coatings. There is a range of options to consider when it comes to wound dressing coatings, but not all manufactures are up to the task of creating what you need when you need it. That means knowing a little more about each company and ensuring that you only choose the provider that matches all of your needs. In today’s extremely competitive healthcare industry, knowing exactly who can provide wound dressing coatings means addressing the following factors.


Ideally, you want to choose a provider of wound dressing coatings who has plenty of experience within the industry. Due to the complex manufacturing process, you need to know that the provider you choose has the experience of the industry while also remaining on the cutting edge of new trends and technologies. It’s the importance of experience that has led to Raleigh Coatings being one of the most popular names in the industry. When you only want the best products for your company, then choosing a supplier with extremely high levels of experience is always going to be the best option.


Whenever you buy a new product or align with a new supplier, knowing more about their reputation is vital. This can be an easy task to accomplish, with many manufacturers having online reviews available to browse through. You should also consider the approach that the providers you’re looking at make in terms of quality standards and compliance. Always make sure that you have access to the industry-recognised quality standards provided by the wound dressing coatings supplier to ensure that you are only getting the best products.


The preference should always be to go with a supplier of coatings who has an in-house Class 7 Cleanroom facility. This type of cleanroom has been specifically designed to prevent contamination in the production or the manufacturing of a product. This is crucial in the wound dressing industry and means that the Class 7 Clean Room facilities have to adhere to a strict set of requirements. These include regular testing, between 60-90 air changes every hour, and a separate room available for gowning. If you opt to use a wound dressing coating supplier who has to outsource their cleanroom tasks, then your costs will rise.

Customer Service

Never underestimate the importance of customer service when it comes to choosing your suppliers. If you’ve ever had experience dealing with a supplier who pays late or fails to deliver on time, then you already know how vital it is to get the suppliers that work hard to keep you happy. Due to the growth of the healthcare industry for the last 20-years, there are a lot of companies that have tried to crack into the supply chain but lack the experience, the training, and the customer service that medical companies rely on.

When it comes to recognising who can (and can’t) provide you with professional, industry recognised, high-quality wound dressing coatings, always do your research. The more that you know about your options, the easier it will be to make the decision that will only move your company forward.

The Five Steps to Creating a New Wound Dressing at Raleigh

When you partner with a production company in order to co-create a new solution for the medical industry, your decision hangs in trust and respect. This is an industry in which corners are never cut and where effectiveness is the key indicator of success. As such, our professional teams have devised the perfect five-step process to help our clients build their solutions alongside us, making the most of our technologies to bring new and exciting wound dressings to market. Here’s an overview of that five-step process.


In this consultation phase, we’ll sit down with a client in order to sketch out their specifications and discuss the kinds of ideas we have to help them achieve what they’re looking for. In this stage, our technologies are introduced, and our previous work may come in useful when deciding on construction and raw material choice.


Next, we’ll take the ideas and the conclusions from these initial discussions, and we’ll bring  the expertise of our production team to help in the development of our customer’s brief. In this trial run, we’ll produce the product from the materials and to the specifications agreed on in the enquiry consultation. The key here is to inspect the design and workability of the products we’ve co-created with clients – checking that they’re at the standard desired. At this stage, a clearer idea of costs and lead times will be agreed with the client.

Development Qualification

This stage is often the most drawn out, as we iron out all of the creases in providing you with an Production quality of materials used in the dressings that you’re looking for. We’ll create pilot line iterations of development products to enable our customers to assess the performance of the trail materials. Once pilot line materials have been approved, then the development product will be scaled up to production trial quantities. At this stage the development construction may well be run on our clients machines . Raleigh welcome the opportunity to be part of this process and help our clients to optimise the product specification.

A price will usually be agreed at this stage.

Operational Qualification

With all the agreements in place and the green light from the  development phase, we’ll then look to gain approval of the manufacturing process. This does not take a long time to secure, which means that we’ll be confirming the quotes and costs with you for a final time before turning on the machines.

Performance Qualification

Finally, we’re simply left with the responsibility of taking all of the development process work that we’ve co-created with you and asking for your final sign-off on the specifications we’ve created. Once we’ve reached this stage, we’ll head into full production.

With many years in the industry, we believe this five-step process is the most effective way of delivering exactly what our clients are looking for in an industry that prizes quality above all else.

How Specialised Wound Dressings Are Developed

At Raleigh Coatings, we’ve made it our mission to provide bespoke and high-quality wound dressings for a variety of medical needs. But how do we do it, and how are the wound dressings you see around you developed in order to be most effective at treating patients with a wide variety of wounds? In this piece, you’ll learn about the key development stage that enables us to protect the wounds of individuals, whether they’ve been burned, cut or bruised.

The Process

Leading wound dressing organisations such as Raleigh are concerned with quality. That’s the bottom line when you’re providing high-quality materials to help doctors and nurses save lives. When we’re developing bespoke and unique products for our clients, we tend to follow a five-step process:

  • Enquiry – Learn about the objectives of the client by listening and learning
  • Samples – Prototypes are created, tested and discussed
  • Trial Run – This involves the development of the main line of product
  • Approval – The approval of the dressing solution and the confirmation of costs
  • Performance Qualification – The final stage, involving the client signing off on a production run

When following these five stages, it’s important that the client and Raleigh are both able to work together in order to determine the best way to develop the coated product  to contribute in the production of a dressing. This involves some specialist knowledge.

Specialist Knowledge

Wound dressing is an incredibly important element in the provision of medical care. Without sterilised and reliable dressings, hospital staff wouldn’t be able to provide help and care with the confidence that the products they’re using are first class. At Raleigh, we’ve spent over 10 years developing products for the wound care industry , which has led our specialists to:

  • Create a Class 7 cleanroom for coating and conversion
  • Have the ability to run a pilot line development service
  • High-tech solutions such as developing multi layered perforated products for wound dressing
  • It’s our specialist knowledge – and the ideas that our clients bring to us – that makes our product and our provision of it so competitive. The development of our wound dressings couldn’t happen without consultation, testing, discussion and evaluation at every step.

Trial Run to Manufacturing

This is the key jump that we are able to facilitate at Raleigh Coatings: from a short and brief trial run of a specific coating, we’re able to scale up in order to produce full production quantities of the  agreed specification.

For our clients, this means both the ability to take the product from lab bench all the way through to full production to suit all of our customer’s demands and requirements.

Making professional-quality coatings is a long and high-tech process perfected by Raleigh Coatings over many years of work.

What Challenges Do We Face in Wound Dressing Manufacture?

Our experience and expert knowledge in the wound care industry make us one of the sector’s most established and trusted companies. Despite our reputation as being one of the wound dressing field’s leading organisations, we still have to overcome a number of hurdles on a daily basis.

We never want to let our standards slip, which is why we embrace these hurdles. To find out what challenges we face and how we face them, be sure to read on.

Challenge no.1: The need to provide a unique service

It is not possible to offer a one-size-fits-all service in the wound care sector. To retain our position at the top of this industry, it’s essential that we provide each individual customer with a bespoke service that is tailored around their unique needs. Anything less, and we wouldn’t be able to provide the optimised service that we have become known for.

Offering a blanket service would be much easier than offering a unique one, that much is for certain. Nevertheless, we strive to manufacture wound dressing products in as bespoke a fashion as possible by following a five-phase process. This helps us to understand the individual requirements of our customers and ultimately develop the best products on the market.

Our five-phase process aids us as we take on the challenge of providing a unique service to each and every customer. It helps us get right to the heart of each individual matter, and it allows us to make the most out of the time we are afforded with our consumers. Here is the exact process that we follow:

Phase 1: Enquiry — We hold an open discussion with our customers to understand their needs, outline a project timeline, and make arrangements with regards to packaging and transportation

Phase 2: Samples — We discuss samples with our customers so that we can attain a better idea of what adjustments need to be made and what prices need to be set

Phase 3: Sample development — We develop our samples while still remaining in close contact with the customer (we may run a pilot line and/or mainline trials at this stage to ensure that the customer in question is 100% happy with our service)

Phase 4: Operational Qualification — Once the customer is happy to proceed, we confirm our final quotes, set our final costs, and move on to the manufacturing process

Phase 5: Performance Qualification — The production, perforation, conversion, packaging, and transport specification are signed off, and we start the manufacturing process

Challenge no.2: Our sector is constantly evolving

All industries undergo changes from time to time, but it’s safe to say that our field undergoes more than most. The wound care sector is in a constant state of flux, simply because there are always new technologies and materials being introduced into the wound care market. In our bid to consistently provide wound dressing products that are befitting of the day, we strive to keep ahead of the curve at all times.

In the fast-paced sector that we work in, this is no mean feat. Our laboratory is constantly abuzz. The expert workforce that we employ stops at nothing to ensure that our products meet high standards and specific specifications.

We assess a whole host of coated bi, tri, and quad laminated products on a daily basis. Some of the specific tests that we perform include:

  • Adhesion
  • Stripping linear force and tack
  • Moisture vapour transmission rate (MVTR)

For more information on how Raleigh Coatings can support your wound dressing requirements, and to find out more about our processes, contact our team on 01785 850 357 or email our Business Development Project Manager, Jenny Reeves ([email protected])

How Raleigh Coatings Turn Concepts into Medical-Grade Products

Frequently Asked Questions

Our specialist wound care coating and conversion services provide a wide range of organisations with high-quality products for advanced wound care needs. We work with you from conception through to the finished product to meet your individual requests, while adhering to stringent quality management standards, both in-house and through the International Organisation of Standardisation (ISO).

The wound care industry requires a distinct and specialist partner to meet medical marketplace needs; our expert knowledge of this sector means we can develop a wide range of products to suit these requirements.

At Raleigh Coatings, we follow a five-phase process to understand your requirements and develop the best products. This process includes:

Phase 1: Enquiry – This stage involves an open discussion to understand your needs. It then goes on to outline the project and agree on timelines and further arrangements about packaging and transportation.

Phase 2: Samples – After the initial discussion, samples are created for evaluation. Any adjustments can be made before sign off, and costs are discussed more thoroughly.

Phase 3: Development Process– After samples have been agreed upon, we move onto the development stage. This may include a pilot line and mainline trials.

Phase 4: Operational Qualification – Once these trails trials have been successful, the next stage moves onto the manufacturing process and final confirmation of costs and quotes.

Phase 5: Performance Qualification – Once the other steps have been completed, this stage signs off the specification with you. This covers everything from production, perforation, conversion, packaging and transport. It also includes technical specifications and standards. Once both parties have signed off this stage, it cannot be changed, and the manufacturing process can begin.

Before you start the process, there are often several questions you may have about how we can develop your wound care dressing products.

In this blog, we cover some frequently asked questions to help you find out more about our wound dressing manufacturing processes and how we can fulfil your wound dressing product requirements.

What are the health and safety requirements for manufacturing a wound dressing?

There are specific standards that are required to manufacture a wound dressing to ensure consistently high standards are met throughout production. A particular aspect of these standards covers manufacturing in a clean room environment, and at Raleigh Coatings, we are proud to have ISO 14644 Class 7 Clean Room. This standard is in place to ensure the specific elements of wound dressing manufacture are upheld;

  • Classification of air cleanliness
  • Specifications for testing
  • Metrology and test methods
  • Design, construction and start-up
  • Operations
  • Enhanced clean devices

What wound care products do we manufacture?

At Raleigh Coatings, we produce bi-laminate and tri-laminate silicone gel coated roll stock constructions for bordered and non-bordered dressings.

What materials can we use for your wound dressing?

We use a variety of raw materials in wound dressing manufacturing to ensure the highest quality medical grade products. The materials we use include:

  • Silicone gel
  • PU film carriers
  • Acrylic pressure-sensitive adhesives
  • Non-woven carriers
  • Polyester carriers

Our medical coatings process also has delamination and relamination capabilities and includes full development facilities, including pilot line requirements.

What production lines do we manufacture products for the wound dressings market on?

Our wound care roll products are manufactured in Class 7 Clean Rooms on lines 1 and 3. We are also able to perforate and slit in clean room facilities . You can find out more about each line in the Phase 3 development stage here.

What is cleanroom coating? How does it differ from industrial coating?

In wound care manufacturing, it is vital to ensure each medical-grade product is produced in a clean and sanitary space. Our clean rooms are air-controlled and continually monitored to ensure containment levels are adhered to, so we consistently provide inclusion free coatings.

This process differs from industrial coatings, as there are stringent standards to be met at each phase of development.

What is the process of perforation?

Perforation in wound dressings is an integral part of the development process and ensures improved performance of the dressing. To perforate wound care products, mechanical perforation takes place in the manufacturing stages.

Our equipment is able to perforate wound dressings in a range of materials such as films, acrylic coated films and silicone gel coated products. The perforator is set to the requirements of the project and can range from 1.5mm – 3mm, however this can be adjusted to a larger measurement if required. Other factors of perforation include the pattern of the hole to ensure consistent open area.

The mechanical perforation process also ensures parameters are consistent, and tooling is used to cut holes cleanly. Our perforator also removes over 99% of all waste produced during the process.

What tests can we perform on your wound care product in our laboratory?

An essential part of the development process is ensuring our wound dressing products meet high standards and specific testing specifications. We assess all coated bi, tri and quad laminated products and perform several tests including:

  • Adhesion
  • Stripping liner force and tack
  • Moisture vapour transmission rate (MVTR)

What are the processes of reel-to-reel slitting and at what stage of manufacture is this process done?

The process of reel-to-reel slitting is an operation that involves cutting large rolls into narrower rolls. We can provide  rewind slitting depending on your requirements.

The reel-to-reel slitting process can be performed before coating or post-coating. However, it is more common to use this process after coating, as this then goes on to produce smaller reels, which then moves on to the process of cutting into wound dressing sizes.

Which delamination and relamination services can we provide for your wound dressing?

At Raleigh Coatings, we provide both delamination and relamination services, depending on your specifications. In a delamination for example, you may need perforated liners to be replaced by fresh liners to change the type of wound dressing product. In a relamination case, there is the option to add additional films such as PU film to the acrylic side of the construction.

Our process is equipped to meet the needs of individual projects. Plus, our new delamination/relamination equipment ensures we are able to perform these requirements accurately and within the required standards.

What challenges do we face in wound dressing manufacture?

Our five-phase Raleigh Coatings process ensures we bring each customer high-quality medical-grade products for every project. Each stage in our development requires stringent testing and monitoring to meet industry standards and in-house quality management tests.

The wound dressing sector is continually evolving, and to keep ahead of the curve, we strive to ensure we innovate to bring top-quality products to our customers. There are challenges that the wound dressing manufacturing industry faces, so check out our next blog to see how we’re tackling these to improve our processes and specialist services.

For more information on how Raleigh Coatings can support your wound dressing requirements, and to find out more about our processes, contact our team on 01785 850 357 or email our Business Development Project Manager, Jenny Reeves ([email protected])