A complete guide to controlling formaldehyde release during the production of silicone hip pads

A complete guide to controlling formaldehyde release during the production of silicone hip pads

Introduction
In today’s society, people are increasingly concerned about health and safety. As a common daily necessity, the quality and safety of silicone hip pads are also of great concern. Formaldehyde, as a harmful substance, has many adverse effects on human health, such as causing respiratory diseases, allergic reactions, and even cancer. Therefore, effectively controlling formaldehyde release during the production of silicone hip pads is crucial to protecting consumer health, improving product quality and market competitiveness. This article will explore in depth the sources of formaldehyde release in the production of silicone hip pads, and introduce in detail various effective methods for controlling formaldehyde release.

1. Sources of formaldehyde release in the production of silicone hip pads
Raw material introduction: Silicone raw materials may be exposed to substances containing formaldehyde during the production process. For example, some silicone raw materials may use catalysts or stabilizers containing formaldehyde during synthesis. If these raw materials are not fully treated or purified, a certain amount of formaldehyde may remain and be released in subsequent production.
Adhesive use: In the process of making silicone hip pads, if adhesives are used to bond different parts or materials, and the selected adhesives contain formaldehyde or formaldehyde-releasing ingredients, it will become an important source of formaldehyde release in silicone hip pads. Some inferior adhesives may contain more free formaldehyde, which will gradually be released into the surrounding environment during the use of silicone hip pads.
Pollution in the production process: Unreasonable or non-standard production processes may also lead to the generation and release of formaldehyde. For example, in some silicone processing processes, some auxiliary chemicals such as cleaning agents and release agents containing formaldehyde may be used. If these chemicals are not completely cleaned or removed, the residual formaldehyde will be slowly released after the silicone hip pad is cured.

2. Raw material selection and control
Selection of high-quality silicone raw materials: Choose high-quality silicone raw materials produced by regular manufacturers. These manufacturers usually strictly control the quality and production process of raw materials during the production process, try to avoid the use of additives containing formaldehyde, and fully purify and treat the silicone raw materials to reduce the content of harmful impurities and reduce the risk of formaldehyde release from the source. When purchasing silicone raw materials, suppliers are required to provide detailed product quality inspection reports, including relevant indicators such as formaldehyde content, to ensure that they meet relevant standards and requirements.
Use environmentally friendly adhesives: During the assembly process of silicone hip pads, if adhesives are needed, environmentally friendly adhesives with no formaldehyde addition or low formaldehyde release should be given priority. This type of adhesive strictly controls the formaldehyde content during production and use, and can effectively reduce the source of formaldehyde in silicone hip pads. For example, some environmentally friendly adhesives with water-based polyurethane adhesives, modified starch adhesives, etc. as the main ingredients have good bonding properties and low formaldehyde release, and can be used in the production of silicone hip pads.
Check the quality of auxiliary materials: For other auxiliary materials that may be used in the production process, such as cleaning agents, release agents, etc., they should also be strictly screened, and products that meet environmental protection requirements, are formaldehyde-free or low in formaldehyde should be selected. Before use, these auxiliary materials should be fully tested and evaluated to ensure that they will not introduce excessive formaldehyde pollution during use.

3. Production process optimization
Improve the mixing process: During the mixing process of silicone, ensure that the raw materials are fully mixed and evenly, so that a good cross-linking structure can be formed between the silicone molecular chains, which helps to improve the stability and durability of silicone and reduce the release of small molecules such as formaldehyde. The mixing effect can be improved by optimizing process parameters such as mixing temperature, time, and rotation speed, as well as using appropriate mixing equipment and mixing methods. For example, appropriately increasing the mixing temperature can accelerate the movement of silicone molecules and the speed of cross-linking reaction, but too high a temperature may cause silicone to cure or decompose prematurely, so it is necessary to determine the optimal mixing temperature range based on the specific silicone raw materials and formulas.
Optimize the molding process: During the molding process of the silicone hip pad, control the molding temperature, pressure, and time parameters to ensure that the silicone can be completely cured and molded, while avoiding excessive cross-linking or thermal decomposition to reduce the generation and release of formaldehyde. For example, in injection molding, the injection speed, holding pressure, and curing time are reasonably adjusted so that the silicone can evenly fill the mold cavity and cure quickly at a lower temperature and pressure, thereby reducing the release of formaldehyde. In addition, the gradual heating curing process can allow the moisture and other volatile substances in the silicone to gradually evaporate and escape, reducing its residue during the curing process, thereby reducing the risk of formaldehyde release.
Add a cleaning process: After the silicone hip pad is produced, add a cleaning process to use pure water, distilled water or other suitable cleaning agents to fully clean the product to remove harmful substances such as formaldehyde, adhesives, and additives remaining on the surface. After cleaning, dry it again to make the moisture content on the surface and inside of the product reach an appropriate level to further reduce the release of formaldehyde. It should be noted that during the cleaning process, cleaning agents containing formaldehyde should be avoided, and it is necessary to ensure that the wastewater after cleaning is properly treated to prevent environmental pollution.

4. Quality inspection and monitoring
Establish a strict quality inspection system: formulate and improve the quality inspection standards and specifications for silicone hip pads, covering various links such as raw material inspection, production process monitoring and finished product inspection, and strictly inspect and control the formaldehyde release. During the raw material inspection stage, the formaldehyde content of each batch of silicone raw materials, adhesives and other auxiliary materials is tested to ensure that they meet the relevant standards and internal quality requirements of the enterprise; during the production process, the semi-finished products on the production line are sampled and tested regularly to promptly discover and solve the formaldehyde release problems that may occur during the production process; during the finished product testing stage, the formaldehyde release of silicone hip pads is strictly tested in accordance with national standards or international standards, such as GB/T 2912.1-2009 “Textiles – Determination of formaldehyde – Part 1: Free and hydrolyzed formaldehyde (water extraction method)”, ISO 14184-1:1998 “Textiles – Determination of formaldehyde – Part 1: Free and hydrolyzed formaldehyde (water extraction method)”, etc. Only qualified products can be shipped and sold.
Adopt advanced testing equipment and technology: Introduce high-precision formaldehyde detection instruments, such as spectrophotometers, gas chromatographs, formaldehyde rapid detectors, etc., which can accurately and quickly detect the formaldehyde content and release in silicone hip pads. At the same time, the testing equipment should be calibrated and maintained regularly to ensure the accuracy and reliability of its measurement results. In addition, some advanced testing technologies and methods, such as sensor technology, spectral analysis technology, etc., can be used to monitor the formaldehyde release of silicone hip pads in real time during the production process, and timely feedback the quality changes in the production process, so as to provide a basis for the adjustment and optimization of the production process.
Carry out third-party testing and certification: In order to improve the credibility and market recognition of product quality, silicone hip pad products can be regularly sent to qualified third-party testing agencies for testing and certification. These third-party testing agencies usually have professional testing equipment, technical experts and strict quality control systems, and can conduct comprehensive, objective and fair testing and evaluation of products in accordance with international standards and specifications, and issue authoritative test reports and certification certificates. Through third-party testing and certification, it can not only enhance consumers’ confidence in product quality, but also help enterprises to promptly discover problems and deficiencies in products and continuously improve product quality and production processes.

5. Post-processing method

Application of adsorbent: Before packaging the silicone hip pad product, some formaldehyde adsorbents, such as activated carbon, bamboo charcoal, diatomaceous earth, etc., can be placed. These adsorbents have a porous structure and a large specific surface area, which can adsorb formaldehyde molecules released from the surface and inside of the product, thereby reducing the formaldehyde concentration in the product. It should be noted that when using adsorbents, the type and amount of adsorbents should be reasonably selected according to factors such as the size, weight and packaging method of the silicone hip pad, and the adsorbent should be replaced regularly to ensure its adsorption effect. In addition, the adsorbent can be placed together with the silicone hip pad in a well-ventilated environment to further improve the formaldehyde removal effect.

Photocatalytic decomposition technology: Using photocatalysts, such as titanium dioxide (TiO₂), zinc oxide (ZnO), etc., under the irradiation of ultraviolet rays or visible light, formaldehyde on the surface of the silicone hip pad and the surrounding environment can be decomposed into harmless substances such as carbon dioxide and water, thereby achieving effective removal of formaldehyde. Photocatalytic materials such as nano-titanium dioxide can be added to the production process of silicone hip pads to form a photocatalytic coating on the surface of the product, or the photocatalytic material can be made into air purification equipment and placed in the storage and use places of silicone hip pads to continuously decompose formaldehyde through light. Photocatalytic decomposition technology has the advantages of high efficiency, environmental protection, and sustainability. It is a promising formaldehyde removal method, but in practical applications, attention should be paid to issues such as the activity, stability, and service life of the photocatalyst to ensure its long-term and effective function.
High temperature treatment: High temperature treatment of silicone hip pads, such as hot air aging treatment, steam treatment, etc., can accelerate the release of formaldehyde to a certain extent, so that the product releases most of the formaldehyde in a short time, thereby reducing its formaldehyde release during normal use. The temperature and time of high temperature treatment need to be optimized and adjusted according to factors such as the material, structure, and performance requirements of the silicone hip pad to avoid excessive treatment leading to product performance degradation, such as discoloration, deformation, aging, etc. For example, the silicone hip pad can be placed in a hot air circulation oven and treated at a temperature of 80℃-120℃ for 1-2 hours, and then naturally cooled to room temperature before packaging and sales. It should be noted that during the high-temperature treatment process, the temperature and time must be strictly controlled to avoid damage to the product, and the product must be quality tested after treatment to ensure that its performance meets relevant standards and requirements.

6. Environmental protection and sustainable development
Strengthen waste gas treatment: In the silicone hip pad production workshop, install effective waste gas collection and treatment equipment to centrally treat the waste gas containing formaldehyde generated during the production process, such as using activated carbon adsorption, catalytic combustion, biological filtration and other technologies to remove harmful substances such as formaldehyde in the waste gas or convert them into harmless substances before discharging them into the atmosphere to reduce pollution to the environment. At the same time, the waste gas treatment equipment should be regularly maintained and updated to ensure its normal operation and treatment effect, in compliance with national and local environmental protection emission standards.
Wastewater treatment and reuse: For wastewater generated during the production of silicone hip pads, such as cleaning wastewater and cooling wastewater, a complete wastewater treatment system should be established, and comprehensive treatment methods such as physical, chemical and biological methods should be adopted to remove and degrade pollutants such as formaldehyde, suspended solids and organic matter in the wastewater, so that the wastewater can be discharged or reused after meeting the discharge standards or reuse requirements. Wastewater reuse can not only reduce the consumption of water resources, but also reduce the impact of wastewater discharge on the environment, and realize the recycling and sustainable development of resources.
Promote the construction of green supply chain: Silicone hip pad manufacturers should strengthen communication and cooperation with partners such as raw material suppliers, adhesive manufacturers, and packaging material suppliers to jointly promote the construction of green supply chain. Encourage suppliers to adopt environmentally friendly raw materials and production processes to reduce the content of harmful substances in raw materials; establish long-term and stable cooperative relationships with suppliers, jointly carry out quality inspection and environmental management work, and ensure the environmental protection and sustainability of the entire supply chain. In addition, enterprises can also promote the green development of the entire industry by carrying out green procurement activities and giving priority to suppliers with environmental certification and good environmental performance.

7. Consumer education and communication
Provide product information: Clearly and accurately mark the formaldehyde emission test results, implementation standards, precautions and other information of the silicone hip pad on the product packaging and instructions, so that consumers can fully understand the quality and safety of the product when purchasing, and make reasonable choices according to their own needs. At the same time, the company’s official website, social media platforms and other channels can also be used to publicize and popularize the formaldehyde emission knowledge, purchase methods and usage skills of silicone hip pads to consumers, so as to improve consumers’ cognitive level and self-protection awareness.
Establish a consumer feedback mechanism: Set up a special consumer feedback channel, such as a customer service hotline, online customer service, e-mail, etc., to promptly listen to and collect consumers’ opinions and suggestions on the quality of silicone hip pads, formaldehyde emission, etc., and carefully investigate and handle the problems reported by consumers, and promptly give consumers satisfactory replies and solutions. Through good communication and interaction with consumers, it can not only improve consumers’ trust and satisfaction with the company, but also help companies to promptly discover product problems and market trends, and provide reference for product improvement and innovation.

8. Summary
Controlling the release of formaldehyde in the production process of silicone hip pads is a systematic project, which requires comprehensive and effective measures from multiple aspects such as raw material selection, production process optimization, quality inspection and monitoring, post-processing methods, environmental protection, and consumer education. As a silicone hip pad manufacturer, it should attach great importance to the issue of formaldehyde release, actively fulfill social responsibilities, strengthen technological innovation and quality management, improve product quality and safety, and provide consumers with healthy, environmentally friendly and comfortable products. At the same time, relevant government departments should also strengthen supervision of the silicone products industry, improve relevant standards and regulations, strengthen supervision and inspection of enterprises and law enforcement, severely crack down on illegal production and sales of silicone hip pads with excessive formaldehyde, and jointly create a safe and healthy market environment to promote the sustainable development of the silicone products industry.