Technology & Manufacturing
The Process Behind Every Cap We Ship
Every Servo-Med closure begins with medical-grade polymer from Europe and ends with a fully inspected, export-ready unit. Here is exactly how we make it.
Everything Starts with the Right Materials
We do not work with local substitutes or unverified polymer grades. Every material used in a Servo-Med closure is specified, tested and traceable — before it ever enters the moulding machine.
Shell Material
LDPE - Low Density Polyethylene
The outer shell of every cap, Euro Head or Twin Port is injection moulded in medical-grade Low Density Polyethylene (LDPE). Our LDPE grades are sourced exclusively from leading European polymer manufacturers: Basell, Borealis and Ineos. These are the same suppliers that European pharmaceutical packaging companies rely on. The grades used are compatible with both injection moulding and blow moulding processes, depending on customer requirements as per bottle.
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Suppliers - Basell / Borealis / Ineos
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Origin - Germany / Europe
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Grade - Medical-grade LDPE
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Process - Injection Moulding compatible
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CoA - Verified on each incoming lot
Septa Material
Bromo Butyl Rubber Discs
The rubber septum the disc that provides sterile spike access and self-sealing re-closure in each port is made of Bromo Butyl rubber. Bromobutyl is the industry standard for IV closure septa, chosen for its low extractables profile, low gas permeability and reliable re-sealability after spike puncture. Our Bromo Butyl discs are sourced exclusively from ISO 9000 certified manufacturers and must comply with the pharmacopoeial standards set by three major pharmacopoeias.
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Material - Bromo Butyl Rubber
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Supplier - QMS ISO 9000 certified manufacturers only
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Compliance - IP (Indian Pharmacopoeia)
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Compliance - BP (British Pharmacopoeia)
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Compliance - USP (United States Pharmacopoeia)
Septa Material
Thermoplastic Elastomer
The dual port material TPE - Thermoplastic Elastomer provides two spike access simultaneously, required low penetration force and self sealable quality & compliance with EP 3.2.9
Both injection sites are covered with Aluminum Foil.
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Material - Thermoplastic Elastomer
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Supplier - QMS ISO 9000 certified manufacturers only
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Compliance - IP (Indian Pharmacopoeia)
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Compliance - BP (British Pharmacopoeia)
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Compliance - USP (United States Pharmacopoeia)
Manufacturing Process
Seven steps from Raw Material to Shipment
A controlled, repeatable, ISO 9001:2015-governed process built over 30 years of production experience. Every step is documented. Every batch is traceable.
Step 1
Incoming Quality Control
Raw Material Receipt & Testing
Every incoming lot of LDPE, Bromobutyl Rubber Discs , Thermoplastic Elastomer and Aluminium Foil are inspected before it enters production. Certificate of Analysis ( CoA ) documents are verified agaist specification . No material enters the moulding or assambly line without passing the gate.
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LDPE : Melt flow index, absence of impurities, physico chemical tests and Bacterial endotoxin tests to be performed.
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Bromobutyl Rubber Discs & Thermoplastic Elastomer : Hardness, penetration force , withstand capacity for sterilization process, self sealability and fragmentation tests to be performed.
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Aluminium Foil : Performance test along with thickness test to be performed on all incoming material.
Step 2
Eurohead Caps
Injection moulding for LDPE shells
Hot runner mould tooling used for precise-consistent shot quality and minimal waste.
Medical grade LDPE is processed through precision injection moulding with hot runner mould tooling.
Temperature, pressure and cycle time are the key parameters to get precise outcomes.
Tooling is maintained to tight dimensional tolerances to ensure consistent & critical seal on IV bottle neck.
Accurate dimensions and consistency are achieved by controlling moulding parameters.
In process checks as per inhouse specification are carried out, at defined intervals during each production run.
Twin Port Caps
Injection moulding for LDPE & TPE caps
Both LDPE and TPE are moulded simultaneously under controlled conditions which helps to prevent contamination & reduce bio burden.
Twin-moulding ensures correct bonding between LDPE and TPE.
In process checks as per in-house specification are carried out at defined intervals during each production run.
Step 3
Eurohead Caps
Assembling
Rubber Disc Seating
Bromo Butyl rubber discs are seated into the moulded LDPE shells by an automated process.
Twin Port Caps
Aluminum Foil Sealing
An aluminum foil is heat-sealed over the assembled TPE septa. This provides an additional tamper-evidence layer and protects the septa from contamination throughout. The seal is applied at controlled temperature and pressure settings to ensure bond integrity without damaging the underlying injection sites.
Each cap is visually inspected for its seal Integrity with highly magnified Cognex camera.
Step 4
Variant-Specific Process
Aluminium Foil Sealing (Twin Port — Sealed Variant)
For the aluminium-sealed design variant of the Twin Port Cap, an aluminium foil is heat-sealed over the assembled TPE septa. This provides an additional tamper-evidence layer and protects the septa from contamination through out. The seal is applied at controlled temperature and pressure settings to ensure bond integrity without damaging the underlying injection sites.
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Bonding of Aluminium Foil seal protects injection sites
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Each cap is visually inspected for its seal Integrity with highly magnified cognex camera
Step 4
Quality Inspection
In-Process & Final Quality Checks
Quality inspection is not an end-of-line activity at Servo-Med — it runs throughout production. Every finished unit passes a multi-point inspection before packaging. Our ISO 9001:2015 system defines the check points, sampling plans and rejection criteria for every product variant.
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100% visual inspection for moulding defects, contamination and seating accuracy.
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Dimensional checks : as per specification on representative samples as per sampling plan, we follow zero tolerance attitude for quality control.
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Functional Tests : fragmentation, leakage, self sealability, penetration force and tear off / peel off test.
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Rejection criteria defined by product specification - non confirming units are rejected and are quarntined with 'Rejected' status.
Step 5
Packaging
Batch Coding & Export Packaging
Released units are packaged in clean conditions with full batch traceability.
Packaging specifications are defined per customer requirements.
Batch codes and production records are retained per ISO 9001:2015 documentation requirements for full traceability of every shipment.
Step 6
Documentation
Export Documentation & Compliance
As a One Star Export House recognised by the Government of India, our documentation for each international shipment is prepared to the required standard. All export paperwork including certificates of origin, quality certificates and customs documentation is handled from our Andheri office.
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Certificate of Origin and Quality Certificate for each shipment.
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Customs documentation per destination country requirements.
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Handled under Star Export House status — IEC: 0395017548.
Step 7
Dispatch
International Shipment
Finished goods are dispatched to pharmaceutical companies across the Middle East and Southeast Asia. Every shipment leaves with full documentation and is traceable back to the raw material lot from which it was made a requirement of our ISO 9001:2015 system and our pharma clients.
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Export to: Middle East and Southeast Asia.
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Full lot traceability from raw material to shipment.
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Dispatch records maintained per ISO 9001:2015.
Looking for a Dependable IV Closure Partner?
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