Each day more than one million condoms are made at the Trojan Condom Manufacturing Facility in Ewing, New Jersey alone. Manufactured at a rate of hundreds per hour and in many different shapes and sizes, these condoms are tested to the highest government and industry standards before being shipped to consumers. So how do they do it? Check out this fascinating video, with images of the highlights above.

Today, condoms are much more than a safety precaution as many people like using them to enhance their sexual experiences. As a result, Trojan has developed more than 3000 custom made glass moulds used to produce numerous different condom types, styles and sizes.

To begin the process, these moulds run along the manufacturer’s mechanical ‘dipping line’ where they are dipped twice into a liquid latex solution for a thin and even coating. The coated moulds then pass through drying and curing ovens to dry the latex material. In its dried form, this latex is a strong and flexible material – as well as a natural one as it comes from rubber trees. (Hence the nickname ‘rubbers’).

Once dry, the resulting condoms are removed from their moulds. The moulds are washed and dried and then returned for another round of dipping, while the condoms are washed in a solution for a super smooth finish.

At this point, each condom is electronically tested. To do so, the condom is placed over a stainless steel shaft and electrified through a test pad. If the electric circuit is complete, there is a fault somewhere and the condom is rejected. If the circuit is not complete, well then you have a perfect condom. These perfect condoms then head to the wrapping process where machines mechanically inject a lubricant and wrap each condom within two opposing foil webs that are heat sealed together.

Next, the condoms head to another round of rather fascinating tests where they are randomly selected for quality checks. One of the coolest checks is the air inflation test, which tests the condoms for strength and elasticity. Each condom is filled with 25 litres of air per minute, which is more than the amount of air needed to fill a basketball.

In other tests for durability, the condoms are filled with water and then vigorously worked by hand, while a tensile test stretches the condoms out in width to see how far they can enlarge and how strong they are. Incredibly, most condoms are able to stretch 750% of their original width.

Finally, the condoms move on to the lab where the chemical composition of the condoms is randomly checked by in house scientists before this particular batch is packed into boxes and sent onward to the consumer!