AtCotton Craft (Pvt) Ltd, we understand that in orthopedic medicine, the strength of the cast is only as good as the safety of the skin beneath it. While Plaster of Paris (POP) or synthetic casting tapes provide the necessary rigidity for fracture healing, they are abrasive and unforgiving. The success of prolonged immobilization often depends on the “invisible” layer—the padding.
IntroducingOrthoban Plus (Absorbent Cotton). Engineered to serve as the ultimate interface between delicate skin and rigid immobilization, Orthoban Plus is designed to prevent pressure necrosis, manage moisture, and ensure patient comfort. It represents the softer side of our commitment to “Healing with Excellence.”
Research & Development: Engineering the Perfect “Loft”
The development of Orthoban Plus was driven by a deep understanding ofcast complications. Our internal medical team and textile engineers analyzed the most common complaints during fracture recovery: skin maceration (softening due to trapped sweat), pressure sores over bony prominences, and severe itching.
To address these, we focused our R&D on two physical properties:Absorbency andLoft Retention.
- Material Science: We selected high-gradeabsorbent cotton rather than synthetic alternatives. Our research confirmed that natural cotton offers superior moisture transport, wicking perspiration away from the skin to keep the limb dry—a critical factor in preventing bacterial growth and maceration.
- Structural Integrity: A common failure in cast padding is flattening—losing its cushioning effect over time. Our engineers developed a specialized carding process that creates a uniform, high-loft web. This structure maintains its resilience (springiness) even under the compressive weight of a cast, ensuring continuous protection for nerves and blood vessels.
Clinical Field Evaluation: Validated by Orthopedic Technicians
Before Orthoban Plus reached the market, it underwent rigorous testing in the orthopedic wards and trauma centers of Pakistan’s busiest hospitals. We placed the product in the hands of the people who use it most: orthopedic surgeons and cast technicians.
The feedback highlighted the product’s exceptionalconformability. Technicians noted that Orthoban Plus possesses the ideal“tear-ability”—it can be easily feathered and torn by hand to contour around complex joints like ankles, elbows, and wrists without bunching or creating ridges.
Key Clinical Findings:
- Skin Protection: Doctors reported a significant reduction in friction burns and pressure spots on patients wearing casts padded with Orthoban Plus.
- Surface Smoothness: The padding provided a seamless, smooth surface, allowing the subsequent Plaster of Paris or fiberglass layer to adhere uniformly, resulting in a stronger, more stable cast.
- Cast Removal Safety: When it came time for cast removal, the distinct density of Orthoban Plus provided a safe buffer zone for the oscillating saw, protecting the patient’s skin from blade heat and abrasion.
In-House Manufacturing Excellence
Located inSundar Industrial Estate, Lahore, Cotton Craft’s manufacturing facility utilizes advanced non-woven textile technology to produce Orthoban Plus.
The process begins with the mechanical cleaning of raw cotton to remove impurities like seeds and leaf fragments, which could become irritants inside a cast. The cotton fibers are then “carded”—aligned in a specific direction—to create a continuous, soft web.
Our production lines are calibrated to ensure uniform density. Whether producing4-inch, 5-inch, or 6-inch rolls, the thickness is monitored automatically. Unlike generic padding that may have thin spots, Orthoban Plus is manufactured to guarantee consistent protection across every centimeter of the roll. The rolling mechanism is designed to wind the product firmly enough to hold shape but loosely enough to preserve the “fluff” or loft of the cotton.
Laboratory Quality Control: Comfort is Quantifiable
At Cotton Craft, soft does not mean imprecise. Every batch of Orthoban Plus undergoes stringent testing in our Quality Control Department.
Our QC Protocols Include:
- GSM (Grams per Square Meter) Verification: Ensuring the padding meets the specific weight requirements for optimal cushioning.
- Absorbency Testing: Verifying the cotton’s ability to absorb moisture instantly, ensuring the patient’s skin remains dry.
- Bioburden Analysis: Ensuring the cotton is biologically clean and free from pathogens, minimizing the risk of infection if the skin is compromised.
- Impurity Check: A zero-tolerance policy for foreign particles that could cause scratching or irritation during weeks of immobilization.
Verification & Market Validation
Orthoban Plus has quickly become a standard requirement in orthopedic departments nationwide. Procurement heads and hospital administrators value the product for its dual role: it enhances patient safety while reducing the likelihood of cast-related complications that require costly interventions.
The availability of three critical sizes—4 inch (paediatric/upper limb), 5 inch (standard), and 6 inch (lower limb/thigh)—ensures that clinicians have the right fit for every anatomical challenge. Distributors report that Orthoban Plus is frequently requested by name due to its consistent quality and ease of application.
Conclusion: The Cushion of Care
Orthoban Plus is more than just cotton; it is a shield. It protects vulnerable skin from rigid plaster, cushions nerves against hard bone, and provides the comfort necessary for healing. AtCotton Craft, we believe that the layer closest to the patient matters the most.
For orthopedic professionals who demand reliability in every layer of their treatment, Orthoban Plus delivers the perfect balance of softness and science.
Cotton Craft (Pvt) Ltd — Healing with Excellence.
Critical Usage & Safety Information
Product: Orthoban Plus (Absorbent Cotton Cast Padding)
Material: 100% Absorbent Cotton fibers.
Available Sizes:
- 4 inch (10cm)
- 5 inch (12.5cm)
- 6 inch (15cm)
Indications:
- Undercast Padding: Used as a protective layer between skin and Plaster of Paris (POP) or synthetic casting tape.
- Cushioning: Protects bony prominences (ankles, elbows, heels) from pressure necrosis.
- Compression Bandaging: Used as a sub-layer in multi-layer compression systems to distribute pressure evenly.
Key Features:
- Highly Absorbent: Manages sweat to prevent skin maceration.
- Conformable: Tears easily (“feathering”) for smooth application around joints.
- Protective: Creates a safety barrier for cast removal saws.
- Hypoallergenic: Chemically inert cotton reduces risk of allergic reactions.1
Precautions:
- Application: Apply smoothly without wrinkles to prevent pressure points.
- Water Exposure: While the cotton absorbs sweat, the cast system should generally be kept dry from external water sources unless waterproof cast liners are used.
- Open Wounds: If applying over an open wound, ensure a sterile primary dressing is applied first.
Storage:
Keep in a cool and dry place. Protect from moisture and dust to maintain the loft and hygiene of the cotton.