See how a Sialkot instrument is made.

Six stations, one shop floor.

Every AJ Brothers instrument passes through six controlled stations, all on a single plot under one ISO 13485 quality system. No sub-contracted forging, no off-site polishing, no third-party packaging house in a different city. Lot traceability is preserved end-to-end.

1. Forging

Bar stock is drop-forged into the instrument blank by master forgers working German-pattern hammers. Stainless 420 for most general instruments; 410 where harder tempering is required; tungsten-carbide inserts on needle-holder and scissors jaws. Forging temperature is logged; raw-material certificates are held by lot.

2. Machining

CNC and manual milling brings the blank to dimensional spec. Jaw geometry, ratchet teeth, joint clearance — all to the drawing. Pieces failing dimensional check are scrapped at this stage, not pushed through.

3. Polishing

Hand polishing by craftsmen with twenty-plus years on the bench. Mirror finish on the outer surfaces; satin finish on the working face if the spec calls for it. This is where Sialkot earns its reputation — automation cannot replicate the polished feel of a hand-finished surgical scissor.

4. Quality Control

AQL 1.0 visible-defect inspection; 0.65 critical-defect inspection by default. Every fifth piece pulled for dimensional re-check against the master gauge. Failures trigger lot re-inspection. QC sign-off is the gate to the marking station, not advisory. See the full quality framework for the audit-trail detail.

5. Laser marking

UDI-compatible laser marking per the spec sheet — manufacturer mark, model number, lot number, optional buyer mark for OEM orders. Mark depth and contrast are verified by random sample. EU MDR Annex VI UDI fields supported on request — see OEM & private label for the buyer-mark workflow.

6. Packing

Individual pouch or peel-pouch; carton; master carton; documentation pouch with QC certificate + lot card + (where applicable) sterilisation indicator. Outer cartons marked with HS code, country of origin, gross/net weight, and customs-ready packing list.

Audits welcome

Distributor and OEM-buyer audits are welcome with two weeks’ notice. We host audit days regularly; the QC team can walk you through the full traceability chain for any lot we have ever shipped. The Sialkot Surgical Industrial Estate is 25 minutes from Sialkot International Airport. Book a factory audit or email qc@ajbrothersent.com.