Introduction to Hand Sanitizer Manufacturing
As the demand for hand sanitizers soared during the COVID-19 pandemic, these unassuming bottles became a global necessity. In this blog, we’ll peel back the layers to reveal the meticulous process of manufacturing hand sanitizers. From the precise formulation of ingredients to the utilization of cutting-edge machinery, we’ll delve into every facet that brings these sanitizing solutions to life. Join us on this journey to understand how these essential tools for post-COVID-19 hygiene are created with utmost care and precision.
The journey of a hand sanitizer begins with its formulation. This is where science meets art. The World Health Organization (WHO) and the U.S. Food and Drug Administration (FDA) have laid out precise guidelines for crafting effective hand sanitizers. These guidelines ensure that the final product not only meets safety standards but also delivers on its promise to protect.
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Hand Sanitizer Manufacturing Process
The preparation of the gel is one of the most critical phases in the manufacturing process. To ensure a clear, bright gel after suppression, an agglomerate-free dispersion is required. Surfactants and moisturizers containing glycerin are being used in some formulations to protect the skin and keep it from drying out. Since they may only make up a small portion of the larger composition, the mixing method must be sufficient of accurately dispersing them in the final result.
The Manufacture of Hand Sanitizers Involves the Following Processes:
1. Hand Sanitizer Formulation
Hand Sanitizer manufacturing need increase very huge in the covid-19 and drug manufacturing establishments are required to register their establishments with FDA. This blog covers a broad range of methods for producing hand sanitizers. After COVID-19, new hand sanitizers manufacturing and production increased. During COVID-19, the FDA released guidelines in March 2020 for expanded production of hand sanitizers. The aim was to increase hand sanitizer production by allowing companies other than previously approved or registered drug manufacturers to produce them. The formula for hand sanitizers is very precise.
The World Health Organization has published an excellent step-by-step guide to make hand sanitizers. The two formula options suggested by the WHO are the same as those suggested by the FDA. The formulas for both hand sanitizers are shown below.
2. Hand Sanitizer Ingrediexnts Mixing Process.
A hand sanitizer mixer performs the following processes:
- Water and Carbopol are mixed, until it forms a viscous gel. To achieve a conglomerate-free mixture, it is ensure that ventilation is prevented during mixing.
- Alcohol is then additional in the second phase of mixing until the mixture forms a uniform product. Initially, the alcohol would have a 96% concentration. Combination it with the other ingredients would dilute it to 70% to 80% attention.
- Triethanolamine may be additional to acquire the right PH of the solution, so it would not bother the skin.
- Humectants can also be added and some preservatives, depending on your formulation.
In order to get an agglomerate-free mixture and reliable batch-to-batch hand gel solutions, you must have a high speed mixer. The action of the blade of a high shear or a powder-liquid mixer will make sure dispersion of the Carbopol into the liquid substances to stop aeration. Air entrapped in the hand gel mixture can effect clouding and can cause harm during the filling process.
3. Hand Sanitizer Packaging (Filling, Capping and Sealing)
We are all aware of the importance of proper hand washing in preventing the spread of harmful germs. To keep hands clean, soaps and hand washes are used. Hand Sanitizers were widely used as a self-protection and personal hygiene measure in hospitals, new born and children\’s care, and hygiene departments in the early 2000s, and during the outbreak of the Novel Corona virus COVID-19, they are widely used as a self-protection and personal hygiene precaution. It is now considered as a major commodity.
Both alcohol and non-alcohol based sanitizers are available in the form of Foaming Solution and Gel. Processing and Packaging of Hand Sanitizer has its own significance. Hand Sanitizer packaging contains squeeze bottles, pumps, sprays, pouches, plastic bags, and several other options.
4. Filling:
Filling machines are used to fill pump bottles automatically according to pre-set volumes. To achieve accuracy filling, machines like these are equipped with a servomotor and other pneumatically powered equipment. Automatic filling machines in factories can manufacture bulk hand sanitizers with over millions of inventories to ship per month.
The procedure will be determined by the product’s viscosity. Filling machines with gravity filling nozzles and piston induced nozzles are available. This is to allow for a wide range of viscosities.
5. Capping:
For capping the bottles, you can utilize automatic capping machines for strongly tightening hand sanitizer screw-capped containers. The pump dispenser head or cap of these devices is used to cap PET hand sanitizer bottles. A capping machine usually has four rollers or heads that apply torque to threaded caps on threaded bottle necks.
Capping machines use a PLC application to change parameters including speed and bottle size automatically. The rollers can be modified to match various cap diameters and heights. As a result, the transition is smoother. Usually, these devices can handle between 40 and 100 bottles per minute.
6. Labeling
Without a stunning label wrapped around the bottle, your hand sanitizer brand is incomplete. That is done for you by a labeling system that wraps labels around the cap and container body automatically
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Ingredients Used for the Preparation of the Hand Sanitizer:
That is everything there is to it. You only need four ingredients and just a little care about making a hand sanitizer that really is ready for the post-COVID-19 world.
Formula 1: Ethanol (volume %)
Glycerin 1.45%; Ethanol 80%; Hydrogen peroxide 0.125%; QS water
Formula 2: Isopropanol (volume %)
Glycerin 1.45%; Ethanol 75%; Hydrogen peroxide 0.125%; QS water
Including Extra Skin Benefit Ingredients and Fragrance
According to FDA regulations, these are strictly forbidden. Glycerin and fragrance are also found in Purell. Glycerin is a natural and low-cost skin-beneficial ingredient. Fragrances in skin care products are common among consumers. Both ingredients are useless and would lift the price of your hand sanitizer’s raw materials.
Sourcing of Materials, and Notes of Caution
Sterile Water: The best and simple way is to boiling the water. Simply stop heating or boiling water near the flammable, high-proof alcohol.
Ethanol: One important thing to consider is that the ethanol must be denatured, or made to taste bad, in order to avoid consumption.
Testing
If you follow the FD’s hand sanitizer guidelines, you will prevent a lot of problems. There’s no need to test your formula’s bug-killing ability. Hand sanitizers with the above formulas have been shown to effectively kill bugs while remaining healthy for the user. After production, the alcohol level – ethanol or isopropyl alcohol – wants to be check by physical chemistry means such as alcoholmeter or hydrometer.
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Hand Sanitizer Manufacturing Machines:
SANITIZER FILLING MACHINE:
Liquid Filling Machine to fill up different sized and shaped Bottles and Jars with different types of technologies to fill Normal, Low-density, Viscous and Foaming material by Semi Automatic and Fully Automatic models.
Digital Filler:
- Volumetric Filing Machine
(10 ML to 1000 Ltr)
- Electronic Filling Machine
(10 ml to 5000 Ltr without help of change parts
SEALING MACHINE:
Second procedure is Bottle and Jar Sealing. The Machine ensures tight closure to keep product. Machine appropriate for different formed bottles like Round, Oval, Flat and Plastic Cap, Flip-off Cap and other varieties with the help of change parts.
- Single head and multi head capping machine
- inner plugging system
- cap feeding system
LABELING MACHINE:
Last procedure is the Labeling which is all about information of product, company information, production content information and consumer attraction towards product. We offer perfect labeler to apply great labels.
Hand sanitizer manufacturing in an FDA-regulated plant require a high level of accuracy in its formulation, mixing and filling processes. To get quality and batch-to-batch consistency, third party tests and in-house testing are perform.
- Round Wrap LABELING MACHINE
- Double Side LABELING MACHINE
- Double Side Cum Round Wrap LABELING MACHINE
