There are various hand sanitizer manufacturers we using every day, do you know the bulk hand sanitizer manufacturing process, following will show you how to manufacture hand sanitizers?
The all kinds of viruses and environmental pollution is still threatening people’s lives, and people’s demand for hand sanitizer has also increased significantly. This puts tremendous pressure on the production of hand sanitizer manufacturers.
Many people in the industry want to produce commercial hand sanitizer, but they don’t know how to produce it. Tychemical factory is a Chinese manufacturer specializing in the production of hand sanitizer, and export the hand sanitizer and disinfectant products to worldwide market.
Hand sanitizer is liquid, gel or foam used to eliminate bacteria and viruses, etc. Different product formulas vary greatly.
The amount of active ingredients, such as benzalkonium chloride, however, the most effective are usually isopropyl or alcohol-based disinfection products. General wine
The refined content is 60-95%. Alcohol and polymer glues, such as carboxyvinyl polymer water dispersion, have a gelling effect, although some are used Low viscosity product of foam pump. The remaining raw materials, including skin care products and perfume, and some pigments can also be added.
Materials- Raw materials for hand sanitizer manufacture
- 95-98% purity ethanol or isopropanol(Main bactericidal component)
- carbomer 940
- glycerol (moisturizer)
- deionized sterile water
- container (IBC drums, bottle or barrel clients specified)
- pump or cap of container
- propylene glycol (optional)
- aloe extract (optional)
- Fragrance (optional)
- Vitamin E (optional)
- Hydrogen peroxide (optional)
Machines – Main machines used for sanitizer manufacture
Temperature display and control, accuracy ± 1 ℃ (or ±0.1 ℃); Mixing Speed display and control; Pressure display and control; Level display and control; Flow display and control; Valve open/close control, etc.
There are many models of filling machine, the main function of this is to inject the mixture liquid to the container automatically. Usually used in Personal Beauty, Healthy Care, Household Chemical industry.
3.Water Deionizerd System
Deionized water is indispensable to the formula, impure water will significantly degrade the effect of hand sanitizer, shorten the shelf life, and may have unexpected side effects.
Apply the label on the container automatically, connected to the filling machine in most time.
optional, if the reactor and the filling machine are connected directly.
Production environment requirements
Requirements/standard for hand sanitizer manufacture
- All manufacturing processes regarding the content of hand sanitizer must be in a class 100,000 ultra-clean room.
- Bottles, labels and other parts must be thoroughly cleaned and disinfected in the ultraviolet ozone disinfection workshop.
Why the strict requirements are so high?
Unqualified workshops cause unpredictable results, and you may get inferior products cased the wholes bulk sanitizer production failed final testing and inspection.
Contact us for bulk private label hand sanitizer production. +
Hand sanitizer formulas from FDA & WHO
Each hand sanitizer brand will have a special formula(Basically the same in manufacturing process and technicals),according to the needs of customers. We have no ability to list all formulas of hand sanitizer, so I put the two formulas provided by FDA and WHO below, these two formulas are roughly the same ,as well as the effectiveness in killing viruses and bacteria.
Basic Hand Sanitizer Formula:
95-98% pure ethanol(62-80% V/V), Glycerol(1.45% V/V), Carbomer 940(0.1%~2% V/V),deionized sterile water(2%~5%)
Formulations may contain a variety of ingredients.
Key Ingredients: A hand sanitizer formulation may contain active ingredients such as:
- Ethyl Alcohol
- Isopropyl Alcohol
- Benzalkonium Chloride
The most important sanitizing ingredient is Ethyl or Isopropyl alcohol at a very high concentration, say at 96% (WHO). This is to ensure that when mixed with the solution, the final product would be around 70 to 80% concentration, as required by the FDA and CDC. Fun fact: hand sanitizer needs to have an alcohol concentration of 60-95%.
- Carbopol– provides gel-like texture. However, hand foams in pump bottle dispensers usually have lower viscosities to provide efficient dispersion.
- Humectants or Moisturizerslike Glycerin
- Fragrance(usually not included in non-scented hand sanitizers)
- Coloring(not included in clear hand sanitizers)
- Bitter-tasting compound– to prevent consumers from drinking the hand sanitizer
Fun fact: you can find Marshmallow Pumpkin Latte, Fresh Sparkling Snow, White Peach Chardonnay-scented hand sanitizers. For real.
Hand Sanitizer Manufacturing Process/ Steps
Compounding the raw materials of hand sanitizer
Measure and add raw materials (according to formulas, recipes, and instructions) into large vessels called batch tanks, mixers, or compounders – this happens manually or automatically, depending upon the type of ingredient and the amount.
Forklifts bring materials/ingredients to the vessels in large drums or bags.
Mechanical agitators within these vessels mix the ingredients to very specific parameters, such as time and speed. Computer operations control these parameters.
The workflow of the hand sanitizer mixer is as follows:
1.Mix the water and carboline until a viscous gel is formed. In order to obtain a clump-free mixture, it is necessary to ensure that aeration is prevented during the mixing process.
2.Then add alcohol to the second stage of mixing until the mixture forms a homogeneous product. At the beginning, the concentration of alcohol is 96%. Mixing it with other ingredients will dilute it to a concentration of 70% to 80%.
3.Triethanolamine can be added to obtain the proper pH of the solution so that it will not irritate the skin.
4.According to your formula, you can also add wetting agents and some preservatives.
In order to achieve a non-clumping mixture and consistent batch-to-batch hand gel solution, you should have a high-speed mixer.
The action of the blades of the high shear or powder-liquid mixer will ensure the dispersion of the carbow into the liquid substance to prevent aeration. Air in the hand gel mixture can cause turbidity and cause problems during the filling process.
In addition, the in-line mixer can effectively circulate and mix in the mixing pipeline to ensure the uniformity of the final product.
Then, use the filling machine to fill the hand sanitizer into a separate container.
(At the same time,bottles, labels and other parts must be thoroughly cleaned and disinfected in the Ultraviolet Ozone Disinfection Workshop)
Let the various raw materials react fully after mixing
According to the volume of hand sanitizer content you need and the model of reactor, reaction time is different. Generally, reaction of 1 ton of hand sanitizer content costs 30-120 minutes.
Test Semi-finished Liquid hand sanitizer
Test the quality of hand sanitizer content, if the sterilization effect and quality of content meet the standard, let’s move to the next step.
Technicians draw samples from the compounding equipment to verify that the product is according to spec, including physical characteristics, viscosity, alcohol percentage, etc.
Next, technicians test samples to approve the batch.
If samples prove the product to be out of spec, technicians will make adjustments accordingly by adding ingredients and/or furthering mix operations.
After approval, the product goes into a holding tank until filling lines are ready for fill operations.
Move the ready hand sanitizer liquid to the filling plants
Most hand sanitizer manufacturers pour the hand sanitizer content into transfer barrel, transfer to another workshop, then connect transfer barrel and filling machine.
Automatic filling machine injects hand sanitizer in bottles
Automatic filling machine accurately injects hand sanitizer gel into the clean bottles and automatically assembles the pump, and have to capping in short time, because the alcohol is volatile.
Filling machines are used to automatically fill pump bottles according to pre-set volumes. Machines like these are equipped with a servo-motor and other pneumatically-powered devices to maintain accuracy filling. Automatic filling machines in factories can produce bulk hand sanitizers with over millions of inventories to ship per month.
The operation would depend on the viscosity of the product. There are filling machines with gravity filling nozzles or piston induced nozzles. That is to accommodate a variety of viscosities.
If you are producing hand sanitizer gels, you might want a piston-induced nozzle as the product is more viscous than sprays, foams and liquids.
Labeling the hand sanitizer bottles
Automatic labeling machine will apply the prepared label to the bottle.Clients usually require labels to be attached to both sides of the bottle, so the labeling machine you need should be able to apply labels on both sides of bottle at the same time.
Many factories are produced private label hand sanitizer for customers. Your hand sanitizer brand is not complete without a stunning label wrapped around its bottle. A labeling machine does that for you – automatically wrapping labels on the cap and container body. This machine works if you are producing more than a thousand inventories a day.
TY hand sanitizer manufacturer is a top private label manufacturer produce a customized label if you have your own hand sanitizer brand.
Boxing and Palletizing
After filling, capping and labeling the bottles, workers place the new products in boxes. These boxes go on pallets for shipment immediately or storage.
Final inspection the whole details of hand sanitizer products.
Quality control checks are ongoing throughout the entire process. They start at initial checks of raw ingredients, to batching operation samples, line inspection of machine operations and bottling components, sampling from the line for any microbial contamination and final inspection after bottling.
clients may require a specific percent of ethanol in hand sanitizer gel (spray), so manufacturer need to use professional instruments or experimental testing methods to test finished-products to ensure that they meet customer requirements. Manufacturing is not the most important thing, product quality is.
Shipping the hand sanitizer products to customer worldwide.
Problems and solutions during the hand sanitizer manufacture process
Problems in the process of hand sanitizer manufacture
Problems that may be encountered in the production of disposable sanitizing gel hand sanitizer:
Low-density powders such as carboxyvinyl polymers are difficult to blend into the liquid phase with ordinary agitators. And may cause dust and air Gas enters the product.
Because the air mixed in the product is difficult to remove, it is necessary to ensure the least air ingress. Because too much air enters the product’s effect, stability and even packaging have an adverse effect, especially the packaging is determined by the volume rather than the weight.
To ensure a uniform dispersion effect often requires a long-time dispersion and stirring process.
The potential full yield is difficult to obtain with traditional mixing; many formulations contain unnecessary high levels of polymer glue to make up for this.
When using traditional mixing equipment together, stratification may occur in the mixing stage, especially where there are multiple stages with different viscosities.
This leads to long stirring, poor consistency and batch variation.
How to solve the problems during the hand sanitizer manufacture
The use of a high-shear vacuum dispersing emulsifier can overcome these problems and provide you with a mixed batch a solution that takes a short time and can defoam.
Add purified water and carbomer in the emulsification tank. When the emulsifier is turned on, the powder and liquid are quickly passed to the high-shear homogenizer by the suction of the stator and rotor rotating at high speed.
The high-speed mechanical force generated by the vacuum dispersing emulsifier allows the multiphase solid-liquid material to undergo powerful dispersion, shearing and mixing through the narrow gap between the stator and rotor.
The dispersion and stirring of the materials can be carried out in a closed vacuum environment, so that the entire mixing process can not only ensure the contact between the materials and the outside world, but also ensure that less air enters the product. After the mixing and stirring are completed, deaeration can be carried out to ensure coagulation. Aeration-free in the glue product truly guarantees the quality of the product.
We are the leading hand sanitizer manufacturer, our factory produced various sanitizer and disinfectant products export to world market.