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How do you make hand sanitizer?

All about hand sanitizers & their commercial manufacturing!
Germs are our everlasting companions, and unfortunately, we cannot control them. In our daily life, most of us encounter roughly around 60,000 germs. These tiny organisms are everywhere to survive in the air, water, plants, food, skin, body, and even on non-living surfaces. In our routine, we expose more germs that can potentially lead to the transmission of infections and illnesses.  

After the outbreak of the COVID-19 pandemic, it has become essential to encourage people to wash their hands throughout the day. Placement of hand-sanitizing stations, bottles, and dispensers in busy business environments has become vital these days. 

A hand sanitizer is either a liquid, gel, or foam that can reduce/eliminate viruses, bacteria, and other harmful germs. Water and soap are the best hand cleaning options. Still, hand sanitizer can be a good substitute. It kills germs and reduces bacteria counts on the hands, decreasing cross-contamination. Hand sanitizers reduce viral loads on the skin and allow people to maintain and promote excellent hand hygiene making the environment more sanitary. Thus, making it one of the necessities, especially in these testing times. 

Commercial Hand Sanitizer:

A commercial sanitizer is not a permanent alternative to complete handwashing. But when handwashing isn't feasible, they're supposed to give you some of the benefits of handwashing. Using commercial hand sanitizers reduces the number of microorganisms on your hands. It chemically destroys them, much as disinfectants kill germs on surfaces.

Formulations for commercial sanitizers might be very different. For example, alcohol-based sanitizing solutions are the most effective, but a benzalkonium chloride option is also available. The typical alcohol percentage of hand sanitizers is between 60 and 95 percent. In addition to these essential components, moisturizers, fragrances, and colors are the additional ingredients of commercial sanitizers. 

Commercial Manufacturing of Hand Sanitizers:

You may make your hand sanitizers. But producing hand sanitizers in mass requires a series of automated procedures, massive mixing and filling equipment. 

•The manufacturing process of hand sanitizers: 

The hand sanitizer manufacturing process involves four main steps:
  1. Batch size mixing of sanitizer formulation
  2. Mixing of hand sanitizer ingredients
  3. The packaging procedure is sub-divided into filling, capping, and labeling.
  4. Shipping

•Formulation & ingredients required: 

The basic formulations of hand sanitizer need three active ingredients that are:
  1. Benzalkonium Chloride (C22H42ClNO)
  2. Isopropyl Alcohol (C3H8O)
  3. Ethyl Alcohol (C2H5OH)

There are two primary hand sanitizers in terms of the active components utilized: Alcohol-based and Alcohol-free. Disinfectants like benzalkonium chloride (BAC) and antimicrobial agents like triclosan are commonly used in alcohol-free goods. These disinfectants & antibacterial agents have rapid and long-lasting effects. 

According to World Health Organization (WHO), Isopropyl or Ethyl alcohol are the primary hands sanitizing ingredients required in their high concentrations (nearly 96%) for alcohol-based hand sanitizers. This high Isopropyl/Ethyl alcohol concentration decreases to 70-80% in the final product. In addition to these active ingredients, additional requirements of commercial sanitizer are: 

  • Bitter tasting compound to stop the consumer from drinking hand sanitizer
  • Carbopol to give hand sanitizer a gel-like texture
  • Coloring to provide it with a particular color (it is not required for clear hand sanitizers)
  • Fragrance for scanted hand sanitizers
  • Glycerin as moisturizer
  • Triethanolamine to maintain the proper pH
  • Mixing of Hand Sanitizer:

To prepare the solution, you need to mix all these ingredients in a sanitizer mixer. The sanitizer mixture should be high speed to avoid accumulation in the mix and get a consistent batch-to-batch final product. 

First, you must mix Carbopol with water until it converts into a viscous gel. Prevent aeration during this mixing process to obtain a conglomerate mixture. Otherwise, air trapped in hand sanitizer may cause clouding and disturb the filling process. 

Next, mix Alcohol in this mixture to get a uniform solution. Using concentrated Alcohol is an essential requirement as it gets diluted to 70-80% at the end of this step. At this point, Triethanolamine is added to avoid any skin irritation. And finally, some preservatives, color, and moisturizers are added to the sanitizer. Different polymers are used to increase the viscosity of hand sanitizer gel. But these are not the essential part of any approved hand sanitizer formula. 

  • Equipment for the Manufacturing of Commercial Hand Sanitizers:

A hand sanitizer manufacturing facility keeps the following equipment for the production and packing of sanitizers: 

  • Mixer: Hand sanitizer solution may be made in small to large quantities using a Vacuum Emulsifier, High Shear Mixer, or Powder-Liquid Disperser. All ingredients are mixed in these mixers to get a sanitizer solution of equal consistency.
  • Filling Machine: Liquid Filling Machines and Viscous Liquid Filling Machines are used to fill a fixed amount of sanitizer in bottles accurately.
  • Capping Machine: Any automated capping machine can be used to limit sanitizer bottles within no time. Rotary Vacuum Screw Capping Machines (RVSCM) and Screw Capping machines (SCM) are two standard capping machine options.
  • Labeling Machine: Labeling machines can emboss or mark bulk containers with precision. Pressure Sensitive Labeler, Inject Printing Machine, Optical Laser Printing Machine, and others are available.
  • Skin Safety & Precautions:

Soap cleansing eliminates skin components and disrupts the skin's natural structure. But in terms of skin protection, hand sanitizers are probably better than repeatedly washing with soap. The alcohol content in hand sanitizers quickly evaporates after killing germs on the skin and has minimal influence on the skin barrier. Fragrance-free hand sanitizer causes no skin irritations. Especially in the case of an allergic reaction to a scent, perfumes can irritate the skin. 

Conclusion:

The complete manufacturing process of hand sanitizers, from formulation and mixing to filling, needs a strictly regulated plant with a high level of accuracy. There are third-party tests, and in-house tests are done to ensure quality and uniformity from batch to batch. 

This supervision of regulatory authorities sets high-quality standards that hand sanitizer makers and formulators must follow. It is helpful for the new producers with a legal avenue to grow hand sanitizer supplies; the law simplifies formulation. We at Chinayxjx follow this procedure and bring you the best hand sanitizer-making machines.


  

Date of Publication: 3 September, 2021  


















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Taihe Town,
Baiyun District,
Guangzhou,
CHINA

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