Cleaners. Sanitizers. Disinfectants.

While cleaning, sanitizing, and disinfecting might seem synonymous, they serve distinct purposes. For this edition of “How It’s Made” with FlexTrades, we’re focusing on sanitizers—specifically, commercial hand sanitizer.​

Hand sanitizers have become a staple in our daily routines, especially in recent times. While many have turned to DIY recipes, we’re diving into the commercial manufacturing process that ensures consistency, efficacy, and safety.

Key Ingredients in Hand Sanitizer

The effectiveness of hand sanitizer hinges on its composition.​

Active Ingredients:

  • Alcohols: Ethyl Alcohol (Ethanol) or Isopropyl Alcohol are primary antiseptic agents. For efficacy, hand sanitizers should contain an alcohol concentration between 60% and 95%.
  • Benzalkonium Chloride: An alternative antiseptic agent used in some formulations.​

Additional Ingredients:

  • Emollients and Gelling Agents: These provide moisturization and contribute to the gel-like consistency.​
  • Denaturants: Added to deter ingestion by imparting a bitter taste.​
  • Fragrances and Colorants: Enhance user experience with pleasant scents and appearance.​

The Manufacturing Process

Producing commercial hand sanitizer involves several meticulous steps to ensure a high-quality product.​

1. Compounding

  • Preparation: Raw materials are measured and added into large vessels known as batch tanks or mixers. Depending on the ingredient, this can be done manually or automatically.​
  • Mixing: Mechanical agitators within these vessels blend the ingredients under controlled parameters, such as time and speed, to achieve a uniform mixture.​

2. Quality Control

  • Sampling: Technicians extract samples from the mixture to verify adherence to specifications, including viscosity and alcohol content.​
  • Adjustments: If deviations are detected, formulations are adjusted accordingly to maintain product integrity.​

3. Filling, Capping, and Labeling

  • Filling: The blended sanitizer is transferred from holding tanks to filling machines, which dispense precise volumes into individual bottles.​
  • Capping: Caps are automatically oriented and secured onto the filled bottles.​
  • Labeling: Bottles receive labels through heat-pressed applications or adhesives, often at impressive speeds reaching up to 200 bottles per minute.​

4. Packaging and Palletizing

  • Boxing: Finished bottles are systematically placed into boxes.​
  • Palletizing: Boxes are stacked onto pallets, ready for storage or shipment to meet consumer demand.​

5. Ongoing Quality Assurance

Throughout the entire production line, continuous quality checks are conducted—from initial raw material assessment to final product inspection—to ensure safety and efficacy.​

Final Thoughts

The production of hand sanitizer is a testament to the precision and dedication inherent in manufacturing. At FlexTrades, we celebrate the intricate processes and skilled professionals that bring essential products to market, ensuring safety and well-being for all.