How It's Made Archives

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.

Spring has officially arrived.

The grass is green again. The birds are chirping. And maybe, just maybe, you’re thinking about that long list of home projects that didn’t get done last fall. But before you pick up the power washer or fire up the lawnmower, take a closer look around you. Odds are, you’ll find a different kind of spring hiding in plain sight.

Not the season. The metal kind.

Springs are everywhere. Inside your household cleaners. Beneath your mower deck. Behind your garage door. They’re small, tightly wound, often overlooked—and absolutely essential.

So, in this edition of “How It’s Made” with FlexTrades, we’re talking about the mechanics, materials, and manufacturing behind the humble spring.

Types of Springs

Springs come in two basic types—stretched and coiled.

Stretched springs store energy when pulled, like the tension in a bow and arrow. Pull back the string, and the spring (the bow) transfers energy to the arrow in a snap.
Coiled springs are the most common. They compress and expand to absorb shock, maintain pressure, or return components to a resting state. The first patent for a coiled spring dates back to 1763. The design has endured for a reason.

How Springs Are Made

No matter the style, the spring manufacturing process is surprisingly precise—and it all starts with the right material.

Materials

Springs are made from a wide range of materials based on end-use needs:

Stainless steel
Non-ferrous alloys like Monel
High-temperature alloys such as Inconel
High-carbon and alloy steels
Plastics (for specialty applications)

Design

Every spring is engineered with precision. The design process involves a surprising amount of math—factors like diameter, length, wire thickness, number of coils, and the amount of force needed are all carefully calculated to match the demands of the application.

Coiling

Once the specs are locked in, it’s time to wind. Coiling machines shape the material using either:

Cold winding for most wire types
Hot winding for thicker wire or bar stock

Not sure how a spring coiler works? Check out Automated Industrial Motion—they break it down with incredible detail.

Tempering

Tempering strengthens the spring and removes stress left over from the coiling process. Springs are exposed to extremely high temperatures for a set amount of time. The result? Better performance and durability under load.

Finishing

From grinding to coating, the final steps are all about getting the spring ready for real-world use.

Grinding flattens the ends of the wire
Shot peening smooths the surface and prepares for coating
Setting ensures the spring holds its shape under stress
Coating protects against corrosion
Quality control checks for exact performance specs

If you want to see the process in action, here’s a great visual to walk you through it.

Final Thoughts

Springs aren’t just for trampolines. They’re everywhere. And understanding how they’re made? That’s just one more way we at FlexTrades celebrate the people and processes that keep manufacturing moving.

Welcome to the first edition of FlexTrades’ “How It’s Made”—where we break down the manufacturing process behind everyday products. Today, we’re rolling out an inside look at how toilet paper is made.

With demand always high, it’s easy to forget that toilet paper hasn’t always been a household staple. If you’re curious about its origins, check out the history of toilet paper—but today, we’re here to focus on how it’s made.

How Is Toilet Paper Made?

Toilet paper is, at its core, just paper—which means its journey starts in the forest, moves to a lumber mill, is processed at a paper mill, and finally, is turned into the final product at a manufacturing facility.

Step 1: Harvesting Wood from Forests

Toilet paper is typically made from a blend of hardwoods and softwoods—about 70% hardwood and 30% softwood. Hardwoods provide softness, while softwoods add strength to the final product. Once trees are harvested, they are shipped to the lumber mill.

Sustainability Note: New trees are planted after harvesting to maintain forest resources.

Step 2: Processing at the Lumber Mill

At the lumber mill, trees go through two key processes:

Debarking – The outer bark is removed while preserving as much usable wood as possible.
Chipping – Logs are cut into small, uniformly sized wood chips (typically 1” x ¼”).

These wood chips are then sent to the paper mill for further processing.

Step 3: Pulping & Sheet Formation at the Paper Mill

At the paper mill, wood chips are turned into pulp through a multi-step process:

Cooking – The chips are “cooked” with chemicals to remove moisture and break them down into pulp.
Processing – The pulp undergoes washing, bleaching, and additional chemical treatments.
Stock Preparation – Water is added to create a paper stock, which is then passed through a series of rollers, dryers, and heaters to reduce moisture.
Sheet Formation – The result is large, matted fiber sheets, which are wound onto jumbo reels (some weighing up to five tons). These reels are sent to manufacturing facilities for final processing.

Step 4: Manufacturing & Packaging

At the manufacturing facility, jumbo reels of paper sheets go through the following steps:

Unwinding & Slitting – Large sheets are unwound, cut to size, and rewound onto cardboard tubes.
Roll Sizing – These large rolls are then cut down to the standard 4.5” x 4.5” toilet paper roll size.
Stacking & Packaging – Finished rolls are stacked, wrapped, and packaged for distribution.

And just like that, the toilet paper rolls you see in stores—or sometimes don’t see—are ready for use.

Want to See It in Action?

Check out this video from Georgia-Pacific, the manufacturer behind Angel Soft and Quilted Northern.

Final Thoughts

Toilet paper is a simple yet essential product, requiring precision, efficiency, and large-scale production to meet demand. And while most of us only think about it when the shelves are empty, the process behind it is a fascinating look at modern manufacturing and supply chain logistics.

Stay tuned for more editions of “How It’s Made” from FlexTrades, where we break down the process behind the products you use every day.

Spring brings warmer weather, melting snow, and… slippery roads. As ice and frost linger on highways and sidewalks, salt trucks hit the streets to keep drivers safe. But have you ever wondered where all that road salt comes from—and what impact it has?

Where Does Road Salt Come From?

The main ingredient in road salt is sodium chloride, the same compound found in table salt. Mines in Ohio, Michigan, New York, Kansas, and Louisiana produce nearly 90% of the salt used on U.S. roads. It’s the most effective and widely used deicing method, but it comes with some serious downsides.

The Environmental & Vehicle Impact of Road Salt

As winter fades and spring arrives, road salt doesn’t just disappear. It runs off into streams, lakes, and rivers, disrupting plant and animal life. Too much salt in these ecosystems can damage habitats and even cause long-term environmental harm.

Salt also accelerates vehicle corrosion. If not washed off regularly, it can eat away at metal components, leading to expensive repairs.

Sand: A Safer, Cheaper Alternative?

Because of these concerns, many states supplement or replace salt with sand. Unlike salt, sand doesn’t melt ice, but it improves traction and helps vehicles maintain control on slick surfaces. It’s also about 75% cheaper and less harmful to the environment.

Stay Safe on the Road

No matter what deicing method is used, icy roads remain a seasonal hazard. Keep an eye out for salt and sand trucks, drive cautiously, and be aware of changing conditions.

Want to learn which states use the most salt and sand? Check out these resources:

State-by-State Salt & Sand Usage
Salt Belt & Vehicle Corrosion Risks

Key Ingredients in Hand Sanitizer

The Manufacturing Process

Final Thoughts

Types of Springs

How Springs Are Made

Final Thoughts

How Is Toilet Paper Made?

Step 1: Harvesting Wood from Forests

Step 2: Processing at the Lumber Mill

Step 3: Pulping & Sheet Formation at the Paper Mill

Step 4: Manufacturing & Packaging

Want to See It in Action?

Final Thoughts

Where Does Road Salt Come From?

The Environmental & Vehicle Impact of Road Salt

Sand: A Safer, Cheaper Alternative?

Stay Safe on the Road

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