Alcohol Gel Formula And Production Line

Small-Batch Alcohol Gel Production Process

(Using Mixing & Emulsification Equipment)

I. Core Formula (75% Alcohol Gel Example)

II. Production Process

1. Pre-Treatment Phase

• Water system: Prepare deionized water (conductivity ≤5 μS/cm)

• Alcohol verification: Calibrate ethanol concentration (96% food-grade recommended)

• Carbomer pre-gel:

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  1. Add 80% of water (60°C) to shear tank  
  2. Slowly sprinkle Carbomer powder (1000 rpm dispersion)  
  3. Stir for 30 min until fully hydrated  

2. Main Mixing Phase

• Equipment: Stainless steel shear-mixing tank (50–100L recommended)

• Procedure:

1. Transfer pre-gel to main tank, start slow mixing (300 rpm)

2. Gradually add ethanol (control temp. <30°C)

3. Incorporate glycerin & other additives

4. Adjust pH with triethanolamine (in-line monitoring)

3. Homogenization & Emulsification

• High-shear mixer: 10,000 rpm × 5 min

• Vacuum: -0.08 MPa (deaeration)

• Final viscosity check: Brookfield RV viscometer (Spindle #6, 20 rpm)

• Key parameters:

4. Filling & Post-Processing

• Alcohol content: GC analysis

• Microbiology: Complies with USP <51>

• Filling: Piston filler (±1g accuracy)

• Curing: 24-hr rest for bubble dissipation

• QC testing:

III. Key Equipment Recommendations

IV. Critical Process Controls

1. Temperature: Maintain 18–25°C during mixing (ethanol evaporation threshold)

2. Viscosity: Adjust via Carbomer/water ratio (target: 15,000–25,000 cP)

3. Alcohol loss compensation: Include 5% overage to account for evaporation

4. Microbial control: Production area ≥ ISO Class 8 cleanliness

V. Troubleshooting Guide

• Gel separation: Verify Carbomer hydration & pH compliance

• Harsh alcohol odor: Add 0.1% menthol as a sensory modifier

• Filling foam: Pre-treat with vacuum deaeration tank

Note: Conduct a 50kg trial batch first. Production area and equipment must meet ATEX standards (alcohol vapor monitoring required).

Requirements for medium and large production capacity: 

Different countries and different demands can increase or decrease the standard according to the actual situation.

such as pure water machine, a storage tank, a CIP cleaning system, etc.

More details,pls contact us!

Ava Duan

Email: sales@grand-packing.com

whatsapp/wechat:86-13787413551