Solid Conditioner Manufacturing Line
Our state-of-the-art Solid Conditioner Manufacturing Line is a game changer for increasing production and improving overall quality.
There is a lot that goes into making solid conditioner, alternative shave product, deodorant and Melt & Pour soap. We’re going to break this down as easily as possible.
Raw Materials – Sourcing basic materials like coconut oil and cocoa butter are easy, 8 on a scale of 1-10. Fragrances can be a bit more difficult to source and are a 6 on a scale of 1-10. The solid surfactants and conditioning agents are the most difficult, 2 on a scale of 1-10. This is why we recommend and insist that we purchase ALL the raw materials before we start production as a cheap hedge against supply shortages and cost increases. (The scale of 1-10 has most difficult to source as a 1 and easiest to source at a 10)
Steam Kettle – Holds over 1200 pounds of material and can reach temperatures of 220ºF+. The 3 HP motor and agitator easily mixes all product thoroughly and in a timely manner.
Filtration – This is a must to make sure small or larger particles of anything, whether it be micas, butters, conditioner agents or undesirables DO NOT end up in the final product.
Heated Volumetric Filling Machine – Every pour has to be above the required weight every time. The heating elements ensure the product flows easily, at just the right temperature, between 30-40 bars per minute.
Cup Die-nester and Cooling Tunnel – Like clockwork, the cup dispenser deposits the cups on the slow moving conveyor, filled with product, and then slowly cooled down to the point where the conditioner bars can be popped out and packaged.
Cartoner Machine – And into your custom carton (box) they go along with a batch number/production date.
Ready for Shipment – For larger orders and repeat clients. We will have custom master-shipper made to hold roughly 200 units and weigh less than 50 pounds. This makes shipping and handling to you or a Fulfillment Center as easy as possible. Need custom master-shippers for Amazon? We can do that too.
Let me add a few items that I know you are going to ask.
Tell Me More About the Cups Being Used.
- These cups are specially made for us to fit our equipment.
- The cups are a single-use-plastic which are thrown away (not always) after each use.
- Now before you go off the deep end and write us a nasty email, hear us out. Silicone molds are NOT a perfect solution either. 1. A 7,500 bar run would require at least 3000 cavities. The cost to purchase all those molds is not too bad. However, how much time, hot water and space does it take to wash, dry, and store those 3000 cavities? Conditioner bar materials like BTMS-50 are not water soluble and only fall off the silicone in the wash. The person washing the cavities has to soak each mold for several minutes in very hot water and then make sure the free conditioner pieces do not end up back in the cavities. This means the water has to be replaced or reheated constantly. Drying 3,000 cavities is going to take around 6 racks and 6 full size totes to store. Did you know that silicone molds do not last for forever? After about 50 uses the molds will start to deform and tear. And last but not least. Some silicone molds will transfer some color to the product you are pouring inside of them. We have seen this with shave soap and Melt & Pour soaps. Still think silicone molds are the best way to go?
- But not hope is lost. Bio-plastics are becoming more readily available and our supplier should be offering them at some point.
Product Packaging
- At 7,000+ conditioner bars per run, boxes are a must.
- We can hand-load with top-loading boxes or machine-load from the side. Machine, or Cartoner, is the best way to go as it does it all.
- Most clients already have their packaging supplier and this is preferred by us because its less to worried about on our end. We do have packaging companies who we can recommend.
How Many Units Can We Make in a Week?
- 50,000 pieces if everything runs smoothly.
Hopefully this has given you a better idea of what our solid conditioner, alternative shave product, deodorant and Melt & Pour soap. line consists of and its capacities.