Solid Shampoo Manufacturing Line: Start Producing Solid Shampoos Today!

Our state-of-the-art Solid Shampoo Manufacturing Line is a game changer for increasing production and improving overall quality.

The manufacturing process of solid shampoo typically involves mixing ingredients, molding them into shape, and allowing them to dry. Some manufacturers may also add fragrances or essential oils for scent. Solid shampoos are a popular eco-friendly alternative to traditional liquid shampoos. There is a lot that goes into making solid shampoo, shave soap, and syndet bar soap. We’re going to break this down as easy as possible.

Raw Materials – Sourcing basic materials like coconut oil and cocoa butter are easy, 8 on a scale of 1-10. Fragrance can be a bit more difficult to source and is 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)

Solid Surfactant Mill and Augers – Solid surfactants, like SCI, come in many different forms with powder costing the most and chips costing the least. Our 10HP hammer mill has 4 different size screens which mills product from powder to 2.5mm. The augers are able to move about 40 lbs of material a minute and the air filtration system keeps the dust down.

Tilt Steam Kettle – Holds over 1500 pounds of material and can reach temperatures of 200ºF+. The 10 HP motor and agitator easily mixes all product thoroughly and in a timely manner.

Duplex Plodder with Vacuum Chamber – This impressive machine takes the soft base and work hardens it while removing any trapped air. The product is extruded through a 2D die into….

Soap Cutter – The rotary indicator ensures that every bar is the precise length the digital controls tells it be. The pneumatic blade is heated and cuts like a hot knife through butter along a free-moving track. A conveyor carries up to 100 bars a minute out of the machine…

Soap Press – The special brass alloy dies are chilled down to -17C to keep the billets from sticking to the 4 cavities. Top speed can deliver over 48 bars per minute.

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.

How do we get bars like Duke Cannon?

  • Easy, the 2D die on the end of the Duplex Plodder can be custom made to almost any size, shape and dimensions.
  • The length of the bar can be as short as 5mm up to 999mm.
  • A stamp can be added so that the bars can be stamped and cut at the same time.
  • The blade is heated to reduce tearing and moves with the bars for straight cuts.
  • The cost starts are roughly $350 for a 2D die and stamp and could be more depending on the complexity.

How do we get 3D Shampoo Bars like LUSH?

  • We have a die that will press a 3oz shampoo bar.
  • A custom die can be made for around $8,000 to $10,000+.  Depending on the volume and frequency, we would cover that cost.

Product Packaging

  • At 7,000+ shampoo bars per run, cartons (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?
37,500 if everything runs smoothly.

Hopefully this has given you a better idea of what our solid shampoo, shave soap and syndet soap line consists of and its capacities.