Equipment for the production of shampoos. Stages of the technological process for obtaining shampoos
The formulation and selection of raw materials must be carried out taking into account the requirements of the Guidelines for cosmetic products approved by the EEC (Directives EEC 76/768) and SanPiN 1.2.681-97 " Hygiene requirements to the production and safety of perfumery and cosmetic products. These documents contain lists of substances that are allowed, not allowed, and limitedly allowed for use in formulating cosmetics and, in particular, hair and scalp care products.
In modern cosmetics, more and more attention is paid to active additives– components that, in a relatively small amount, can significantly affect the properties finished product. However, in many cases, the introduction of active ingredients into the finished formulation is limited by their chemical nature: an unpleasant odor, low solubility, rapid degradation due to oxidation, sensitivity to UV radiation or water, and poor skin tolerance when applied at higher concentrations. In a number In some cases, antioxidants, complexing agents, and UV filters can improve the quality of the finished product by preventing it from oxidizing, discoloring, delamination, and the like. At the same time, it is more difficult to influence parameters such as the bioavailability of the active ingredient and the tolerance of the scalp and hair to it, since they largely depend on the formulation. When choosing a base, a cosmetics developer (unlike a pharmacist) is usually guided by other motives than increasing bioavailability active component. Consumer qualities of the finished product and its safety come to the fore here. It often happens that the selected base cannot protect the active compound from degradation, as a result of which it not only loses its biological activity, but, moreover, becomes toxic. When applied to the skin, the “unprotected” active compound comes into contact with air and quickly oxidizes or exposed to direct sunlight and destroyed by their action. classic examples such hypersensitive compounds are unsaturated fatty acids, vitamins A (retinol) and C (ascorbic acid). So, being oxidized at the site of unsaturated double bonds, unsaturated fatty acids contribute to quick spoilage product (rancidity). When oxidized, vitamin C loses its antioxidant properties, and vitamin A can cause severe irritation. Encapsulation of active ingredients, i.e. enclosing them in a protective shell is considered as a promising solution to this problem. Microcapsules are, as a rule, spherical systems in which the active components are located in the core (core). The nucleus is surrounded by one or more shell layers. There is a wide range of materials for capsule shells on the market today. Natural or synthetic polymers, such as collagen, alginate, chitosan, lactic acid, polycaprolactone, polyacrylates, and waxes, are most widely used. The effectiveness of microcapsules in the composition of the finished product largely depends on their behavior in the cosmetic base. In addition, it should be taken into account that encapsulation requires time and additional costs. So only those components whose encapsulation is dictated by necessity are worthy of being enclosed in a protective shell. 3.2 Technology for obtaining cosmetic detergents The preparation of shampoos belongs to the category of relatively simple industries. In general, a piece of equipment is a stainless steel apparatus equipped with a jacket for heating and cooling and a stirrer (for liquid and creamy shampoos, the stirrer is somewhat different). It is important that all shampoos must pass mandatory tests. First, an assessment is made of organoleptic indicators (appearance, texture, color, smell), which are determined by sensory evaluation. Then, physical and chemical characteristics are examined, including safety indicators: the value of the pH value, mass fraction dry matter, foaming capacity, rheological characteristics (viscosity), heavy metal content, and also determine microbiological stability. Consumer properties of shampoo are studied on volunteers (volunteers). Particular attention is paid to the study of the toxicological properties of shampoos, and in recent years, in vitro methods have been increasingly used, which are used instead of testing on animals and on volunteers (in vivo).
1 - crane; 2 – mixer 4 t; 3 – mixer 10 t; 4 - water heating;
5 - water purification system; 6 - pump; 7 - filter; 8 – capacity 2 t;
9 - dispenser
Figure 3.1 - Technology system receiving shampoos
Technological process shampoo production (Figure 3.1) begins with the selection and verification of raw materials. They must be harmless in the concentrations administered and not form toxic combinations with each other. Shampoo ingredients must be compatible, balanced and stable at the specified pH value. First of all, you need to prepare the water, because. it is the main ingredient of the shampoo. Water must be purified from mechanical impurities, iron, softened and microbiologically neutralized. The content of heavy metals in water should not exceed the established norms. Surfactants must be prepared in advance, weighed, and in winter placed in a warm room to avoid their solidification, but at a temperature not exceeding 50 ° C to prevent their destruction. Basically, the shampoo preparation technology is the mixing and dissolution of the components. stages technological process Shampoos are as follows. Preparation of raw materials. Raw materials received at the warehouse, before being used in production, must be subjected to external examination and laboratory analysis for compliance with the requirements provided for by this technology, after which it is fed to the reactor for unloading. Means preparation. Shampoos are prepared by mechanical mixing of the components with water in a reactor equipped with a stirrer. The use of a specially designed agitator prevents foaming of the mass. Mixing of components is carried out at the temperature of the production room and atmospheric pressure. Water-alcohol extract and surfactant are sequentially loaded into the reactor with the stirrer turned on, which are then stirred. Drinking water undergoes purification at the water treatment complex and is fed into the reactor with the mixer turned off. A sample of this water is preliminarily taken for compliance with the requirements for the quality of water for the preparation of shampoos. The water supply is controlled by a water meter. Next, the components of the shampoo are mixed with water. Formalin and fragrance are added. Next, with the mixer turned off, a pre-prepared sodium chloride solution is poured using a pump and mixed. The finished product with the help of a pump is fed into the intermediate tank for settling. The product is settled, after which a sample is taken and an analysis is made for compliance specifications, and upon receipt of positive results, the product is sent for packaging. 3.3 Characteristics of raw materials for the production of care products behind the hair Modern shampoo is no longer just a specialized hair wash, but a complex composition that can perform three main tasks: remove impurities, remove static electricity from hair and protect the scalp. If a hair care product solves the first problem, it's just a shampoo, if the second is a conditioner, and the third is a hair mask. The combination, to one degree or another, of the last two properties will make the composition a balm-rinse, the first two - a shampoo-conditioner ("two in one"), and all three - a three-in-one shampoo. All raw materials used for the production of care products hair, can be divided: - into natural (animal or plant origin); - synthetic. The fruits of hybrid coconut palms (Figure 3.2) serve as raw materials for the production of many components of shampoos.Figure 3.2 - Hybrid coconut tree
The biggest challenge facing shampoo chemists is the compatibility of different components. Oil is known to be an effective suds suppressor. But this means that the addition of such emollient components to shampoos must necessarily affect the quantity and quality of the foam, and therefore worsen the washing properties of the composition. To avoid this, so-called emulsifiers are introduced into the mixture - substances that can envelop fat droplets insoluble in water. The emulsifier microfilm prevents the oil from coming into direct contact with the surfactant and also prevents the shampoo from separating by preventing tiny globules of oil from merging with each other.More modern way combine the incompatible - the solubilization of components that are insoluble in water, that is, their translation into a soluble state with the help of special additives. The fact is that many surfactants form in water not true, but micellar solutions. This is due to the structural features of surfactant molecules, which have a polar head and a long uncharged tail - a hydrocarbon radical (R) C 12 -C 14 (Figure 3.3).D
Figure 3.3 - Structure
surfactant molecules
The tins interact with water molecules, and the tails tend to get closer to each other, as a result of which the correct conglomerates of molecules appear - micelles. If the surfactant concentration in the solution is not very high, micelles resemble balls, if it grows, the balls merge with each other, forming tubes ( figure 3.4). Micelles are formed due to electrostatic interactions of the polar heads of surfactant molecules with water molecules. Sometimes fat-like substances can “dissolve” inside such structures. M 
The microenvironment inside the balls and tubes is electrically neutral, and substances that are insoluble in water, such as oils, may well “dissolve” here. However, not all surfactant molecules are able to solubilize various additives equally well, and the emergence of products that are active in this regard has brought the production of shampoos to a completely different level.
Figure 3.4 - Mechanism of micellization
It is no less difficult to “reconcile” anionic substances with cationic ones in one vial. This became possible only after the invention of amphoteric and crypto-anionic surfactants. Crypto-anionic surfactants are a class of substances that combine the properties of anionic and nonionic surfactants. Molecules of such surfactants carry both a positive charge (mainly on nitrogen) and a negative charge. They form a bridge between the detergent molecule and the conditioning agent molecule, forming weak bonds with them, which allows the shampoo components to act more or less independently. So, surfactants are the basis for the production of hair washing products, auxiliary surfactants (cosurfactants) and thickeners are components removing impurities from the hair and scalp. Additionally, to solve other problems facing hair care products, they introduce: condensing additives, dyes, opacifiers, fragrances, vegetable oils, plant extracts, vitamins, preservatives. In total, the composition of shampoos includes several dozen substances. 3.3.1 Surfactants The main active principle of the shampoo are detergents- surfactants that cause foam when mixed with water and air. Detergent is the main "sense" component of the shampoo. On the label of any shampoo, the detergent is usually one of the first in the composition. Surfactants have the following properties:
reduce the surface tension between water and fat particles, thus facilitating the removal of these particles and dirt;
form foam;
form a suspension of dirt particles in the foam and prevent the re-settling of dirt on the hair;
stabilize other shampoo ingredients or keep them dissolved;
increase the viscosity of shampoos.
anionic surfactants - in an aqueous solution they decompose with the formation of negatively charged ions;
cationic surfactants - in an aqueous solution they decompose with the formation of positively charged ions;
amphoteric surfactants - in an aqueous solution, depending on the pH of the medium, they can exhibit cationic (in an acidic pH<7) или анионные свойства (в щелочной среде рН>7);
nonionic surfactants - do not form ions in an aqueous solution.
Figure 3.5 - Classification of detergents
The washing action is provided mainly anionic surfactants. The molecule of anionic surfactants contains a water-soluble (hydrophilic) part, negatively charged, and a fat-soluble (hydrophobic), neutral part. The fat-soluble part of the molecule binds and envelops dirt particles and the secretion of the sebaceous glands. The water-soluble part of the molecule is oriented away from the hair, which carries a negative charge, as a result of which the dirt particles connected with the surfactant are rejected by the hair, dissolved in water and removed. Anionic detergents(surfactants containing negative ions) are the most common substances used in shampoos and washing gels. A typical representative of anionic surfactants are salts of alkyl ether sulfates, which are obtained by sulfation of ethoxylated higher fatty alcohols, followed by neutralization and the formation of sodium, less often magnesium, ammonium salts. More often than others, ethoxylated sodium lauryl sulfate is used - sodium laureth sulfate. Oxyethylated magnesium lauryl sulfate - magnesium laureth sulfate is used mainly in children's shampoos, because. he is the softest. Cationic surfactants in an aqueous solution decompose with the formation of positively charged ions, have a weak washing effect, however, they are well “attracted” to negatively charged hair (substantiality) and fix the bioadditive on the hair. Cationic surfactants (contain positive ions) are used less frequently and in high concentrations. Many of them cause irritation when in contact with the eyes. These include salts of quaternary ammonium compounds, cationic polymers, quaternized protein hydrolysates, plant polysaccharide derivatives, and others. Amphoteric surfactants(contain positive or negative ions depending on the pH value of the shampoo). Amphoteric surfactants are used in shampoos for damaged and dry hair. These include: alkylamidopropyl betaines, which are used in combination with anionic surfactants to obtain a mild detergent substance. Recently, amphoteric imidazole derivatives of surfactants (cocoamphoacetate) are increasingly used in formulations, which, in combination with anionic surfactants, improve foaming ability and increase the safety of formulations. And in combination with cationic polymers, they enhance the positive effect of silicones and polymers on hair and skin. Nonionic surfactants used in shampoos to improve consistency, rheological characteristics, make hair silky and soft. More often than others, ethoxylated alcohols, ethoxylated castor oil, propylene glycol esters of high molecular weight fatty acids are used. Nonionic surfactants cause a less pronounced denaturing effect than anionic ones, but they have a greater penetrating ability into the skin. If you arrange all detergents in ascending order of their quality, then the list will look something like So: Ammonium Lauryl Sulfate(ammonium lauryl sulfate) - an anionic surfactant; Ammonium Laureth Sulfate(ammonium laureth sulfate) - an anionic surfactant; Sodium Lauryl Sulfate(sodium lauryl sulfate) - cationic surfactant; Sodium Laureth Sulfate(sodium laureth sulfate) - cationic surfactant; TEA Layril Sulfate(TEA lauryl sulfate) - an anionic surfactant; TEM Laureth Sulfate(TEA laureth sulfate) is an anionic surfactant. Thus, the last three surfactants are the best. In terms of foaming ability, laureth sulfate still has no competitors, but its foam is loose and unstable. Only non-ethoxylated lauryl sulfate could compete with it, but this substance costs twice as much and is more irritating to the scalp. In small concentrations (about 1%), it is used in toothpastes, and it is rarely introduced into shampoo formulations if it is necessary to correct the properties of the finished product, and always together with laureth sulfate. However, if shampoos contain only one of the above detergents, in particular, laureth sulfate, then with frequent use of shampoo, the skin may become inflamed, and dandruff may appear. In addition, since laureth sulfate is obtained in the form of an aqueous solution with an active substance concentration of 5% to 15%, such a liquid component is very inconvenient for dosing. Therefore, in addition to the above detergents, any shampoo necessarily contains one or more "soft" surfactants that have a beneficial effect on properties of the finished product. Cosurfactant– it is an auxiliary surfactant that contributes to the creation of optimally balanced recipes. Cosurfactants such as cocoglycosides, alkyl ether carboxylates and others make it possible to obtain dermatologically mild shampoos with stable intense foam, which can be recommended not only for washing the hair, but also for the body. cosurfactant solve several problems at once. The main thing is to reduce irritation of the skin and mucous membranes of the eyes. The first cosurfactants were sodium laureth sulfosuccinates (anionic surfactants based on succinic acid). These substances have a mild cleansing effect and are good at reducing the dermatological harshness of the overall cleaning composition, even if they replace only a third or even a quarter of the laureth sulfate in the shampoo. Sulfosuccinates are still included in some “no tears” baby shampoos. Over the past 40 years, chemists have synthesized many mild cosurfactants, but the price of any of them exceeds the cost of the main detergent, as a rule, by two to three times. The search for soft surfactants continues all the time . Immediately after sulfosuccinates in shampoos, including children's shampoos, sodium cocoamphodiacetates (BETADET THC-2) appeared, which have good dermatological properties. But the real breakthrough in hair washes has been with betaines (or cocoamidopropyl betaines). – BETADET HR-50K), which appeared in the early 70s. These substances do not just make shampoos softer: even a small addition of betaines can reduce the concentration of electrolytes in shampoos, since they themselves can thicken solutions of sodium laureth sulfate. In addition, compared to sulfosuccinates and cocoamphodiacetates, betaines are much more physically stable. If the former, during long-term storage or a decrease in temperature, can precipitate and make the finished product cloudy, and the latter sometimes give shampoos an undesirable yellowish tint, then shampoos with new generation betaines (the so-called sulfobetaines) can be stored even at low temperatures. Such solutions do not become cloudy down to minus 10 °C. From cryptoanionic surfactants the most widely used alkyl ether carboxylate. He provides increased efficiency cationic conditioning agents, reduces irritant action, increases foaming. Phosphates and ether carboxylates are used in cosmetic products as dispersants, emulsifiers, solubilizers. 3.3.2 Conditioners Due to the transition of part of the sebum into the soapy solution, a small negative charge remains on the hair, which it is desirable to neutralize. For this purpose, conditioning compositions are used, the main components of which are cationic active substances and cationic polymers. Adsorbing on the hair, they remove the charge from them, make them softer and more manageable. Conditioning agents are designed to perform the following functions:removing static electricity, reducing the "flying" of hair;
smoothing and leveling damaged areas of hair shafts;
easy combing of wet and dry hair;
minimizing porosity;
giving hair shine and silkiness;
providing protection against thermal and mechanical damage;
moisturizing;
increase in volume and mass;
reconditioning of damaged hair.
At the same time, it is known that when correct selection a combination of surfactants, it is possible to obtain the required viscosity with a lower content of thickeners. Polymers are used as thickeners: polyvinylpyrrolidone, structured copolymers of acrylates, etc. The role of thickeners can be performed by modified glyceryl esters of fatty acids, derivatives of plant polysaccharides, as well as some cationic polymers. Often sodium chloride or sodium citrate (2–4%) is used as a thickener. However, sodium chloride can reduce the adsorption of the cationic polymer on the hair and thus prevent the conditioning effect. In addition, if you wash your hair poorly, salt will remain on the scalp, which will also contribute to irritation. Multifunctional additives such as coconut oil fatty acid diethanolamides can also be used as a thickener. Such an additive, in addition, increases the frost resistance of the product, protects the skin from degreasing when washing, allowing it to maintain its natural water-lipophilic balance. These substances have other advantages: for example, they stabilize the foam and allow various dispersed additives to be introduced into shampoos without the risk that the mixture will delaminate.
Cost-effective is pretty simple. But keep in mind that to start you need to invest a significant amount in equipment for the production of shampoos. To use it, you will not need any special knowledge or skills. All that is needed from entrepreneurs is to register a business and equip shampoo factories.
When buying a line, keep in mind that the equipment is universal for many cosmetics. With this in mind, in the future, your shampoo production may grow into the production of cosmetics.
Laboratory equipment
The first stage of production is the formulation of the recipe. Manufacturers offer products according to their unique recipe, based on numerous studies, samples, tests.
Upon completion of the manufacturing process, each batch undergoes quality control, that is, a laboratory will again be needed. You will need:
- - 16,000 rubles;
- - 90,000 rubles;
- - up to 70,000 rubles;
- 37 ° С - about 35,000 rubles;
- shaking apparatus - up to 10,000 rubles;
- with maintaining a temperature of 45 ° C - up to 15,000 rubles;
- - 8,000 - 20,000 rubles;
- - 30,000 rubles;
- - less than 1,000 rubles;
- - 5,000 rubles;
- flasks, pipettes, mortars, magnifying glasses, cups, coverslips - all together will tighten up to 5,000 rubles.
Raw material cost:
For 1 ton of finished shampoo, it is necessary to use raw materials for 14,000-15,000 rubles. Separately, to this amount you need to add the cost of packaging - about 15 rubles. for 1 bottle.
production line
The production of shampoos can include both separate equipment and a complete line of everything you need. Shampoo factories include special liquid containers, mixing reactors and rotary pumps.
Shampoo production equipment Russian market provided by several companies, among which Agromash is a manufacturer of diverse technological and food equipment.
This business is suitable for a universal line for the production of shampoos and cosmetics. Manufactured products: shampoo, cream, gel, soap, tonics and lotions. Includes:
- a steel boiler to heat water for 500 liters, temperature 150 - 1,000 ° C, power - up to 30 kW; one of the elements is a centrifugal pump;
- ventilation caps;
- digester made of steel with a stirrer for 250 l., temperature - 300-950 ° C;
- boiler 250 l. to dissolve the ingredients;
- boiler 250 l. for the accumulation of various additives;
- boiler-refrigerator, where the ingredients are mixed and cooled;
- tank washing system;
- control Panel.
Liquid dosing and filling line
Manufacturers offer many automatic dosing machines for filling bottles of different sizes. The cost of such machines reaches 1,600,000 rubles.
Pay attention to the bottling machine with a capacity of 3,000 bottles per hour, with a volume of 0.2-1 liter.
Typically, such machines are suitable for bottling any liquids and are easily reconfigured for any container.
Equipment advantages:
- bottle position control by sensors;
- high dosing accuracy;
- simple reconfiguration to any desires.
The line includes:
- adjustment system;
- cork winding device, which is regulated by the remote control;
- cap feed hopper;
- automatic labeling mechanism;
- automatic washing;
- emergency protection;
- filling control system;
- product counting sensor.
Characteristics:
- container volume for bottling - up to 1,000 ml;
- dosing accuracy – ±1 ml;
- supply voltage - 50 Hz;
- power consumption - 2 kW;
- installation weight - 1,000 kg;
- number of operators - 5 people.
Filling Equipment Feihong Machinery:
| Characteristic | Meaning |
|---|---|
| Productivity, bottles/hour | 4 000 - 7 000 |
| Container volume, g | 10 - 200 |
| Consumption compressed air, cubic meters/h | 36 |
| Voltage, V | 380 |
| power, kWt | 2.5 |
| Size, mm | 4150×2650×1600 |
Labeling line
The production of hair shampoo also requires a special labeling machine. The cost reaches 200,000 rubles.
Purchase the Cavagnino & Gatti automated machine, model CG80, which applies hot glue to polypropylene labels by spraying.
Peculiarities:
- the presence of a printer;
- 4 sticker formats;
- productivity - 2,000 stickers per hour;
- speed adjustment;
- manual height adjustment of the bottle;
- 1 kg of glue is enough for 35,000 labels.
Choice of labeling equipment:
| Company manufacturer | Model | Productivity, b/h |
|---|---|---|
| Cavagnino & Gatti | CG80 | 2 000 |
| Cavagnino & Gatti | CG-84DRX 3-9 | 5 000 |
| Cavagnino & Gatti | RE-15T-4S | 10 000 |
| Roll Rotary | 540-9T | 9 000 |
| Rollfed | 12-640 1RA | 12 000 |
| GERNEP | Rollfed 12-640 1RA | 15 000 |
| ETICAP | XR-FACILE 3T 1S | 2 000 |
| KRONES | Vinetta 72 | 7 000 |
| KOSME | EXTRA 8T S1 E1 | 7 000 |
Optional equipment
When setting up production, especially in large scale you will need additional machines.
Conveyor system (conveyor)
Needed to move products between production stages. The system consists of separate assembly elements, the quantity of which is usually ordered individually, taking into account the parameters of the production shop.
The material of the system is stainless steel.
Quality conveyors include an electric drive and a regulator.
inspection equipment
It is also more suitable for large volumes of production and it is necessary to reject low-quality shampoo bottles (violation of the integrity of the form, tightness).
Video: how is a quality shampoo made?
WHAT IS THE ARTICLE ABOUT?
What is shampoo
Shampoo is the most popular hair care product. Its main task is to cleanse. But besides this, it can perform a number of additional ones:
- Prevents static electricity from appearing;
- Cares for the scalp;
- Protects from the sun, cold, high humidity and other factors;
- Makes hair stronger.
Shampoo is not only in liquid form, as we are used to seeing it. Also exist:
- Gels;
- cream;
- Aerosols;
- In the form of a powder;
The most common are gel and liquid forms due to their convenience.
Let's get back to additional features. Depending on the ingredients that make up the products on the market are:
- With a healing effect;
- Ordinary cosmetic;
- With careful care;
- Baby;
- For various types hair and scalp;
Shampoo composition
To make the most common cosmetic shampoo, 12 components must be mixed at the factory:
How shampoo is made in production
The technical process consists in mixing all the ingredients. To prepare shampoos, each ingredient is weighed on special scales. The mass must exactly match the cooking sheet, that is, the recipe. Then all substances are mixed together. Some of the components are immersed in a boiler and boiled at a temperature of 60 degrees. The ingredients are mixed until smooth, and then cooled to 35-40 degrees.
Quality control is carried out in 2 stages. First, the laboratory assistant takes a small amount of shampoo directly from the cauldron and tests it for viscosity and foaming ability. It should be noted that the buyer judges the quality of the shampoo by the presence of a large amount of foam on his head, although this is far from a key indicator.
The second check - and the presence of yeast and bacteria occurs after the shampoo is poured from the boiler into specially prepared barrels. They are sealed inside. Microbiological analysis is carried out in the laboratory using special wipes.
First, a 10% solution of the finished product is made, stirred, and the laboratory assistant draws 1 ml into the pipette. the resulting liquid, and then drips it on napkins. Then he puts them in a heating cabinet for three days, and only after this period you can understand how high-quality and safe the product is. If the wipes are clean and free of fungal growths, then you can give permission for bottling.
After the checks, the shampoo cooled in barrels is brought to the filling machine. And here it is - the final stage of the production process - packaging. in most factories it is made using an automatic bottling line. The machine doses required amount in a container. Each manufacturer uses their own bottle options.
For example, when packaged in tubes, they pass through a special device - heating element, which heats the package with hot air in a couple of seconds and it is filled with shampoo. All irregularities are cut off from the container and a cap is put on. The finished tube is thrown onto the conveyor to the cartoning machine, where it is packed into a box.
How to make shampoo at home with your own hands
The first option for making shampoo at home is from clay. Choose the clay that best suits your hair type, although any healing clay will work on its own. The preparation process consists in dissolving clay in warm water to the state of liquid sour cream. The second option is mustard shampoo. It consists in diluting mustard in water. These substances are absorbent, so additional components can be added to provide some benefit to the hair, but not oils, since you will not be able to mix them.
The best option is to use a decoction of herbs instead of water or essential oils. But keep in mind that oils must be added to dry powder and only then poured with water.
The third recipe is to prepare dry shampoo with your own hands. To do this, use ordinary soda. Apply a small amount (in dry form) to the head, and then simply comb through. Hair will become cleaner and voluminous. But this method is more suitable for people with blond hair, as soda brightens a little.
Another shampoo recipe can be made from black bread. It must be poured with hot water and let it brew for about 15 minutes, after which you can wash your hair. You can add the yolk, but not in hot water, as it will boil immediately. Add it after your infusion has cooled.
There is also a mono-component shampoo that does not even need to be prepared - these are soap nuts. They are very common good feedback and many people use them.
Business in the automotive industry is becoming increasingly attractive to entrepreneurs. And this niche does not always mean high costs to open a business. For example, the production of car shampoos compares favorably with other business ideas in its simplicity. At competent organization activity is quite realistic in the shortest possible time to reach the break-even point.
Our business valuation:
Starting investments - from 800,000 rubles.
Market saturation is average.
The complexity of starting a business is 6/10.
Detergents for the machine differ in composition from the "standard" household chemicals- the composition contains more aggressive substances that can remove even severe dirt from the surface of the car. The products are actively used by both car owners and car washes.
What makes a business attractive?
- In Russia, there are not many enterprises producing auto chemical goods. Products in demand on the market, if you think about it marketing strategy will quickly find its customers.
- A simple technology will allow even those who studied chemistry at school to start a business. The production process is carried out using automated equipment, which will allow you to avoid spending on paying salaries to qualified specialists - you can hire employees with professional education.
- There is a large selection of process lines on the market - choose inexpensive machines to minimize capital costs.
- Compact equipment will make it possible to open a mini-enterprise in small areas - even in a garage.
Where to begin?
The production of car shampoo as a business is an attractive direction. But before you start implementing the idea, it does not hurt to study the market:
- Are there similar companies in the region?
- Is there a high demand for detergents for cars?
- Are there many car washes and potential wholesale buyers finished products?
In parallel with the market analysis, start looking for wholesale customers. So you open the workshop, having already concluded lucrative contracts with buyers. Having finished collecting information, you can begin to register a business, search for premises, purchase raw materials and equipment.
Legal registration of business
The production of car wash shampoo is not subject to compulsory licensing. All that an entrepreneur needs is to register an individual entrepreneur or LLC, choose a taxation scheme, and obtain permission to conduct activities from supervisory services.
Obtaining documents from the fire and sanitary inspections may be delayed, since in the process of producing finished products, a chemical concentrate and other flammable substances harmful to human health will be used.
If you plan to produce car shampoos under your own brand, you will have to invest in brand development and registration.
Technology for the manufacture of car shampoos
You will need a recipe, according to which production will continue in the future. To develop a mixture, you can involve a specialist. If you have enough experience and knowledge, you can do the preparation of the recipe yourself.
To expand your customer base, plan to release several types of car shampoos - for automatic car washes (non-contact) and private use, for cars and trucks.
Non-contact car shampoo is produced on the basis of demineralized water, chemical concentrates and additives. All ingredients are commercially available and are relatively inexpensive. Choose only high-quality raw materials - this will directly affect final result car wash. Car washes will refuse to cooperate with you if you supply them with shampoo that does not perform its functions.
The car shampoo production technology consists of several stages:
- Dosing and mixing of components.
- Heating the mixture.
- Mixture cooling.
- Pouring liquids into containers.
Production is considered waste-free - the soapy water released during the process can be used in the next production cycle.
Technical equipment of the workshop
The main feature of this line of business is equipment for the production of car shampoo for contactless washing, which can additionally produce windscreen cleaning and cooling auto fluids. All that is required for this is to reconfigure and thoroughly flush the line.
The production line is the most expensive part of organizing a business. You will buy equipment with a capacity of up to 700 kg / h for at least 700,000 rubles. This is enough for a small business. You can reduce your investment by purchasing a used line.
The production of contactless car shampoo is carried out on the following equipment:
- dispensers,
- drives,
- vacuum reactor,
- filling machine,
- washing equipment.
The line is compact in size - it can be mounted on 15 m 2 . But additional space will also be required - rooms for staff, warehouses for raw materials and finished products, an office.
Sales channels and profit calculation
To buy equipment for the production of car shampoo and equip a room to start work, you will need at least 800,000 rubles (including supported equipment). It’s great if by the time you open the enterprise you will already find buyers! Products can be offered to auto shops, car washes, gas stations.
The production of car shampoo for contactless washing with well-established sales channels will pay off all costs after 1-2 years. Detergents for cars stand on wholesale market from 70 rubles. At the same time, their cost is lower by 30-50%.
At 171 factories around the world, the German company Henkel produces cleaning and detergents, cosmetics and personal care products, as well as adhesives and sealants. In Russia, cosmetics are made at the Henkel plant near Noginsk. The production supplies our country and five other CIS countries with cosmetics in aerosol packaging (for example, hair sprays and deodorants), hair dyes, shampoos and shower gels. The Village visited the factory and learned how the latter are produced.
Photos
EFREM IVANOV
Factory
Alexey Zubov is now in charge of the plant - he meets The Village correspondents in a red-gray uniform and a branded baseball cap and talks about himself and production. Zubov worked almost all his life in the food industry: he started as a stacker operator, and for the last year and a half he has been working as the director of the Henkel Rus branch in Noginsk. He notes that the production process of cosmetics is similar to "food": the requirements are just as stringent, because the products come into contact with human skin and hair. Several times a year, Zubov travels to Germany, Slovenia and the Netherlands - even more often commissions from the global office visit the plant themselves.
The Noginsk plant has been operating since 2006, initially it did not belong to Henkel. The German company bought it at the end of 2013 and invested about 30 million euros in expanding production. Six months ago, it opened after a major renovation. One of the workshops began to produce Sсhauma, Syoss, Gliss Kur shampoos and Fa shower gels.
All areas where ingredients and finished products are produced and stored are united under one roof. Production manager Svetlana Zinikova explains that this eliminates the risk of microbial contamination. The entire territory of the enterprise is divided into three zones - clean "white", transitional "gray" and conditionally dirty "black". You can get into the clean zone by first putting on a bathrobe, hat and beard, as well as disinfecting your hands and shoes.
OOO Henkel Rus
Location: Noginsky district, Moscow region
Date of purchase: December 2013
Employees: 190 people
Range: more than 300 articles, shampoos Schauma, Syoss, Gliss Kur, shower gels Fa
Production area: 22 hectares
Volume of production: up to 18 million units per month
Geography of deliveries: Russia, Ukraine, Belarus, Kazakhstan, Uzbekistan, Kyrgyzstan
How new shampoos and gels appear
The concept of new products is being developed at the beauty care headquarters. In Hamburg there is the main center of expertise for hair, in Düsseldorf - for shower gels. In addition, the company has regional hubs - for example, in North America or the Asia-Pacific region, where they develop products for the local market. In Russia, such a hub appeared shortly after the acquisition of the plant in Noginsk, so part of the development is carried out here.
The first task after defining the concept of a new product is to develop a formula in the laboratory. The head of the R&D department, Marat Fazylbekov, notes that this process can take from two to five years, depending on the ingredients. Once the formula is developed, perfume companies are involved in the process. The flavor of the product is an important selection factor. A prototype is being tested on focus groups: “If we want to make a shampoo for severely damaged hair, then, naturally, we are looking for those who regularly dye for a long time, bleach several times, and tint. It makes no sense to test it on those who have never painted in their lives, ”Marat notes. Further, the semi-finished product is waiting for extended testing - dermatological, microbiological, toxicological, clinical and laboratory. In Russia, the last stage is mandatory and is carried out with the involvement of volunteers.
Novelty production - to a large extent marketing history, agrees Fazylbekov. “There is some truth in this, but do not exaggerate. It is not enough to know the list of ingredients - it is already on every package. They can be combined in different ways, which will lead to different results,” he notes. Among the trends now are true-organic products and green cosmetics, various hair restoration products and products from the Korean and Japanese markets. A new direction - cosmetics according to individual recipes. Fazylbekov says that many companies will soon come to this.
What are shampoos and shower gels made of?
For the production of shampoos and gels, demineralized water is used. Water passes reverse osmosis purification - through a special membrane, the pores of which allow water to pass through, but do not allow dissolved impurities to pass through. Purified water is stored in storage tanks.
The main component of shampoos and shower gels is surface-active substances (surfactants). “They envelop dirt particles, excess sebum and urban dust and transfer them to the water phase, where they are washed off without problems. This is the main task of all detergents,” explains Marat Fazylbekov. Shampoos are chemically based on anionic surfactants. They have a negative charge - as a result, dirt particles combined with a surfactant are repelled from the hair and washed off with water. With balms and conditioners, the opposite is true. They contain cationic surfactants that are attracted to the hair and, when combined with other ingredients, achieve the desired effect, such as fullness. There are also non-ionic surfactants, but their main drawback is low foaming. “For consumers, not only the result is important, but also the process - they like to feel a lot of foam, they are confident in such a product,” says Fazylbekov.
The second group of ingredients are caring substances. “If we are talking about the function of hair restoration, then these are protein derivatives - keratin, wheat protein hydrolysates and others. natural products. They are built into the structure of the hair, filling it, - says Fazylbekov. - Or these are oils that cover the cuticular layer and give shine from visible effects. If we are talking about fighting dandruff, then these are safe fungicides that fight the fungus - for example, zinc pyrithione, which is popular in the cosmetic industry. The fundamental difference between shampoos and shower gels is precisely in these ingredients. In shampoos, components that restore the hair structure and close the cuticular layer are more active. They are not used in shower gels. In the composition and variety of care products lies the difference between male and female shampoos. Women's hair is more susceptible to damage, so shampoos contain protein, keratin, oils and panthenol. And men's shampoos have an increased alkaline environment, contain substances that normalize the production of sebum.
Other constituents are preservatives, which provide microbiological stability, and a perfume composition, which determines the smell and appearance product. Plant extracts and animal ingredients are often added to shampoos and gels. The consistency is largely determined by the set of surfactants, but thickeners can also be added if necessary. The appearance is affected by the use of dyes and technological conditions production - temperature or mixing time.
Mixing
The technological process for the production of shampoos and shower gels is seemingly simple and not very spectacular. All the main things happen in mixers, where the ingredients are mixed, and the final product is obtained.
In the workshop where mixing takes place, three groups of mixers of different sizes are installed. In the small one, preliminary mixing is carried out, and in the final, the product enters a large mixer with a volume of 10 tons. Svetlana compares the mixer with a small spaceship- this equipment allows you to prepare the product by simply entering the formula into the "on-board computer". In the mixer, future shampoo or shower gel can spend from two to four hours. Ingredients of different consistency - powders, emulsions and solutions - enter the mixer through a system of flexible hoses, each type has its own formula and set of components. An employee working at the mixer only needs to scan the barcodes on the drums of raw materials he is loading.
One of the most difficult to produce is a transparent product containing oils. To achieve transparency, special technological control is needed: “It is worth not mixing for five minutes, and we will get a cloudy product that is unsuitable for use,” says Svetlana. It remains only to be disposed of. The plant does not throw out garbage on its own - all waste is taken out, processed and disposed of specialized company on outsourcing.
Stock
The necessary raw materials are brought to the plant in Noginsk from all over the world. Each region has its own specifics: synthetic products are delivered from China, oil processing products and complex polymers are delivered from Europe. For example, black caviar extract can be brought from Japan (it is in demand in cosmetology), although the plant is constantly looking for new suppliers and is now negotiating with Russian fisheries. Another promising import substitution is the replacement of palm and coconut oils with Russian derivatives of sunflower and rapeseed oils.
Most of the ingredients are stored in large blue barrels: at the beginning of the warehouse you can find "sea buckthorn madness", a little further - "jojoba oil", and everything ends with "sodium benzoate". Preservatives have the longest shelf life and expire the fastest natural oils and extracts.
Laboratory
Raw materials, semi-finished products, finished products and hygienic conditions in industrial premises controls the quality department of the plant. 24 people work in two laboratories - physical-chemical and microbiological. “Starting from the input control of components and each ingredient, we control the physical, chemical and organoleptic parameters of the product in mixing and then take samples from each batch of finished products to confirm the quality and approve the shipment to the warehouse. We check the finished product for viscosity, density, chloride content, pH, appearance, smell and color,” says Stanislav Vasilevsky, head of the quality management service. There is a reference sample for each product at the plant - it is prepared in the laboratory and updated every six months. “Each batch of the product is compared with the standard. For example, to check the appearance and smell, we pour two cups and compare,” says Stanislav. A complete analysis of the finished product lasts five days, it must be checked, including for pathogenic microorganisms - for example, E. coli.
A black and orange "Biohazard" sign hangs at the entrance to the microbiology laboratory. Stanislav explains: “We also work with pure cultures of samples. In case an emergency occurs - for example, a test tube slips out of your hands and infection occurs - we have clear instructions. The person must take off their clothes, take a shower and leave the room. Then the process begins to clean up, localize and destroy the outbreak so that there is no release to production.” The production must be perfectly clean - the laboratory regularly analyzes the swabs from the equipment and even checks the hands of the workers.
Package
After mixing, shampoos and shower gels enter the packaging line. Three packaging lines operate at speeds up to 200 pieces per minute. The process is fully automated: “When you enter the workshop, your jaw drops and you want to stand and watch how the robots work,” says the director of the plant. Bullets for empty vials are fed into a special hopper, after which the machine sets them each in its own cell. The bottles are distributed on special “shoes” stands and sent for filling, where shampoo, gel or conditioner is poured from the dispenser. The bottle is sealed with a cap and sent for labeling and marking - this is also done by the machine. At the end, the robot sends the vials to carton boxes and on pallets.
Packing line workers randomly check caps, vials and filling, and every ten minutes put visual control finished product.
It takes one and a half to two hours to pack one batch. After that, the product is ready to go to the store shelves. Shampoos and shower gels are not stored in the warehouse for a long time: the logistics are built in such a way that the trucks that bring raw materials leave not empty, but with ready-made batches. The volume of output depends on demand and varies from month to month. Peak loadings occur at the end of summer, and March is considered the worst time - the factory says that after February 23 and March 8, no one is in a hurry to buy new shower gels.
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