Cream & Lotions
Clean Cream Operations!
At PureNSM, we approach our cream manufacturing process with the same dedication to purity, safety, and precision that we apply to our supplements. We believe that high-quality skincare products should be created with the utmost care, ensuring that each batch is not only effective but also free from contaminants and produced with a commitment to your health and well-being.
At PureNSM, we now make lotions, salves, creams, and other cosmetic and personal care products. Using cutting-edge technology, our three-tank cream manufacturing system ensures the highest standards of quality, stability, and consistency in every batch.
Our advanced system integrates water-soluble and oil-soluble ingredients to create stable emulsions, perfect for delivering smooth, effective skincare formulations that meet your exact specifications.
Contact Melody Huang, our resident expert on cream manufacturing, today for a consultation and discover how we can assist in your product development journey. Please contact us here.
Our Three-Tank Manufacturing System
We use a specialized three-tank system, each designed to handle a unique part of the manufacturing process. The system consists of:
- Water Phase Vessel (Tank 1)
- Wax/Oil Phase Vessel (Tank 2)
- Manufacturing/Emulsifying Vessel (Tank 3)
All tanks are made of stainless steel (SS316L), providing durability and hygiene, and equipped with advanced features like agitators, heating/cooling jackets, and vacuum systems to ensure that each product is flawlessly mixed and stable.
Key Equipment & Functions
1. Water Phase Vessel (Tank 1)
- Function: This vessel is designed to handle water-soluble ingredients, ensuring they are properly dissolved and mixed.
- Key Features:
- Propeller Stirrer: Efficiently dissolves water-based ingredients.
- Heating/Cooling Jackets: Regulates the temperature for optimal mixing conditions.
2. Wax/Oil Phase Vessel (Tank 2)
- Function: Handles oil-soluble ingredients and melts waxes, ensuring the right consistency before emulsification.
- Key Features:
- Propeller/Anchor Stirrer: Ensures smooth, consistent melting and mixing.
- Heating/Cooling Jackets: Controls the temperature of oil-based ingredients for perfect blending.
3. Manufacturing/Main Vessel (Tank 3)
- Function: This is the central unit for combining the water and oil phases to create a stable emulsion.
- Key Features:
- High-Shear Homogenizer: Reduces particle size for smooth textures and better product stability.
- Anchor Agitator with Scrapers: Prevents ingredients from sticking and ensures thorough mixing.
- Vacuum System: Removes air from the mixture, eliminating bubbles and ensuring a perfectly smooth product.
- Vacuum Pump: Further enhances deaeration and ensures product stability.
4. Transfer Pump
- Function: Efficiently moves ingredients from the phase vessels to the main manufacturing vessel.
- Key Features:
- Lobe Pump or Vacuum Transfer System ensures smooth, consistent flow of ingredients.
5. Control Panel
- Function: Manages the entire process automatically, offering full control over the production process.
- Key Features:
- Automated PLC/SCADA System: Controls temperatures, stirring speeds, and vacuum pressures for optimal conditions during manufacturing.
Wet Granulation
Weighing & Mixing: Ingredients (active and excipients) are mixed together to ensure uniformity.
- Binder Solution: A liquid binder (water or alcohol-based) is prepared.
- Adding Binder: The binder is gradually added to the powder mixture, causing particles to agglomerate into larger particles (granules).
- Wet Massing: The mixture is stirred or mixed to enhance granule formation.
- Granulation: The wet mass is processed through a granulator to form uniform granules.
- Drying: The granules are dried in our fluid bed dryer to remove excess moisture.
- Sieving: Dried granules are screened to achieve consistent size.
The process improves blend uniformity, helps powder fit into capsule because of increased density of powder, increase flowability, compressibility, and uniformity for tablet or capsule production.
- Poorly flowing powders that need improved flowability and density.
- Ingredients that require better compressibility for tablet formation.
- Poorly mixed ingredients that need improved uniformity and consistency.
- Heat-sensitive actives (with controlled moisture and drying processes).
- Granules that require coating, encapsulation, or improved size consistency.
Why Choose PureNSM for Your Cream Manufacturing Needs?
- Advanced Technology: Our state-of-the-art three-tank system is designed to create perfect emulsions, resulting in smoother, more stable products.
- Precision and Customization: With precise control over every aspect of the manufacturing process, we tailor each product to meet your specific needs.
- Reliable and Scalable: Whether you’re creating small batches or large-scale production runs, our system is scalable and adaptable.
- High-Quality Standards: We use the highest quality materials and employ strict quality control measures to ensure every product meets industry standards.
- Eco-Friendly and Hygienic: Stainless steel (SS316L) ensures durability and meets the hygiene standards required for cosmetic product manufacturing.
Start Your Project with PureNSM
At PureNSM, we understand the importance of high-quality products that your customers trust. Our advanced manufacturing system guarantees consistent, safe, and effective lotions, creams, and salves that meet your brand’s needs.
Whether you’re launching a new product or scaling up an existing one, we’re here to help you bring your vision to life.
Ready to start?
Contact Melody today for a consultation and discover how we can assist in your product development journey.
(A) Developing a New Cream Formula
- Concept and Research
- Identify Goals: Define the desired benefits, target market, and product claims (e.g., moisturizing, anti-aging, etc.).
- Ingredient Selection: Choose active ingredients (e.g., plant extracts, vitamins) and excipients (e.g., emulsifiers, preservatives).
- Formulation Research: Study ingredient compatibility, efficacy, and stability based on industry research and guidelines.
- Prototype Development
- Initial Testing: Develop small-scale prototypes based on the chosen ingredients.
- Stability Testing: Ensure the formula maintains stability under various temperature, humidity, and light conditions.
- Performance Testing: Evaluate sensory properties like texture, absorption, and fragrance.
- Scaling Up
- Batch Formulation: Scale the prototype to a larger batch, adjusting proportions for production.
- Pilot Production: Run a small batch in the manufacturing system (e.g., water phase, oil phase, emulsification).
- Evaluation: Conduct internal testing for quality control and consistency.
- Finalization and Documentation
- SOP Creation: Develop a detailed Standard Operating Procedure (SOP) for manufacturing, quality control, and packaging.
- Packaging Design: Design appropriate packaging that aligns with the brand and preserves product integrity.
- Regulatory Compliance: Ensure the formula complies with regulations (e.g., FDA, Health Canada).
- Production and Launch
- Full-Scale Production: Once testing and regulatory checks are complete, move to large-scale production.
- Market Launch: Begin marketing and distribution to target customers.
(B) Moving an Existing Cream Formula to PureNSM
- Gather Formula and Documentation
- Obtain Formula: Ensure you have the exact recipe with ingredients, percentages, and SOP.
- Obtain Example Batch Record: Get a record of previous batches to understand typical production quantities, procedures, and timing.
- Analysis and Review
- Evaluate Formula and SOP: Compare the provided formula and SOP to PureNSM’s existing capabilities. Identify any modifications needed to fit PureNSM’s three-tank system.
- Ingredient Compatibility: Confirm that the ingredients are compatible with the equipment and processes at PureNSM.
- Pilot Batch Production
- Run a Pilot Batch: Use PureNSM’s three-tank system to create a small test batch. Monitor for consistency in texture, stability, and efficacy.
- Quality Control Checks: Perform internal testing for purity, emulsification, and sensory properties (e.g., fragrance, absorption).
- Refine and Scale
- Adjust Parameters: If any issues are identified in the pilot batch, make necessary adjustments (e.g., mixing speeds, temperatures, ingredient additions).
- Full-Scale Production: Once the batch is approved, move to full-scale production, ensuring quality assurance procedures are in place.
- Documentation
- SOP Finalization: If needed, adjust the SOP to match PureNSM’s operational procedures.
Regulatory Checks: Confirm all regulatory documentation is up to date, and ensure that labeling complies with industry standards.
(C) Reverse Engineering an Unknown Formula
- Initial Assessment
- Gather Samples: Obtain samples of the cream to be reverse-engineered.
- Ingredient Analysis: Use techniques like HPLC or GC-MS to analyze the ingredients and their concentrations.
- Evaluate Texture and Sensory Properties: Assess the texture, fragrance, and other physical properties of the cream.
- Prototype Development
- Identify Base Ingredients: Use the analysis to identify the core base ingredients (e.g., emulsifiers, oils, water-soluble components).
- Formulate a Hypothetical Recipe: Create a working formula based on the identified ingredients and typical concentrations.
- Stability and Efficacy Testing
- Create Small Batch: Use the hypothesized formula to create a small-scale batch in PureNSM’s manufacturing system.
- Stability Testing: Test for emulsion stability, sensory properties, and any potential breakdown of the formula over time.
- Optimization and Refinement
- Adjust Formula: Based on test results, adjust ingredient concentrations, blending techniques, and processing times to achieve the desired product.
- Quality Control: Perform quality assurance checks for consistency, efficacy, and texture.
- Documentation and Scaling
- Finalize Formula: Once the reverse-engineered formula matches the desired product, document it.
- Develop SOP: Create a detailed SOP for manufacturing, quality control, and packaging.
- Regulatory Compliance: Ensure compliance with relevant cosmetic regulations and certifications (e.g., GMP).
- Launch Production
- Pilot Batch: Run a larger batch to ensure the formula is ready for full-scale production.
- Finalize Production and Launch: Once the reverse-engineered product is finalized, launch production and bring the product to market.
Summary
- New Formula: Start with research, prototype development, testing, scaling, and regulatory checks.
- Existing Formula: Gather documentation, review compatibility, run a pilot batch, refine the process, and scale production.
- Reverse Engineering: Analyze the cream, hypothesize a formula, test, optimize, and ensure quality and compliance before scaling.
In all scenarios, the focus is on precision, consistency, and regulatory compliance, ensuring the cream meets the desired quality and performance standards while utilizing PureNSM’s advanced manufacturing system.
Here’s a summary of expected costs for each of the three services related to cream manufacturing at PureNSM:
(A) Pricing for a New Cream Formula
- Research and Development
- Formulation Development: $2,000 – $5,000
- Ingredient Sourcing: $500 – $2,000
- Stability and Performance Testing: $1,000 – $3,000
- Pilot Batch Production
- Small-Scale Batch Production: $500 – $2,000
- Testing & Evaluation: $300 – $1,000
- Full-Scale Production
- Scale-Up Costs: $3,000 – $10,000 (depending on batch size)
- Quality Control & Regulatory Compliance: $1,000 – $3,000
- Total Estimated Cost for New Formula Development
$8,300 – $23,000 (depending on complexity and volume)
(B) Pricing for Moving an Existing Cream Formula to PureNSM
- Review and Evaluation
- Formula and SOP Review: $500 – $1,000
- Compatibility Check with PureNSM’s Equipment: $500 – $1,500
- Pilot Batch Production
- Small-Scale Production: $500 – $2,000
- Stability and Sensory Testing: $300 – $1,000
- Adjustments (if needed): $500 – $2,000
- Full-Scale Production
- Large-Scale Production: $2,500 – $8,000 (depends on batch size)
- Regulatory Checks and Documentation: $500 – $2,000
- Total Estimated Cost for Existing Formula Transfer
$4,800 – $14,500 (depending on batch size and adjustments needed)
(C) Pricing for Reverse Engineering an Unknown Formula
- Initial Assessment and Ingredient Analysis
- Ingredient Analysis (HPLC/GC-MS): $1,000 – $3,000
- Texture and Sensory Evaluation: $300 – $1,000
- Prototype Development
- Small Batch Production (Initial Prototype): $500 – $2,000
- Stability and Efficacy Testing: $500 – $2,000
- Optimization and Refinement
- Adjustments and Fine-Tuning: $500 – $1,500
- Quality Control Testing: $300 – $1,000
- Full-Scale Production and Launch
- Full-Scale Production: $2,500 – $8,000 (depending on batch size)
- Regulatory and Compliance Costs: $500 – $2,000
- Total Estimated Cost for Reverse Engineering
$5,600 – $17,500 (depending on complexity of formula and testing required)
Summary of Estimated Costs
- New Formula Development: $8,300 – $23,000
- Existing Formula Transfer: $4,800 – $14,500
- Reverse Engineering: $5,600 – $17,500
The costs vary depending on ingredient complexity, batch size, testing requirements, and any necessary adjustments to match desired product specifications. If you’d like to dive deeper into specific cost components or explore additional factors, feel free to ask!