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As a result of this shift, hand sanitizer products have become a critical component to every re-opening plan. According to Fact.MR’s “Hand Sanitizer Market Forecast, Trend Analysis & Competition Tracking – Global Market Insights 2020 to 2030” study, the global hand sanitizer market is expected to surpass a value of ~$1.4 billion in 2020 and double from 2020 through 2030 to exceed ~$2.8 billion. With this increased market demand, many personal care and over-the-counter (OTC) brands are reallocating their resources toward amplified hand sanitizer production.

PRODUCING AEROSOL HAND SANITIZER SPRAYS

For brand owners looking to expand or build upon their offerings to include these new necessities, it’s important to note that hand sanitizers are classified as OTC drug products and they need to be treated as such. They come in a variety of formulations featuring both alcohol and non-alcohol actives, including aerosol spray, bag-on-valve (BOV) spray, gel, foam and liquid – to name a few

Read our “Aerosol Hand Sanitizer – An Essential Guide” article in World Aerosols or download the article PDF below to learn about the formulation and delivery requirements for bringing both alcohol and non-alcohol aerosol hand sanitizer products to market, including a review of the various attributes and benefits of each. It will also detail the key considerations for ensuring the quality, safety and efficacy of aerosol hand sanitizer products, as well as advice for selecting the proper components and packaging to meet the high standards of quality assurance and control required for hand sanitizer production.

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Product Development Tips for the Fall’s Hottest Backpack Essential – Hand Sanitizer

As schools across the country begin to reopen, there are a variety of approaches for re-introducing students to their learning environments. All in-person and hybrid models involve an updated focus on cleaning and sanitization that has given rise to a new back-to-school supply category. As a result of this shift, hand sanitizer products have become one of the hottest backpack essentials on every child’s list this fall. For companies formulating these over-the-counter (OTC) products, there are many product development variables to consider.

Hand Sanitizer Product Development – Tips for Producing This Year’s Hottest Backpack Essential

Traditional alcohol-based hand sanitizer formulations are the most commonly produced. They feature alcohol as the active ingredient, mainly in the form of either ethanol or isopropyl alcohol. Alcohol-based hand sanitizers effectively kill germs and viruses by working immediately on the skin to deliver fast-drying properties.

Since the majority of hand sanitizers feature clear containers, it is also especially critical to add the right type and level of additives to achieve the desired product clarity, color and formulation consistency.

Quality Documentation and Efficacy Claims for Hand Sanitizers

Quality documentation and efficacy claims are critical to ensuring the safety and effectiveness of hand sanitizers. Our facility is EPA, DEP, ATF and FDA (OTC drug and medical device) registered, ensuring the highest standards of quality assurance and control. We are also a Health Canada approved filler and an Organic Certified Co-Packer, with business philosophy and quality operating systems based on ISO 9001 and current Good Manufacturing Practice Guidelines (ISO 22716 and CFR 21 Parts 210 and 211). Our formulation and product development specialists can help guide clients through the testing requirements for making efficacy claims such as “kills 99.99% of germs” if desired.

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Quality documentation and efficacy claims are critical to ensuring the safety and effectiveness of hand sanitizers. Our facility is EPA, DEP, ATF and FDA (OTC drug and medical device) registered, ensuring the highest standards of quality assurance and control. We are also a Health Canada approved filler and an Organic Certified Co-Packer, with business philosophy and quality operating systems based on ISO 9001 and current Good Manufacturing Practice Guidelines (ISO 22716 and CFR 21 Parts 210 and 211). Our formulation and product development specialists can help guide clients through the testing requirements for making efficacy claims such as “kills 99.99% of germs” if desired.

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As a single-source provider, Precise Packaging understands that the formulation, delivery and packaging options for hand sanitizer solutions vary greatly. We have been working with customers for over a decade to bring both alcohol and non-alcohol, liquid or aerosol hand sanitizer options to market. Our formulation and filling specialists guide the research, product development and packaging process to deliver hand sanitizer formulations for liquid pump sprays, squeeze bottles, foaming solutions, aerosol sprays and beyond.

HAND SANITIZER FORMULATIONS

Traditional alcohol-based hand sanitizer formulations are the most common. As the name implies, alcohol-based hand sanitizers feature alcohol as the active ingredient, mainly in the form of either ethyl alcohol or isopropyl alcohol.

These sanitizers effectively kill germs, bacteria and most viruses. The alcohol works immediately on the skin to deliver fast-drying properties. While this is a strong selling point, frequent users such as doctors, teachers and caregivers may find alcohol solutions to be drying on their skin after repeated uses.

Non-alcohol based formulations present an attractive alternative, as they do not strip away the skin oils that retain moisture. Non-alcohol hand sanitizers feature antimicrobials, such as benzalkonium chloride, as the active ingredient for delivering effective germ protection. Beyond their moisturizing benefits, the popularity of non-alcohol hand sanitizers has recently gained traction among consumers seeking minimalist formulas that use natural ingredients.

HAND SANITIZER PACKAGING

Once the desired formulation is identified, Precise Packaging product development and packaging experts work closely with customers to determine the appropriate delivery method for the product. Due to their small size, travel-size hand sanitizers require more accurate fill weights with much tighter tolerances, as well as smaller packaging and dispensing components.

Our formulation and filling specialists advise customers on the proper components required to meet the need for packages featuring liquid fill sizes as low as 5 ml and aerosol fill sizes as low as 0.25 oz., with valve sizes from 13 mm up to 1 inch. Other important packaging considerations include the choice of appropriate caps for product protection, proper actuator selection to ensure that the packaging works with the product formulation, the presence of an expiration date to meet FDA requirements, as well as the overall packaging style and durability.

Since the majority of hand sanitizers feature clear containers, it is also especially critical to add the right type and level of additives to achieve the desired product clarity, color and formulation consistency. Additives may also be added to provide benefits such as fragrance and/or moisturizing oil to meet specifications.

MEETING FDA REQUIREMENTS

Throughout the process, quality and documentation are paramount to ensuring the safety and effectiveness of OTC hand sanitizer products. As an FDA-registered manufacturer of OTC drugs, Precise Packaging adheres to strict quality and documentation standards by meeting FDA requirements for process control, documentation and testing. We also advise on factors such as the level and types of actives, selection of appropriate caps for product protection, and the use of proper actuators to ensure product safety and effectiveness.

Visit our products webpage to learn how Precise Packaging can help you to bring high quality, aerosol and liquid hand sanitizer products to market quickly and efficiently for convenient grab-and-go germ protection.

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Less is more

Traveling “carry-on only” requires a new approach to packing; minimalism is in. Liquids, gels and aerosols must be limited to 3.4-ounce containers. We are all too familiar with TSA agents who make you toss out the water bottle you forgot you had before you can proceed through security. But what if you had to throw out something special – a luxury perfume, a $40 bottle of foundation – just to catch your flight on time?

Some savvy travelers sidestep the risk by purchasing travel-friendly containers to decant their favorite products into. An even easier solution is to buy these products in trial-sized containers. Universal staples like shampoo, soap, and deodorant are easy enough to find in smaller sizes. But what about the special items we use every day, like perfume?

A marriage of convenience

Specialty stores like Sephora and Ulta offer fabulous sampling sections where some of their finest products are offered in miniature containers. These product samples serve two purposes: first, they give you the chance to try out a product before you invest in the full size; and second, they are travel-friendly and are a great option to take the products you already love on the go.

Door-to-door sampling service

E-commerce brings an entirely new dimension to product sampling. Enter subscription and sampling boxes like Birchbox, Ipsy, and many others. It’s tough to beat the fun surprise of opening a box filled with little treats. Packaging beauty and personal care products in attractive, functional sample sizes that can be incorporated into thematic collections creates opportunities to gain new customers and potential brand loyalists, to be associated with an already-beloved service brand, and to generate the feel-good vibe that consumers are looking for. Plus, those samples easily fill the need for portable, quality products that don’t feel mundane. The brand benefits, and so does the buyer.

Favorite things in small packages

More and more CPGs are developing products to meet consumers’ growing preference for “snack-sized” experiences. Starting with the miniature version of a product, especially in cosmetics, helps to mitigate our fear of taking risks when it comes to buying things that vary so greatly from person to person. Consider a pricey beauty product, like perhaps a $50 makeup foundation. You might hesitate to make that investment if you aren’t sure how the product will react to your skin type. What works for one person might cause breakouts and irritation for another. Trial size is just that – the perfect amount to try something out and see if it works before you commit to the full size. Not to mention that travel sizes are portable, easier to use up before they expire (who has ever managed to completely finish a mascara before it dried out?), and sometimes even cheaper per unit weight than the full size!

At PLZ, we offer unique powder aerosol formulations and filling capabilities for high-growth products such as makeup mousses and sprays, hair care products, and body/foot powder sprays, as well as dual-function product solutions such as moisturizing body foam with SPF – in the sample and travel-sized products on up, with valve sizes from 13mm to 1 inch. Contact us today to learn how your product can be right-sized for sampling and travel.

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