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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FALL RIVER, Massachusetts, February 20, 2019 – PLZ Corp, a premier value-added strategic partner offering complete product solutions from formulation development to product design, compounding, filling, labeling, packaging and more for aerosol and liquid products, announces enhanced capabilities for the creation of moisturizing hand sanitizer products. Precise Packaging has been working with customers to bring alcohol and non-alcohol liquid and aerosol hand sanitizer solutions to market for over a decade. The addition of moisturizing attributes addresses market demand for hand sanitizer formulations that deliver the benefits of germ control without drying skin.

Moisturizing ingredients can be added to a wide variety of hand sanitizer formats including liquid pump sprays, squeeze bottles, foaming solutions and aerosol sprays, available with packaging and dispensing components to accommodate liquid fill sizes as low as 5 ml, aerosol fill sizes as low as 0.25 oz., and valve sizes from 13 mm up to 1 inch. As an FDA-registered manufacturer of OTC drugs, Precise Packaging also adheres to strict quality and documentation standards to meet FDA requirements for process control, documentation and testing.

“Hand sanitizers have become a staple product on retail shelves because of their ability to kill bacteria and prevent the spread of disease and contamination,” said Shaun Gaus, CEO of Precise Packaging. “As a single-source provider, we help customers formulate and fill aerosol and liquid hand sanitizer products. Travel-size moisturizing hand sanitizers present an attractive alternative for frequent users such as doctors, teachers and caregivers, as they deliver convenient grab-and-go germ protection without stripping away skin oils that retain moisture.”

PLZ Corp specialists guide the research, product development and packaging process and advise on factors such as the level and types of actives, selection of appropriate caps for product protection and the addition of natural and fragrance attributes to meet customer specifications.

For additional information, view our capabilities.

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According to a recent survey of 7,565 U.S. beauty and personal care consumers aged 18+ by The Benchmarking Company, CBD usage is blossoming. A large number of non-users are curious about CBD and willing to try out CBD oil-based products.

Read our article in World Aerosols to learn how to capitalize on consumer demand for CBD oil products. Brand owners must work closely with product development and packaging specialists to bring their CBD oil product ideas to life. Innovation and know-how can enable the development of a variety of high-growth CBD products that meet consumers’ expectations in hair care, skincare, men’s grooming, multicultural hair care and over-the-counter products in the increasingly competitive aerosol personal care industry. Read our “Trailblazing with CBD Oil” article.

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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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Formulation, Delivery & Packaging Considerations

With cold and flu season right around the corner, CPG companies and retailers are stocking store shelves with hand sanitizers to meet customer demand. Designed for use after washing hands or for instances where soap and water are not available, hand sanitizers deliver convenient germ protection wherever consumers may be – from airplanes to doctor’s offices to school settings.

While the end goal for all hand sanitizer solutions remains the same – to kill bacteria and prevent the spread of diseases and contamination – the formulation, delivery and packaging options vary greatly.

Some customers want proven alcohol-based solutions, while others prefer non-alcohol hand sanitizers. More and more hand sanitizers are also featuring natural and moisturizing attributes. Consumers want these sanitizer formulations in a wide variety of delivery formats to meet their on-the-go lifestyles and preferences – from liquid pump sprays to foaming solutions to aerosol sprays and beyond.

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RISE IN TRIAL-SIZE BEAUTY AND PERSONAL CARE PRODUCTS

Specialty stores like Sephora and Ulta, and even big-box retailers like Target are responding to the demand for sample products by offering miniaturized versions of their finest products. In addition, popular e-commerce subscription box services like Birchbox and Ipsy are packaging beauty and personal care products in attractive, functional sample sizes for thematic collections.

These product samples benefit both brand and buyer by establishing brand connections and generating the feel-good vibe that consumers desire – creating the opportunity to gain new customers and potential brand loyalists. Trial-size products can also be produced in smaller batches and shorter runs for filling and packaging more variations of a product. These can be used to efficiently test out new scents or formulations.

CONSIDERATIONS FOR TRAVEL AND TRIAL-SIZE PRODUCT FORMULATION

Brand owners must first ensure that their trial-size products function as well as their full-size counterparts. Not every product formulation is easily converted to trial size, as there may be fewer options for smaller packaging and dispensing components. An established aerosol and liquid formulation and contract filling partner can guide research and development, and advise on factors such as the levels and types of ingredients in the formulation, packaging and delivery of the finished products.

PLZ understands the unique demands of these smaller sizes, which require more accurate fill weights with much tighter tolerances. We have over 30 years of specialized expertise in this area, advising customers on how to select the right components and test for stability and compatibility. PLZ works with customers through formulation and package development, testing/validation, filling, packaging and delivery to ensure that travel-size products function and look like their full-sized products.

AEROSOL AND LIQUID CONTRACT FILLING AND MANUFACTURING

We produce packaging as small as 5 ml and accommodate crimping of valve sizes as small as 13 mm to produce a variety of high-growth, trial-size products including breath sprays, hair and dry shampoo sprays, body sprays, air and surface disinfectant sprays, and beyond. PLZ processes and expertise also accommodate the complexity of small batches, fast changeovers and nimble production. We can fill and package variations more quickly and easily than larger fillers. Product innovations include proprietary flip-top, trial-size PET packaging for liquid pump sprays to pen-size aerosol formats that fit in a small purse.

Whether your company is launching a new product or looking to offer a lower-priced, trial-size version of an existing product, our unparalleled expertise makes PLZ the right strategic partner. We help guide customers through development and manufacturing to bring high-quality travel-size aerosol and liquid products to market quickly and efficiently.

For additional information on PLZ trial-size product capabilities, visit our capabilities or contact us today.

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FALL RIVER, Massachusetts, August 29, 2018 – PLZ, a premier value-added strategic partner offering complete product solutions from formulation development to product design, compounding, filling, labeling, packaging and more for aerosol and liquid products, has expanded its travel and trial-size product solutions to include even more formulation options in pen-size aerosol spray packaging. The new formulation options are in response to increasing consumer demand for smaller products across the personal care, household and over-the-counter (OTC) markets.

As a single-source partner, PLZ understands the unique requirements of travel-size products, which require more accurate fill weights with much tighter tolerances. The company can produce aerosol products with fill sizes as small as 0.1 oz and with valve sizes as small as 13 mm. PLZ advises its customers on formulation ingredients and properties, components selection, testing/validation, packaging and delivery to ensure that their travel-size products function as well as their full-size counterparts. The new formulation options can be used to translate customer ideas into various high-growth travel-/sample-size products, including antiperspirants, breath sprays, hair sprays, body sprays, air and surface disinfectants sprays, and beyond.

“Consumers want products that they can take with them on-the-go, so we’ve worked hard over the past 30 years to develop specialized aerosol and liquid formulation and filling capabilities for travel and trial-size products,” said Shaun Gaus, CEO of PLZ. “We are excited to broaden our product solution capabilities for our innovative pen-size aerosol spray packaging. We’ve already helped our customers bring various applications to market, including new pen-size antiperspirant sprays and on-the-go hair care sprays. These new products can be easily thrown into a gym bag, purse, or pocket for convenient use.”

In addition to the new pen-size aerosol product solutions, PLZ’s travel and trial-size product solutions include its proprietary flip-top PET packaging for liquid pump sprays, twist-top spray bottle for personal care products and more. For additional information, visit our capabilities.

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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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