FORMULATING PRODUCTS
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Batch manufacturing procedure
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Product quality test parameters​
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Formulating Tips & Troubleshooting
Skin Cream
Skin Cream
Base ingredients: DM water, O/W emulsifier, Fatty Acids/oils, thickener, neutralizer, Fragrance, emollients & preservative.
Formulation Steps:
1) Take DM water and add 20-30% of neutralizer. Mix well at slow rpm.
2) Add thickener and mix well till a homogeneous(no lumps) solution is formed.
3) Add liquid O/W Emulsifier and mix well(Mix-A).
4) Heat all wax, oils, fatty acids(non-polar phase - Mix-B) in separate container to 40-50deg.
5) Add Mix-B content to main vessel(Mix-A) while maintaining temperature and mix well at high rpm. If needed use homogenizer.
6) Stop heating. Once the solution is below 30deg add fragrance and remaining quantity of neutralizer and mix well
7) Add preservative while continuous stirring and mix well
Critical points: Partial neutralization of thickener, correct thickener and emulsifier selection. Homogenizer and its rpm
Concentration of emulsifier and thickener will depend on the concentration of oil phase
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Fatty acids: Cetostearyl Alcohol, Stearic Acid, EGDS or EGMS
Natural Oils: Coconut oil, Almond Oil or Olive Oil
Emulsifier: Hydrogenated castor oil - PEG40
Thickener: Acrylic acid polymer like Carbomer 980
Body Perfume Spray
Body Perfume Spray
As this is aerosol product: G:C ratio is important, Gas(G) is propellant or LPG – Mixture of Butane and propane. Concentrate(C) is: Solution or blend of Natural oils(as per EDP-EDT-EDC-EF) and high vapor pressure solvents; like denatured ethanol.
Formulation Steps:
1) Add base solvent – alcohol 80-90% with continuous and slow stirring
2) Add all natural oils and fragrance – one-by-one with continuous stirring till its clear
3) Add other ingredient and mix well until homogeneous solution is obtained
4) Fill the prepared concentrate into aerosol cans.
5) Perform the crimping of aerosol valve. Do the propellant filling as per G:C ratio (60:40)
Critical points:
Controlled temperature and humidity
Low stirrer speed
Safety
Consideration and selection:
Appropriate Aerosol Valve, Can and Actuator as per the desired cone - spray pattern
and spray rate​​
Hair Shampoo
Hair Shampoo
Base ingredients: DM water, surfactants, thickener, neutralizer, natural extracts/oils, conditioner, Fragrance and Preservative
Formulation Steps:
1) Add DM water and add 20-30% of neutralizer, mix well at low rpm
2) Add thickener and mix well, until homogeneous solution is obtained(Sol-A)
3) Slowly add all surfactants and mix well, until homogeneous solution is obtained(Sol-B)
4) Slowly add Sol-B to Sol-A with continuous stirring and mix to achieve homogeneous mix
5) Add remaining quantity of neutralizer
6) Add conditioning agent and mix well
7) Add natural extracts and preservative. Mix well
8) Add fragrance and mix well
9) Adjust pH to 4.5 - 5.5 and mix well
10) Ensure appropriate rpm to avoid excessive foam generation
Critical points: Partial neutralization of thickener, correct thickener selection and surfactants combination. Stirrer rpm
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Specialty ingredient: Hair nourishment natural Extracts​
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Hair Nourishment Cream
Hair Nourishment Cream
Base ingredients: DM water, O/W emulsifiers – Primary and co-emulsifiers, Fatty Acids, conditioners, thickener, neutralizer, Fragrance, Preservative
Speciality ing: Hair nourishment extracts and oils
Formulation Steps:
1) Take DM water and add 20-30% of neutralizer. Mix well at slow rpm.
2) Add thickener and mix well till a homogeneous(no lumps) solution is formed.
3) Add liquid O/W Emulsifier and mix well(Mix-A).
4) Heat all wax, oils, fatty acids(non-polar phase - Mix-B) in separate container to 40-50deg.
5) Slowly add Mix-B content to main vessel(Mix-A) while maintaining temperature and mix well at high rpm. If needed use homogenizer.
6) Stop heating. Once the solution is below 30degC add fragrance and remaining quantity of neutralizer and mix well
7) Add preservative while continuous stirring and mix well
Critical points: Partial neutralization of thickener, correct thickener and emulsifier selection. Homogenizer and its rpm
Concentration of emulsifier and thickener will depend on the concentration of oil phase
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Specialty ingredient: Hair nourishment natural Extracts and oils
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Face Wash
Face Wash
Base ingredients: DM water, O/W emulsifiers – Primary and co-emulsifiers, Surfactants, thickener, neutralizer, Natural Extracts, oils, Fragrance and Preservative.
Speciality ingredient: Conditioners, skin nourishing extracts and oils
Formulation Steps:
1) Add DM water and add 20-30% of neutralizer, mix well at low rpm
2) Add thickener and mix well, until homogeneous solution is obtained(Sol-A)
3) Slowly add all surfactants and mix well, until homogeneous solution is obtained(Sol-B)
4) Slowly add Sol-B to Sol-A with continuous stirring and mix to achieve homogeneous mix
5) Add remaining quantity of neutralizer
6) Add conditioning agent and mix well
7) Add natural extracts and preservative. Mix well
8) Add fragrance and mix well
9) Ensure appropriate rpm to avoid excessive foam generation
Critical points: Partial neutralization of thickener, correct thickener & emulsifier selection and surfactants combination. Stirrer rpm
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Specialty ingredient: Conditioners, natural Extracts and oils
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Shave Foam
Shave Foam
Base ingredients: DM water, O/W emulsifier, Fatty Acids/oils, surfactants, neutralizer, Fragrance, Preservative
Speciality ingredient: Skin oils
Formulation Steps:
1)Take fatty acids and heat them to 70-80deg C and mix well (Sol-A)
2)Take DM water in main mixing vessel and heat it to 70-80degC and slowly add emulsifiers to it with continuous mixing until homogeneous (Sol-B)
3) Slowly add Sol-a to Sol-B with continuous stirring at low rpm, until homogeneous.
4) Cool the solution to 50degC and start adding surfactants & other essential oils.
5) Stop heating and once the temperature of the solution is below 35degC add fragrance and preservatives and mix well.
6)Adjust the pH to 8.0 - 10.00
7)Fill this concentrate into aerosol cans and add LPG (G:C ratio 5:95)
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Critical points: pH, fatty acids and emulsifier selection
Homogenizer and its rpm
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Consideration and selection:
Appropriate Aerosol Valve, Can and Actuator as per the desired cone - spray pattern
and spray rate
Pain Relief Spray (Ayurvedic)
Pain Relief Spray (Ayurvedic)
As this is aerosol product: G:C ratio is important, Gas(G) is propellant or LPG – Mixture of Butane and propane.
Concentrate(C) is: Natural oils and fast evaporating, volatile solvents like IPA, ethanol
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Formulation Steps:
1) In the main vessel, add base solvent with continuous stirring at slow rpm in mixing vessel in
control temperature and humidity conditions
2) Slowly add all natural oils – one-by-one with continuous stirring till the solution is clear
3) Slowly add preservatives and anti-oxidants. Mix well till the solution is completely clear
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Critical points: Controlled temperature and humidity. Stirrer rpm.
Ratio Conc.:Gas – 55:45
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Consideration and selection:
Appropriate Aerosol Valve, Can and Actuator as per the desired cone - spray pattern
and spray rate
Pain Relief Spray
Pain Relief Spray
​As this is aerosol product: G:C ratio is important, Gas(G) is propellant or LPG – Mixture of Butane and propane.
Concentrate(C) is: Natural oils and fast evaporating, volatile solvents like IPA, ethanol
Drug: Diclofenac Diethylamine and Cyclobenzaprine HCl. Preservative and Quenching agent
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Formulation Steps:
1) In the main vessel, add base solvent with continuous stirring at slow rpm in mixing vessel in
control temperature and humidity conditions
2) Slowly add the drug/active and mix well until clear homogeneous solution is obtained.
3) Slowly add all natural oils – one-by-one with continuous stirring till the solution is clear
4) Slowly add preservatives and anti-oxidants. Mix well till the solution is completely clear
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Critical points: Controlled temperature and humidity. Stirrer rpm.
Ratio Conc.:Gas – 55:45
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Consideration and selection:
Appropriate Aerosol Valve, Can and Actuator as per the desired cone - spray pattern
and spray rate
Surface Cleaner
Surface Cleaner
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Base ingredients: DM water, surfactants, foaming agents, water softeners, pH modifiers, Fragrance, Preservative
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Formulation Steps:
1)Take 70% of DM water in main vessel and slowly add surfactants to it and mix well at low rpm
2)Slowly add foaming agents at slow stirring speed and mix well until clear homogeneous solution is obtained
3)In another small vessel take remaining 30% of DM water and dissolve water softeners followed by pH modifiers to it and mix well until clear.
4)Add above mix to main mixing vessel and mix well with slow stirring speed to avoid foam generation
5)Add preservatives and mix well
6)Add fragrance and mix well until the solution is clear.
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Critical points: addition of surfactants and foaming agent to avoid any foam generation
Fabric Cleaner Liquid
Fabric Cleaner Liquid
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Base ingredients: DM water, surfactants, thickener, foaming agent, water softeners, neutralizer, Fragrance, Preservative
Speciality ingredients: Fragrance, enzymes and brighteners
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Formulation Steps:
1)Take 70% of DM water in main vessel and add 50% neutralizer to it and mix well
2)Slowly add thickener with continuous stirring and mix well at low rpm so that no lump are formed
3)Slowly add surfactants with continuous stirring and mix well until homogeneous
4)Slowly add foaming agent at slow stirring speed and mix well.
5)Add remaining quantity of neutralizer and mix well until homogeneous
6)In another small vessel take 30% of DM water and add water softeners followed by brightener and preservative. Mix well until clear.
7)Add above mix to main mixing vessel and mix well with slow stirring speed until homogeneous, to avoid foam generation.
8)Add fragrance and enzymes and mix well until a clear thick liquid gel is produced
Critical points: addition of surfactants and foaming agent to avoid foam generation. Thickener selection is crucial because, if the selected surfactant mix is not compatible with the thickener it can disrupt the crosslinking structure of the gel
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Formulation Tips & Troubleshooting
No theory can replace the knowledge and understanding acquired through practically formulating products/batches in laboratory. Practical experience gives the sense, impression correct processing habit etc.
So we have crafted below checklist which has been curated through knowledge and experience acquired through practical hands, with intention to help the formulators best
Depending upon the type of formula or product, applicable or appropriate parameter to be ensured from below checklist. This will provide best surety for a stable formula over the intended product shelf life
Formulation Checklist
Manufacturing Checklist
Depending upon the type of formula or product, appropriate parameter to be ensured from below checklist. This will provide best surety for a stable formula over the intended product shelf life.
The list has been curated based upon practical experience of the industry experts
