Alcohol Hand Sanitizer Gel Formulation (Sample 100g)

Okay, I can help you create an alcohol hand sanitizer gel using the ingredients you have. Based on the ingredients you listed and the product information, here is a guideline for the quantities and mixing steps.

The key to an effective hand sanitizer is the final alcohol concentration, which should be between 60-95%. Using 95% Ethyl Alcohol, we need to calculate the amount needed to reach a concentration within this range in the final product. A common and effective concentration is around 70-75% alcohol in the final product.

Here is a sample formulation for a 100g batch using your ingredients, aiming for approximately 70% alcohol in the final gel:

• Ethyl Alcohol (95%): 74g (This amount of 95% alcohol will give you approximately 70.3% actual alcohol in the final 100g gel, which is effective)
• Water: 18g
• Pro Polymer™ (Gel Maker): 1.5g
• MOIST24: 3g
• Aloe Vera Extract (10:1 FullAssay™): 3g
• Tea Tree Essential Oil (100%): 0.5g (See note below regarding this ingredient)

Total: 100g

Important Note on Tea Tree Essential Oil (100%): Standard essential oils are oil-soluble and will not mix well into a water and alcohol-based gel without a solubilizer. If you use 100% pure Tea Tree Essential Oil without a solubilizer (which is not in your ingredient list), it will likely separate in the gel. It is recommended to use a Water Soluble Tea Tree Oil if you want it to properly incorporate into the gel. If you only have the 100% oil and no solubilizer, it's best to omit it from this formula. The instructions below assume you are either omitting the standard oil or using a water-soluble version. If using a water-soluble version, add it with the Water phase ingredients.

Mixing Instructions

Here is the recommended mixing order:

1. Prepare the Gel Base: Weigh the Water into a clean container. Slowly sprinkle the Pro Polymer™ powder onto the surface of the water while stirring gently. Stir just enough to wet the powder and prevent clumps.
2. Hydrate the Gel Maker: Let the mixture sit undisturbed for several hours, ideally overnight. This allows the Pro Polymer™ to fully absorb the water and swell into a gel without needing high-speed mixing, which can damage the polymer structure.
3. Develop the Gel: After the hydration period, gently stir the mixture until a smooth, uniform gel is formed. Avoid vigorous mixing.
4. Add Water-Soluble Ingredients: Add the MOIST24 and Aloe Vera Extract to the gel base. If using Water Soluble Tea Tree Oil, add it now as well. Stir gently until all ingredients are fully incorporated and the gel is clear.
5. Add Alcohol: Slowly add the Ethyl Alcohol (95%) to the gel mixture while stirring gently. Continue stirring until the alcohol is completely mixed in and the gel is uniform.
6. Final Check: The gel should be clear and consistent. If it's too thick or too thin, you may need to adjust the Pro Polymer™ amount in future batches.

Answering Your Questions

• Does the gel maker need to be left overnight? Yes, for Pro Polymer™, letting it hydrate overnight in the water phase is recommended, especially if you don't have a high-shear mixer. This helps it dissolve fully and create a smooth gel texture more easily.
• What is the mixing order? The recommended order is to first hydrate the Pro Polymer™ in water, then add other water-soluble ingredients (MOIST24, Aloe Vera Extract, Water Soluble Tea Tree Oil if used), and finally slowly add the Ethyl Alcohol.

This formulation and method should help you create an effective alcohol hand sanitizer gel.