Cosmetic Production Workflow and Quality Control for Creams, Sunscreens, and Serums

The production process for cosmetics like creams, sunscreens, scrubs, and serums follows a structured workflow to ensure safety, stability, and efficacy. Below is a detailed breakdown of the production line from raw materials to finished goods (FG).

1. Receiving and Quality Control of Raw Materials (IQC)

• Process: Receiving raw materials and packaging.
• QA/QC: Check Certificate of Analysis (COA), physical appearance, color, odor, and perform microbial testing if necessary.
• Equipment: Weighing scales, sampling tools.

2. Preparation and Weighing

• Process: Weighing ingredients according to the formula.
• QA/QC: Double-check weights against the Batch Manufacturing Record (BMR).
• Equipment: Precision digital scales.

3. Bulk Production (Mixing and Emulsification)

This stage varies slightly depending on the product type:

• Creams and Sunscreens: Usually involve an oil phase and a water phase heated separately (approx. 70-75°C) and then emulsified using high shear.
  • Sunscreens require intensive homogenization to ensure even dispersion of UV filters.
• Serums: Often water-based. Ingredients are dissolved or dispersed. If it's an emulsion serum, a homogenizer is used.
• Scrubs: Similar to cream or gel bases, but scrub particles (exfoliants) are added at the final stage at a lower temperature and lower mixing speed to prevent damage to the particles.
• Equipment:
  • Homogenizers: Essential for creating stable emulsions (e.g., Bearing (Composite) Homogenizer 2.2KW or 4.0KW).
  • Heating Tanks: For melting waxes and oils.

4. In-Process Control (IPC)

• Process: Testing the "Bulk" before filling.
• QA/QC:
  • pH Testing: Using a pH meter (with pH Calibration Buffers).
  • Viscosity: Ensuring the thickness is correct (using a Viscometer).
  • Stability/Appearance: Color, odor, and texture check.
• Equipment: pH meter, Viscometer.

5. Filling and Packaging

• Process: Transferring the bulk into primary packaging (bottles, tubes, jars).
• QA/QC: Check filling weight/volume accuracy and seal integrity.
• Equipment:
  • Filling Machines: For liquids or creams.
  • Sealing Machines: For tubes (e.g., Ultrasonic tube filling and sealing machine).

6. Final Quality Control (FQC) and QA

• Process: Final check of the finished product.
• QA/QC:
  • Microbial Testing: Ensuring no contamination (using a Microbial Limit Tester).
  • Packaging Check: Labeling accuracy, batch coding, and overall appearance.
• Equipment: Microbial Limit Tester, Vacuum Pump.

7. Storage and Distribution

• Process: Storing in a temperature-controlled warehouse before shipping.

Differences in Production Lines

• Viscosity: Serums (low viscosity) use different filling pumps than thick scrubs or creams.
• Shear Force: Sunscreens and creams need high-shear homogenization, while scrubs need gentle mixing for the particles.
• Temperature: Some serums with heat-sensitive actives must be processed at room temperature (Cold Process).

MySkinRecipes Support

MySkinRecipes provides various industrial-grade tools to support your production line, including:

• Mixing & Emulsifying: High-performance homogenizers ranging from 2.2KW to 7.5KW for different batch sizes.
• Filling & Sealing: Ultrasonic tube sealing systems for professional packaging.
• Lab & QC: pH calibration solutions, viscosity measurement tools, and microbial testing equipment to ensure your products meet standard requirements.