Cost-effective is pretty simple. But keep in mind that to start you need to invest a significant amount in equipment for the production of shampoos. To use it, you will not need any special knowledge or skills. All that entrepreneurs need is to register a business and set up shampoo factories.

When buying a line, keep in mind that the equipment is universal for many cosmetics. With this in mind, in the future, your shampoo production may expand to make cosmetics.

Laboratory equipment

  The first stage of production is the formulation. Manufacturers offer products according to their unique recipe, based on numerous studies, samples, and tests.

Upon completion of the manufacturing process, each batch undergoes quality control, that is, a laboratory will be needed again. You will need:

•   - 16 000 rubles .;
•   - 90 000 rubles .;
•   - up to 70,000 rubles .;
•   37 ° C - about 35,000 rubles;
• shaking apparatus - up to 10 000 rubles .;
•   maintaining the temperature of 45 ° С - up to 15 000 rubles .;
•   - 8,000 - 20,000 rubles;
•   - 30 000 rubles .;
•   - less than 1,000 rubles;
•   - 5 000 rubles .;
• flasks, pipettes, mortars, magnifying glass, cups, coverslips - all together will delay up to 5,000 rubles.

The cost of raw materials:

For 1 ton of finished shampoo, it is necessary to use raw materials for 14000-15000 rubles. Separately to this amount you need to add the cost of packaging - about 15 rubles. for 1 bottle.

Production line

The production of shampoos can include both separate equipment and a complete line of everything you need. Shampoo plants include special fluid tanks, component mixing reactors, and rotary pumps.

Equipment for the production of shampoo on the Russian market is provided by several companies, among which Agromash is a manufacturer of diverse technological and food equipment.

This business is suitable for a universal line for the production of shampoos and cosmetics. Manufactured products: shampoo, cream, gel, soap, tonics and lotions. Includes:

• steel boiler to heat water for 500 l., temperature 150 - 1000 ° C, power - up to 30 kW; one of the elements is a centrifugal pump;
• ventilation caps;
• a steel digester with a 250 liter stirrer, temperature - 300-950 ° С;
• 250 liter boiler for dissolving the ingredients;
• 250 liter boiler to accumulate various additives;
• refrigerator-boiler, where the ingredients are mixed and cooled;
• tank washing system;
• control Panel.

Liquid Dosing and Spill Line

  Manufacturers offer many automatic dosing machines for filling bottles of different volumes. The cost of such machines reaches 1,600,000 rubles.

Pay attention to the filling machine with a capacity of 3,000 bottles per hour, with a volume of 0.2-1 liters.

Typically, such machines are suitable for filling any liquids and are easily rebuilt for any container.

Advantages of equipment:

• bottle position monitoring by sensors;
• high dosage accuracy;
• simple reconfiguration to any desires.

The line includes:

• adjustment system;
• cork winding device, which is controlled by the remote control;
• hopper feed cap;
• automatic labeling mechanism;
• automatic washing;
• emergency protection;
• loading control system;
• product counting sensor.

Specifications:

• the volume of containers for bottling - up to 1,000 ml;
• dosing accuracy - ± 1 ml;
• supply voltage - 50 Hz;
• power consumption - 2 kW;
• installation weight - 1,000 kg;
• the number of operators is 5 people.

Feihong Machinery Spill Equipment:

Labeling line

  The production of hair shampoo also requires a special machine for gluing product labels. The cost reaches 200,000 rubles.

Get the Cavagnino & Gatti Automated Machine, Model CG80 — Spray polypropylene labels with hot glue.

Features:

• the presence of a printer;
• 4 sticker formats;
• productivity - 2,000 stickers per hour;
• speed adjustment;
• manual adjustment of bottle height;
• 1 kg of glue is enough for 35,000 labels.

Selection of labeling equipment:

Optional equipment

When setting up production, especially on a large scale, you will need additional machines.

Conveyor system (conveyor)

It is necessary for moving products between stages of production. The system consists of individual assembly elements, the amount of which is usually ordered individually, taking into account the parameters of the production workshop.

System material - stainless steel.

Quality conveyors include an electric drive and a regulator.

Inspection equipment

It is also more suitable for large volumes of production and it is necessary to discard low-quality bottles with shampoo (violation of the integrity of the form, tightness).

Video: how is high-quality shampoo made?

Formulation and selection of raw materials should be carried out taking into account the requirements of the Guidelines for cosmetic products approved by the EEC (EEC Directives 76/768) and SanPiN 1.2.681-97 “Hygienic requirements for the production and safety of perfumes and cosmetics”. These documents contain lists of substances that are allowed, not permitted and limited to be used in the formulation of cosmetics and, in particular, hair and scalp care products.

In modern cosmetics, more and more attention is paid to active additives - components that in a relatively small amount can significantly affect the properties of the finished product. However, in many cases, the introduction of active ingredients into the finished formulation is limited by their chemical nature: unpleasant odor, low solubility, rapid degradation due to oxidation, sensitivity to UV radiation or water, and poor skin tolerance when applied at higher concentrations. In some cases, antioxidants, complexing agents and UV filters can improve the quality of the finished product, protecting it from oxidation, discoloration, delamination, etc. At the same time, it is more difficult to influence parameters such as the bioavailability of the active component and the tolerance of the scalp and hair to it, since they largely depend on the formulation. When choosing a base, the cosmetics developer (as opposed to the pharmacist) is usually guided by other motives than increasing the bioavailability active component. The consumer qualities of the finished product and its safety come to the fore here. It often happens that the chosen base cannot protect the active compound from degradation, as a result of which it not only loses its biological activity, but, moreover, becomes toxic. When applied to the skin, an “unprotected" active compound comes in contact with air and quickly oxidizes or falls under direct sunlight and is destroyed by their action. Classical examples of such hypersensitive compounds are unsaturated fatty acids, vitamins A (retinol) and C (ascorbic acid). So, oxidizing at the site of unsaturated double bonds, unsaturated fatty acids contribute to the rapid deterioration of the product (its rancidity). When oxidized, vitamin C loses its antioxidant properties, and vitamin A can cause severe irritation. Encapsulation of active components, i.e. enclosing them in a protective shell is considered as a promising solution to this problem. Microcapsules are, as a rule, spherical systems in which the active components are located in the core (core). The core is surrounded by one or more layers of the shell. A wide selection of materials for capsule shells is presented on the modern market. The most widely used are natural or synthetic polymers such as collagen, alginate, chitosan, lactic acid, polycaprolactone, polyacrylates, as well as waxes. The effectiveness of microcapsules in the composition of the finished product largely depends on their behavior in the cosmetic base. In addition, it should be borne in mind that encapsulation requires time and additional cash costs. So only those components whose encapsulation is dictated by necessity are worthy of being enclosed in a protective sheath. 3.2 Technology for cosmetic detergents The preparation of shampoos belongs to the category of relatively simple industries. In the general case, the unit of equipment is a stainless steel apparatus equipped with a jacket for heating and cooling and a stirrer (for liquid and creamy shampoos, the stirrer is slightly different). It is important that all shampoos must undergo mandatory tests. First, an assessment of organoleptic indicators (appearance, consistency, color, smell), which are determined by sensory evaluation. Then, physical and chemical characteristics are examined, including safety indicators: pH value, mass fraction of dry matter, foaming ability, rheological characteristics (viscosity), heavy metals content, and also determine microbiological stability. Consumer properties of shampoo are studied on volunteers (volunteers). Particular attention is paid to the study of the toxicological properties of shampoos, and in recent years, in vitro methods, which are used instead of testing on animals and on volunteers (in vivo), are increasingly being used.

1 - crane; 2 - 4 t mixer; 3 - mixer 10 t; 4 - water heating;

5 - water purification system; 6 - pump; 7 - filter; 8 - capacity of 2 tons;

9 - dispenser

Figure 3.1 - The technological scheme for the production of shampoos

Figure 3.2 - Hybrid Coconut Palm

The most difficult task facing shampoo chemists is the problem of the compatibility of various components. Oil, as you know, can be an effective foam dampener. But this means that the addition of such emollients to shampoos must necessarily affect the quantity and quality of the foam, and therefore worsen the washing properties of the composition. To avoid this, the so-called emulsifiers are introduced into the mixture - substances capable of enveloping water-insoluble droplets of fats. The microfilm from the emulsifier does not allow the oil to contact the surfactant directly, and also prevents the shampoo from stratifying, preventing tiny balls of oil from merging with each other. Another more modern way to combine the incompatible is to solubilize components that are insoluble in water, that is, their translation into a soluble state using special additives. The fact is that many surfactants form in the water not true, but micellar solutions. This is due to structural features of surfactant molecules that have a polar head and a long uncharged tail - a hydrocarbon radical (R) C 12 –C 14 (Figure 3.3). D

Figure 3.3 - Building
surfactant molecules

Tins interact with water molecules, and tails tend to come closer to each other, resulting in the formation of regular conglomerates of molecules - micelles. If the surfactant concentration in the solution is not very high, micelles resemble balls, if it grows, the balls merge with each other to form tubes ( Figure 3.4). Micelles are formed due to the electrostatic interactions of the polar heads of surfactant molecules with water molecules. Sometimes fatty substances can “dissolve” inside such structures. M the environment inside the balls and tubes is electrically neutral, and substances that are insoluble in water, such as oils, may well “dissolve” here. However, not all surfactant molecules are able to solubilize various additives equally well, and the appearance of products active in this regard has brought the production of shampoos to a completely different level.

Figure 3.4 - Micelle formation mechanism

It is no less difficult to “reconcile” anionic substances with cationic ones in one bottle. This became possible only after the invention of amphoteric and crypto-anionic surfactants. Crypto-anionic surfactants are a class of substances that combine the properties of anionic and nonionic surfactants. Molecules of such surfactants carry both a positive charge (mainly on nitrogen) and a negative charge. They stand as a bridge between the washing molecule and the conditioning agent molecule, forming weak bonds with them, which allows the components of the shampoo to act more or less independently. So, the basis for the production of hair washing products are surfactants, auxiliary surfactants (co-surfactants) and thickeners are components, providing removal of pollution from hair and scalp. Additionally, to solve other problems facing hair care products, they introduce: condensing additives, dyes, opacifiers, perfumes, vegetable oils, plant extracts, vitamins, preservatives. In total, several dozens of substances are included in shampoos. 3.3.1 SurfactantsThe main active principle of shampoo are detergents  - surfactants that cause the appearance of foam when mixed with water and air. Detergent is the main "semantic" component of shampoo. The detergent is usually one of the first in the composition on the label of any shampoo. Surfactants have the following properties:

reduce the surface tension between water and fat particles, thereby facilitating the removal of these particles and dirt;

form a foam;

form a suspension of dirt particles in the foam and prevent re-sedimentation of dirt on the hair;

stabilize other shampoo ingredients or keep them dissolved;

increase the viscosity of shampoos.

anionic surfactants - in an aqueous solution decompose with the formation of negatively charged ions;

cationic surfactants - in an aqueous solution decompose with the formation of positively charged ions;

amphoteric surfactants - in an aqueous solution, depending on the pH of the medium, they can exhibit cationic (in an acidic environment, pH<7) или анионные свойства (в щелочной среде рН>7);

nonionic surfactants - do not form ions in an aqueous solution.

Figure 3.5 - Classification of detergents

removal of static electricity, reduction of hair “flying”;

smoothing and aligning damaged areas of hair shafts;

easy combing of wet and dry hair;

porosity minimization;

giving hair shine and silkiness;

providing protection against thermal and mechanical damage;

moisturizing;

increase in volume and mass;

reconditioning damaged hair.

Business in the automotive industry is becoming increasingly attractive to entrepreneurs. And this niche does not always mean high costs for opening an enterprise. For example, the production of car shampoos compares favorably with other business ideas in its simplicity. With the competent organization of activities, it is quite possible to quickly reach the breakeven point.

Our business rating:

Starting investments - from 800,000 rubles.

Market saturation is average.

The complexity of starting a business is 6/10.

Detergents for the car are different in composition from the “standard” household chemicals - the composition contains more aggressive substances that can remove even heavy dirt from the surface of the car. Products are actively used by car owners and car washes.

What is attractive business?

• In Russia, there are not many enterprises producing auto chemicals. The products demanded in the market, if you think about a marketing strategy, will quickly find your customers.
• Simple technology will allow you to run a business even for those who studied chemistry only at school. The production process is carried out using automated equipment, which will avoid the cost of paying salaries to qualified specialists - you can hire employees with professional education.
• There is a wide selection of production lines on the market - choose low-cost machines to minimize capital costs.
• Compact equipment will make it possible to open a mini-enterprise in small areas - even in a garage.

Where to begin?

Car shampoo production as a business is an attractive area. But before you start implementing the idea, it does not hurt to study the market:

• Are there any enterprises of a similar direction in the region?
• Is there a high demand for detergents for cars?
• Are there many car washes and potential wholesale buyers of finished products?

In parallel with market analysis, start looking for wholesale customers. So you open a workshop, having already concluded profitable contracts with customers. Having finished with the collection of information, you can begin to register a business, search for premises, purchase of raw materials and equipment.

Legal registration of business

The production of car wash shampoos is not subject to mandatory licensing. All that an entrepreneur needs is to issue an IP or LLC, choose a taxation scheme, and obtain permission to conduct activities from supervisory services.

Obtaining documents from the fire and sanitary inspections may be delayed, since in the process of manufacturing finished products, chemical concentrate and other fire hazardous substances harmful to human health will be used.

If you plan to produce car shampoos under your own brand, you have to invest in brand development and its registration.

Manufacturing technology of car shampoos

A recipe will be required, according to which in the future the release of products will occur. You can hire a specialist to develop the mixture. If you have enough experience and knowledge, you can do it yourself.

To expand your customer base, plan to release several types of car shampoos - for automatic washes (non-contact) and private use, for cars and trucks.

Contactless car shampoo is produced on the basis of demineralized water, chemical concentrates and additives. All ingredients are commercially available and are relatively inexpensive. Choose only high-quality raw materials - this will directly affect the final result of washing the machine. Car washes will refuse to cooperate with you if you begin to supply them with shampoo that does not fulfill its functions.

The technology for the production of car shampoo consists of several stages:

• Dosing and mixing components.
• Heating the mixture.
• Cooling the mixture.
• Bottling liquids in containers.

Production is considered non-waste - soapy water released in the process can be used in the next production cycle.

Technical equipment of the workshop

The main feature of this business line is the equipment for the production of car shampoo for contactless washing, which can additionally produce glass cleaning and cooling car fluids. All that is required is to reconfigure and thoroughly flush the line.

A technological line is the most expensive part of organizing a business. Equipment with a capacity of up to 700 kg / hour you will buy for at least 700,000 rubles. This is enough for a small business. You can reduce investment if you purchase a supported line.

Contactless car shampoo production is carried out on the following equipment:

• dispensers
• drives
• vacuum reactor
• filling machine
• washing equipment.

The line is compact in size - it can be mounted on 15 m 2. But additional space will also be required - rooms for staff, warehouses of raw materials and finished products, office.

Sales channels and profit counting

To buy equipment for the production of car shampoo and equip a room to start work, you will need at least 800,000 rubles (including supported equipment). Well, if by the time you open the enterprise you will already find buyers! Products can be offered to car dealerships, car washes, gas stations.

The production of car shampoo for contactless washing with established sales channels will pay off all costs after 1-2 years. Detergents for cars are on the wholesale market from 70 rubles. Moreover, their cost is 30-50% lower.

Sterilizers, storage tank, cooking tank, digester, cooking reactor, grease oven, fat melter, homogenizer, vacuum pump, vacuum mixer, mixer, vacuum mixer, etc.

Vacuum homogenizing machine for preparing shampoo

HAV-150. Three-layer vacuum capacity. Material food grade AISI 304 stainless steel. Bottom cone. The working volume of the tank is 150 liters.

Frame stirrer with 0.75 kW gear motor. The speed of rotation of the shaft of the mixer is 0-30 revolutions per minute adjustable by means of the Vesper speed converter. PTFE scrapers.

The heating shirt is voluminous. Heating by means of built-in heaters with a power of 9 kW (two groups of 4.5 kW each).

Remote control with the function of automatic and forced on and off heating, automatic temperature control, heating and cooling process, the function of controlling the mixer, homogenizer and screw pump.

Capacity cooling system through a coil built into the heating jacket with pneumatic valves "FESTO" to the inlet and outlet of the coolant. The union for water supply. Two temperature controllers of two-channel Aries. Temperature sensors (in the product and in the heating jacket).

Shutoff valves with disk locks, with a diameter of 80 mm on an unloading branch pipe in the center of the bottom of the tank.

The system of circulation and discharge of the product through a homogenizer and a screw pump with butterfly valves.

Cover the cone. Manual cover lift with shock absorbers.

Capacity on a stainless steel frame. Vacuum pump, electromagnetic monovacuum meter, non-return valve, vacuum pipe with trap and drain tank.

Viewing window DN 100 mm with illumination of the inside of the reactor.

Two funnels for introducing dry and liquid components during the cooking process.

In 171 factories around the world, the German company Henkel produces cleaning and detergents, cosmetics and personal care products, as well as adhesives and sealants. In Russia, cosmetics are made at the Henkel factory near Noginsk. Production supplies our country and five other CIS countries with aerosolized cosmetics (for example, hair sprays and deodorants), hair dyes, shampoos and shower gels. The Village visited the factory and found out how the latter are produced.

Photo

EFREM IVANOV

Plant

Now the plant is managed by Alexei Zubov - he meets The Village correspondents in a red-gray uniform and branded baseball cap and talks about himself and the production. Zubov spent almost his entire life in the food industry: he began as a packing operator, and for the past year and a half he has been working as the director of the Henkel Rus branch in Noginsk. He notes that the cosmetics production process is similar to the “food industry”: the requirements are just as stringent because the products come in contact with human skin and hair. Several times a year, Zubov travels to Germany, Slovenia and the Netherlands - more often commissions from the global office visit the plant themselves.

The Noginsk plant has been operating since 2006; initially it did not belong to Henkel. The German company bought it at the end of 2013 and invested about 30 million euros in the expansion of production. Six months ago, it opened after a massive reconstruction. In one of the workshops, Shauma, Syoss, Gliss Kur and Fa shower gels were launched.

All rooms where ingredients and finished products are produced and stored are combined under one roof. Production manager Svetlana Zinikova explains that this eliminates the risks of microbial infection. The entire territory of the enterprise is divided into three zones - pure “white”, transitional “gray” and conditionally dirty “black”. You can get into the clean area by first putting on a dressing gown, hat and a set-up, as well as disinfecting your hands and shoes.

Henkel Rus LLC

Location:  Noginsky district, Moscow region

Date of purchase:  December 2013

Staff:  190 people

Range:  more than 300 items, shampoos Schauma, Syoss, Gliss Kur, Fa shower gels

Production Territory:  22 hectares

Volume of production:  up to 18 million units per month

Supply geography:  Russia, Ukraine, Belarus, Kazakhstan, Uzbekistan, Kyrgyzstan

How new shampoos and gels appear

The concept of new products is being developed at the headquarters of the beauty care business. In Hamburg, there is the main center of expertise for hair, in Dusseldorf - for shower gels. In addition, the company has regional hubs - for example, in North America or the Asia-Pacific region, where they develop products for the local market. In Russia, such a hub appeared shortly after the acquisition of the plant in Noginsk, so some of the development is being carried out here.

The first task after defining the concept of a new product is to develop a formula in the laboratory. The head of the R&D department, Marat Fazylbekov, notes that this process can take from two to five years, depending on the ingredients. After developing a formula, companies involved in perfume compositions are involved in the process. The flavor of the product is an important factor of choice. The prototype is tested on focus groups: “If we want to make shampoo for severely damaged hair, then, of course, we are looking for those who regularly color for a long time, bleach several times, and tint. Testing it for those who have never painted in their lives makes no sense, ”says Marat. Further, the semi-finished product is waiting for advanced testing - dermatological, microbiological, toxicological, clinical and laboratory. In Russia, the last stage is mandatory and is carried out with the involvement of volunteers.

New production is largely a marketing story, Fazylbekov agrees. “There is some truth in this, but do not exaggerate. It’s not enough to know the list of ingredients - it is already on every package. They can be combined in different ways, which will lead to different results, ”he notes. Among the trends now are true organic products and green cosmetics, various hair restoration products and products from the Korean and Japanese markets. A new direction is cosmetics according to individual recipes. Fazylbekov says many companies will come to this soon.

What shampoos and shower gels are made of

For the production of shampoos and gels, demineralized water is used. Water undergoes reverse osmosis treatment through a special membrane, the pores of which pass water, but do not allow dissolved impurities. Purified water is stored in storage tanks.

The main component of shampoos and shower gels is surface-active substances (surfactants). “They envelop particles of dirt, excess sebum and urban dust and transfer them to the water phase, where they are washed off without problems. This is the main task of all detergents, ”explains Marat Fazylbekov. The chemical basis of shampoos is anionic surfactants. They have a negative charge - as a result, dirt particles connected to a surfactant are repelled from the hair and washed off with water. With balms and conditioners, the opposite is true. They contain cationic surfactants that are attracted to the hair and in combination with other ingredients can achieve the desired effect - for example, fluffiness. There are nonionic surfactants, but their main disadvantage is low foaming. “Not only the result is important for consumers, but also the process - they like to feel a lot of foam, they are sure of such a product,” says Fazylbekov.

The second group of ingredients is caring substances. “If we are talking about the function of hair restoration, then these are protein derivatives - keratin, hydrolysates of wheat proteins and other natural products. They are embedded in the hair structure, filling it, ”says Fazylbekov. “Or these are oils that cover the cuticular layer and give shine from visible effects.” If we are talking about the fight against dandruff, then these are safe fungicides that fight against fungus - for example, zinc pyrithione, which is popular in the cosmetics industry. ” The fundamental difference between shampoos and shower gels is precisely in these ingredients. In shampoos, the components that restore the structure of the hair and cover the cuticular layer are more active. They are not used in shower gels. In the composition and variety of care products lies the difference between male and female shampoos. Women's hair is more prone to damage, so shampoos contain protein, keratin, oils and panthenol. And men's shampoos have an increased alkaline environment, contain substances that normalize the production of sebum.

Other components are preservatives that provide microbiological stability, and a perfume composition that determines the smell and appearance of the product. Plant extracts and animal components are often added to shampoos and gels. Consistency is largely determined by a set of surfactants, but thickeners can be added if necessary. The appearance is affected by the use of dyes and technological conditions of production - temperature or mixing time.

Mixing

The technological process for the production of shampoos and shower gels seems simple and not very entertaining. All the main thing happens in mixers, where the ingredients are mixed, and the finished product is obtained at the output.

In the workshop where the mixing takes place, three groups of mixers of different volumes are installed. In the small one, preliminary mixing is performed, and in the final, the product falls into a large mixer with a volume of 10 tons. Svetlana compares the mixer with a small spaceship - this equipment allows you to cook a product by simply scoring the formula in the “on-board computer”. In a mixer, a future shampoo or shower gel can spend from two to four hours. Ingredients of different consistencies - powders, emulsions and solutions - get into the mixer through a flexible hose system, each type has its own formula and set of components. An employee working on a mixer only needs to scan barcodes on barrels of raw materials that he loads.

One of the most difficult in production is a transparent product containing oils. To achieve transparency, a special technological control is needed: “It’s worth it for five minutes to get in the way, and we will get a muddy product, unsuitable for use,” says Svetlana. It only remains to be disposed of. The plant does not throw garbage on its own - all the waste is taken out, processed and utilized by a specialized company for outsourcing.

Warehouse

The necessary raw materials are brought to Noginsk from all over the world. Each region has its own specifics: synthetic products are delivered from China, oil products and complex polymers are delivered from Europe. For example, they can bring black caviar extract from Japan (it is in demand in cosmetology), although the plant is constantly in search of new suppliers and is now negotiating with Russian fisheries. Another promising import substitution is the replacement of palm and coconut oils with Russian derivatives of sunflower and rapeseed.

Most of the ingredients are stored in large blue barrels: at the beginning of the warehouse you can find "sea buckthorn madness", a little further - "jojoba oil", and everything ends with "sodium benzoate". Preservatives are stored the longest, the fastest expiration date for natural oils and extracts.

Laboratory

Raw materials, semi-finished products, finished products and hygienic conditions in production facilities are controlled by the plant's quality service. 24 people work in two laboratories - physico-chemical and microbiological. “Starting from the input control of components and each ingredient, we control the physicochemical and organoleptic parameters of the product in the mix and then we take samples from each batch of finished products to confirm the quality and approve shipment to the warehouse. We check viscosity, density, chloride content, pH, appearance, smell and color of the finished products, ”says Stanislav Vasilevsky, head of the quality management service. There is a reference sample for each product at the plant - it is prepared in the laboratory and updated every six months. “Each batch of product is compared with a standard. For example, to check the appearance and smell, we pour two glasses and compare, ”says Stanislav. A complete analysis of the finished product lasts five days, it should be checked including pathogens - for example, E. coli.

At the entrance to the microbiological laboratory there is a black and orange sign “Biological hazard”. Stanislav explains: “We also work with pure sample cultures. In case an emergency occurs - for example, a test tube slips out of your hands and becomes infected - we have clear instructions. A person must take off his clothes, take a shower and leave the room. Next, the process of cleaning, localizing and destroying the outbreak begins so that there is no release to production. ” It should be perfectly clean at the factory - the laboratory regularly analyzes flushing from equipment and even checks the hands of workers.

Packaging

After mixing, shampoos and shower gels fall onto the packaging line. Three packaging lines operate at speeds up to 200 pieces per minute. The process is fully automated: “When you enter the workshop, the jaw drops out and you want to stand and watch how the robots work,” says the director of the plant. Bullets for empty bottles are fed into a special hopper, after which the machine sets them each in its own cell. Bottles are distributed on special coasters - “shoes” and sent for filling, where shampoo, gel or conditioner is poured from the dispenser. The bottle is corked with a cap and sent for labeling and marking - this is also the machine's job. At the end, the robot sends the bottles to cardboard boxes and pallets.

Workers who monitor the packaging line selectively check caps, vials, and filling, and every ten minutes they put visual inspection of the finished product.

It takes one and a half to two hours to pack one batch. After this, the product is ready to go to store shelves. Shampoos and shower gels are not stored at the warehouse for a long time: the logistics are built in such a way that the machines that bring the raw materials leave not empty, but with ready-made lots. The volume of output depends on demand and varies from month to month. Peak downloads occur at the end of summer, and March is considered the worst time - the factory says that after February 23 and March 8 no one is in a hurry to buy new shower gels.