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Process Systems & Pilot Plants

FAQ: Continuous Blending for Hand Sanitizer Manufacturers

Hand sanitizer manufacturer clients often have questions early in the design/build process for continuous blending sanitizer systems. It is important to understand what these systems are capable of and whether they are a good fit for your processing needs. Below we’ve provided answers to the most frequently asked questions about continuous blending systems for hand sanitizer.

continuous blending sanitizer system for hand sanitizer manufacturers

Click here to view EPIC’s standard continuous blending sanitizer skid.

Answers to Questions About Continuous Blending of Sanitizer Skids

EPIC’s process engineers deliver this skid 8 weeks after the purchase order has been received. This time will be spent tweaking the physical design for your existing plant processes, automation systems, fabrication time and installation of your skid.

The exact cost depends on the desired output rates and the specific options and upgrades you chose.  It is better to discuss your production needs with an engineer prior to setting a price. Call 314-714-1580 to speak with an engineer about your project or call or reserve a standard skid online.

EPIC’s standard sanitizer processing skids meet FDA/OTC compliance for validation and regulation. Hand sanitizer manufacturing qualifies as a drug-related classification and is regulated accordingly. This system is designed for tight tolerance and to make it easy for record-keeping and sampling. For additional guidance on FDA policies for processing hand sanitizer, visit

Hand sanitizer manufacturers will be required to follow Class 1 Division II regulations. Because hand sanitizer skids utilize a flammable alcohol ingredient, they can only be stored and mixed in Class 1, Division II locations. You must provide an adequate understanding of the following three situations to convert your area to a Class I, Division II location.

  • In the event that volatile flammable liquids or flammable gases are handled, processed, or used, you must make considerations for the ingredients. Hazardous liquids, vapors or gases must normally be restricted within closed containers or closed systems from where they can escape only during an accidental breach or failure of the containers or systems, or due to unexpected operation of the equipment.
  • Ventilation must be considered per industry and government regulations and guidelines. Ignitable concentrations of gases or vapors must utilize positive mechanical ventilation. Equipment must be checked and maintained to not become hazardous through failure or abnormal operations of the ventilation system.
  • Areas adjacent to a Class I, Division II location, where ignitable concentrations of gases or vapors might occasionally be circulated must be checked and tested regularly unless prevented from exposure. To be excluded from exposure testing, areas must have sufficient positive-pressure ventilation from a clean air source, and effective safeguards must be provided by the company against ventilation breakdowns.

Yes! While EPIC has developed a standard design for this skid, we understand that every plant has different requirements. Our engineers are prepared to customize the specs of this continuous blending sanitizer skid to meet your production needs. Additionally, we can design and build additional unit operations (pre-mix systems, CIP, etc..) to support your process.

EPIC’s standard skid is capable of a dosing accuracy within 1%.

Yes. EPIC offers a wide range of custom-designed process applications including batch or continuous mixing, distillation systems, solvent recovery, dosing systems, pre-mix skids, clean-in-place (CIP) systems, and more.  View EPIC’s custom-built process skids.

With EPIC’s standard sanitizer blending solution your product will be homogeneous every batch. Immediately after each ingredient addition point, a static or high shear mixer ensures adequate blending of ingredients. Agitation can also be provided in the finished product surge tank for larger systems. Catch samples from the inline mix system verify finished product is indistinguishable from a product made in a batch process.

Our expert automation strategies control blending system startup to ensure that formula percentage is held constant as the continuous blending system comes up to full rate. A surge tank provides extra backup that helps average blending and avoid system shutdown during brief filler stoppages.

System automation triggers an alarm in advance of running out of any raw material, allowing plenty of time for the operator to replenish raw materials while the system is still running. Flow meters monitor ingredient flow and the system will shut down if any ingredients quantity starts to decrease below specifications. Process instrumentation also monitors other critical aspects of the making process such as density, temperature, etc.

EPIC Modular Process Systems
4134 Meramec Bottom Rd
St. Louis, MO 63129, US