Complete Guide to Shampoo Manufacturing Plant Setup: 3 Process Selections + Compliance Pitfalls to Avoid (A Must-Read for Entrepreneurs)

I. Core of Plant Setup: Determine Process Before Framework (Experience-Based Content)

1. Cost and Scenario Adaptation of Three Production Processes

Cold Mixing Method: Suitable for startup factories (daily capacity < 5 tons), requiring only mixing tanks + homogenizers (equipment cost: approximately RMB 80,000 – 150,000). Raw materials must be fully water-soluble (e.g., green surfactants like C12-14 Alkyl Glycosides [APG]) . The operation sequence must strictly follow “chelating agent → primary surfactant → secondary surfactant → moisturizer → fragrance”. Case study: A small factory in Guangzhou produced amino acid shampoo using this method, controlling raw material loss rate within 3%.

Hot Mixing Method: Designed for formulas containing solid oils (e.g., nourishing shampoo), requiring a steam heating system (additional investment: RMB 200,000 – 300,000). After heating to 75°C for dissolution, low-speed stirring is needed for 30 minutes to eliminate foam. Note: If stratification occurs, first test the pH value (check citric acid dosage) then inspect raw material batch differences .

Partial Hot Mixing Method: Preferred for medium-sized factories (daily capacity 10-20 tons). On-site production of pearlescent paste can reduce raw material costs by 20%. The key is temperature control: “cool hot materials to 45°C before mixing with cold materials”.

2. Compliance Red Lines for Workshop Layout

According to GB/T 29679-2013 “Hair shampoo, cream shampoo” (under revision in 2025) , the production area must be divided into 3 core zones:

Raw Material Warehouse: Humidity ≤ 65%, surfactants and preservatives stored separately (distance ≥ 1.5 meters)

Emulsification Workshop: Epoxy anti-corrosion floor treatment, 0.8-meter operating channel reserved between equipment

Testing Room: Must be equipped with heavy metal analyzers (lead ≤ 10ppm, mercury ≤ 1ppm)

II. Equipment Selection: Pitfall-Avoidance Guide and Cost Control (Professional Content)

1. Core Equipment Configuration List (Classified by Capacity)

Production Capacity Level	Emulsification Tank Specification	Auxiliary Equipment	Total Investment Budget
Small (< 5 tons/day)	500L stainless steel tank × 2	Vacuum defoaming machine, semi-automatic filling machine	RMB 150,000 – 250,000
Medium (10-20 tons/day)	2000L heating tank × 3	Automatic labeling machine, microbial testing bench	RMB 800,000 – 1,200,000
Large (> 30 tons/day)	5000L reaction kettle × 5	Online viscometer, CIP cleaning system	RMB 3,000,000+

2. Three Most Problem-Prone Equipment Types

Low-cost homogenizers: Rotational speed < 3000r/min causes uneven silicone oil dispersion; 380V industrial-grade models are recommended

Non-stainless steel storage tanks: Ordinary carbon steel tanks lead to excessive heavy metals; 304 food-grade stainless steel is mandatory

Manual filling machines: Error > ±2ml; fully automatic models are required when daily capacity exceeds 5 tons (saves 80% labor)

III. Compliance Lifeline: Domestic Certification and Export Requirements (Authoritative Content)

1. Key Materials for Domestic SC Certification (Food Production License)

Raw material acceptance records (must include supplier qualifications for new materials like APG-1214)

Third-party test report (must meet pH value 4.0-8.0 requirements in GB/T 29679-2013)

2. Shortcuts for ASEAN Market Access

According to ASEAN Common Requirements (ACR) rules:

Using ASEAN Mutual Recognition Arrangement (MRA) reduces duplicate testing costs by 60%

IV. Raw Materials and Costs: Breakthrough Strategies for SMEs (Credible Content)

1. Green Raw Material Substitution Plan

Replace 50% Sodium Lauryl Sulfate (SLS) with C12-14 Alkyl Glycosides:

Irritation reduced by 40% (skin patch test pass rate increased to 98% in practice)

2. 30% Cost Reduction Techniques

Procurement: Bulk purchase of surfactants ≥ 5 tons/month reduces unit price by 8-12%

Energy consumption: Waste heat recovery system for hot mixing method saves RMB 12,000 in electricity costs monthly

Loss control: Automatic weighing devices in filling process reduce raw material loss from 5% to 1.8%

V. Practical Misconception Warnings (Experience-Based Supplement)

Wrong Process Selection: Startup factories blindly adopt hot mixing method, leading to 60% equipment idle rate (cold mixing method recommended for trial production first)