Facial Dry Wipe with Pre-Soaped, Fragrance Infused Coating

A client from the consumer product industry approached Sierra Coating Technologies LLC to develop, manufacture, coat, and package a cosmetic grade dry wipe with a fragrance infused soap coating. The client came to Sierra® because their current vendor did not have the proper equipment to meet their quality and yield needs.

dry facial wipes coated

Over a two month period, we developed a more efficient manufacturing process that both met FDA guidelines and lowered costs by increasing production speeds and reducing waste. We then tested three different nonwoven fabrics and eight variations of fragrance infused soaps to arrive at the final product.

We then manufactured the wipes into rolls that were 3,000 linear feet long, had a 60 inch outside diameter and weighed up to 5,000 pounds. The rolls were coated with 17 pounds of dry soap per 3,000 square feet of material. After production, the rolls were specially packaged, wrapped, bagged, and then shipped to the client’s Green Bay, Wisconsin location. The minimum production volume per order was 18 rolls of 700 linear feet.

For more information about this project, please see the details below. To learn about our other services, contact Sierra Coating today.

Daily Facial Cosmetic Dry Wipe Project Highlights

Product NameDaily Facial – Cosmetic Dry Wipe
Product DescriptionCustomer supplied nonwoven with customer supplied fragrance infused soap
Consumer product company asked for contract manufacturing or Toll Coating of nonwoven with a custom made fragrance infused soap
They were testing product for national marketing: Their current vendor’s equipment was not meeting the quality and yields needed in the manufacturing of the product.
Project ScopeDevelop a more efficient cost-effective manufacturing process for consumer product
Meet FDA guidelines for consumer cosmetic product
Development WorkQualification of equipment and facility to produce cosmetic grade dry wipe
Low overall cost of product by reducing waste and speed of production
Testing NeededFacility passing microbiological testing and Good Manufacturing Practices (GMP)
Customer quality audits
Product maintaining consistent maximum loading of supplied soap
Trial CostsSet for multiple test days over 2 months of development
Cost sharing on new systems to ensure quality
Raw Material CostsControlled by customer
Testing of 3 brands of nonwoven
Testing of 8 variations of fragrance infused soap
Shipping CostShipping arranged by Sierra and billed to customer
Capabilities Applied/Processes of Aqueous Coatings in Roll to Roll ProcessGravure application – Tested
Slot die application – Qualified and used in production
Pan & Blade application – Not Tested
Tightest ToleranceCoating weight measured to 17 lbs. of dry soap per 3,000 square feet of nonwoven. ±2% ( 27.68 g/sq. meter)
Moisture of finished product to maintain 20% ±2%.
Material TypeNonwoven
Soap base with added fragrance and botanicals
Material ThicknessNonwoven – 1.73 oz. per sq. yard or 36 lbs./ream
Product LengthRoll length from 3000 linear feet to 60 inch outside diameter rolls
Up to 5000 lb. rolls
Production Quantities – Multiple truck loads
Product WidthProduction widths from 45 inches to 62 inches
ColorColor matching with LAB meters and light source
Used to define product specification
Temperature RangeFlotation drying with temperature settings 120˚ F. to 425˚ F.
Material FinishProduct defined to specific target. Defined by total added soap
Achieved by variations in coating and coating weights
PackagingSpecial packaging rolls wrapped and bagged
Secondary Operations AppliedCustom slit rolls to size and packaging
Industry for UseConsumer products
VolumeMinimum volume production is 18 rolls of 7,000 linear feet
Master rolls production 125,000 linear feet
Slit roll production 1,100,000 linear feet
Delivery TimeTen working days from material delivery
Delivery LocationProduct is shipped from Green Bay, Wisconsin
Standards Met (Customer Supplied Print, ISO, ASTM, etc…)Products are made to customer supplied specifications
Cosmetic Grade
FDA Food Grade
National Sanitary Foundation
Good Manufacturing Processes (GMP)

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