Face Mask Sachets Production Process Introduction
With the continuous increase in demand for skin care products among modern consumers, facial masks have become essential for daily skin care routines. As an important packaging for facial masks, facial mask sachets not only provide protection but also directly impact the effectiveness of the mask and the brand image. The form of facial mask sachets has undergone several years of different iterations, no longer confined to quadrilateral shapes, with a variety of colors including some reverting to the original film color, black, white, and gray, and some even becoming transparent. Moreover, there is a diverse range of materials and crafting techniques being employed. High-end facial masks have become a trend, and on aluminum foil packaging sachets, besides showcasing excellent performance and texture, they also require longer shelf life. Most facial masks have a shelf life exceeding 12 months, with some even lasting up to 36 months. Understanding the production process of facial mask sachets not only helps us better select facial mask products but also makes us aware of the importance of packaging technology in the beauty industry. This article will delve into the various stages of production of facial mask sachets, from material selection to final forming, and explore their impact on product quality and environmental protection!
Basic Materials for Facial Mask Sachets
Polyethylene(PE)：Characteristics: Soft, transparent, and resistant to low temperatures. Often used as the inner layer of facial mask sachets to directly contact the mask and essence, ensuring safety and flexibility. Flexibility: PE material is soft and has a certain elasticity, suitable for packaging that requires flexibility. Transparency: High transparency PE allows the product inside the package to be visible, although the transparency may vary with different types of PE. Low Temperature Resistance: PE material maintains good flexibility even under low-temperature conditions without becoming brittle. Chemical Inertness: Exhibits good resistance to most chemicals, making it resistant to corrosion or dissolution. Sealability: Possesses excellent heat sealing properties, forming reliable seals to prevent liquid leakage.
Aluminum Foil (AL): Characteristics: Excellent barrier properties, moisture resistance, and oxidation resistance. Used as the middle layer in high-end facial mask sachets to provide optimal protection, preventing light and air from entering and maintaining the activity of the essence. Barrier Properties: Aluminum foil has extremely high barrier properties, effectively blocking light, air, water vapor, and odors to protect the stability of the internal contents. High and Low-temperature Resistance: Withstands high-temperature sterilization and low-temperature storage without deformation. Strength: Despite being thin, aluminum foil has good mechanical strength and is not easily torn. Gloss and Reflectivity: Smooth surface with good reflective properties, enhancing the appearance of the product.
Paper-Plastics Composite Material: It combines the advantages of paper and plastic. Facial mask sachets made from paper-plastic composite materials not only protect the essence of the mask but also have an environmentally friendly and aesthetically pleasing appearance, making them ideal for skin care products with high packaging requirements. Excellent Comprehensive Performance:：It offers the environmental friendliness and good printing properties of paper, as well as the moisture resistance and sealability of plastic, providing both environmental protection and good protective performance. Strong Customizability: It can customize different combinations of paper and plastic layers according to specific requirements to meet the packaging needs of different products. Environmental Awareness: Compared to pure plastic packaging, paper-plastic composite materials are more environmentally friendly, meeting consumer expectations for green packaging.
Facial Mask Sachets Design and Sampling
Facial Mask Sachets Design Process Requirement Analysis Customer Needs: Understand specific requirements including product positioning, target market, design style, and functional requirements. Competitive Analysis: Study similar products in the market, analyze their strengths and weaknesses to provide design references.
Conceptual Design Design Sketch: Designers draw preliminary design sketches based on customer needs and market analysis to determine basic sachets types, sizes, sealing methods, etc. Colors and Patterns: Choose colors and patterns that fit the brand image to attract target consumers.
Detailed Design Material Selection: Choose suitable materials such as PE, aluminum foil, paper-plastic composite materials based on product functional requirements. Structural Design: Determine the specific structure of the sachets, including the composite method of several layers of materials, heat sealing position, tear notch design, etc. Printing Design: Create printing files, determine the specific positions and colors of patterns, text, and logos.
Customer Review Initial Draft Review: Submit detailed design proposals to customers for review, collect feedback, and make modifications. Final Confirmation: After the customer confirms the design proposal, prepare to enter the sampling stage.
Facial Mask Sachets Sampling Process Sampling Preparation Equipment Preparation: Prepare the necessary equipment and materials for sampling, including printing machines, laminating machines, slitting machines, heat sealers, etc. Process Preparation: Determine the process flow and parameters required for sampling to ensure that each operation meets the design requirements.
Sample Production Printing: Print the design patterns on the selected materials using techniques such as gravure printing or flexographic printing to ensure color and pattern accuracy. Lamination: Composite the printed materials with other layers of materials to form a multi-layer structure to improve the overall performance of the sachets. Slitting: Cut the laminated materials into individual facial mask sachets sheets according to the design dimensions. Forming and Heat Sealing: Seal the facial mask sachets sheets using heat sealing technology to form the final shape of the facial mask sachets and ensure the seal is firm.
Quality Inspection Virtual Inspection: Check the appearance of the samples, including color, pattern, size, sealing, etc., to ensure they meet the design requirements. Functional Testing: Conduct tests on sealing, moisture resistance, strength, etc., to ensure that the samples can effectively protect the facial masks during use.
Customer Confirmation Sample Submission: Submit the sampled facial mask sachets to customers for confirmation and collect customer feedback. Modification: Make necessary modifications and adjustments to the samples based on customer feedback until they are satisfied.
Batch Production Preparation Process Standardization: After confirming the final samples with the customer, determine the process parameters and workflow required for batch production. Material Preparation: Prepare materials and equipment required for batch production based on the final confirmation of design and process requirements.
Printing Techniques
1. Gravure Printing High Quality: Gravure printing achieves high precision and saturation in pattern printing, with vibrant colors and strong depth. Durability: Gravure printing plates are durable, suitable for large-scale production without compromising quality over time. Detail Representation: Capable of depicting intricate patterns and small text with precision. Process: Patterns are etched or laser engraved onto metal cylinders. Ink is applied to the surface of the cylinder, excess ink is scraped off, leaving ink only in the recessed areas. Ink is transferred from the recessed areas to the printing material, completing the pattern printing.
2. Flexographic Printing Low Cost: Flexographic printing plates have relatively low production costs, suitable for small to medium batch production. Wide Material Compatibility: It can print on various materials including paper, plastic films, etc. Fast Speed: High printing speed, suitable for rapid production. Process: Flexographic plates are made from photosensitive resin plates or rubber plates. Ink is transferred to the flexographic plates via an anilox roller, then transferred from the plates to the printing material.
3. Digital Printing High Flexibility: No need for plate-making, can directly print from digital files, suitable for small batch and customized production. Quick Turnaround: Short production cycle, able to quickly respond to market demands. Variable Data Printing: Suitable for printing variable information such as QR codes, serial numbers, etc., on facial mask sachets. Process: Prepare digital pattern files, ensuring accuracy of patterns and colors. Print patterns directly onto materials using inkjet or laser technology.
4. Other Printing Techniques Screen Printing: Vivid colors, thick ink layers, suitable for printing single-color or few-color patterns. Suitable for simple patterns with few colors, especially designs requiring thick ink layers. Offset Printing: Suitable for high-quality, multi-color printing with fine patterns, but less durable than gravure printing. Suitable for high-quality printing with small to medium batch sizes of facial mask sachets.
Composite Techniques
Composite Selection Double-Layer Composite Simple Structure: Double-layer composite consists of two layers of materials, typically combining two different materials through composite technology. Basic Combinations: Common double-layer composite structures include polyethylene (PE) with aluminum foil, polyethylene (PE) with polyamide (PA), etc. Wide Application: Double-layer composite is suitable for the production of general facial mask sachets, offering good functionality and cost control. Conventional Packaging: Used for packaging general facial mask products, providing basic moisture resistance, freshness, and barrier functions. Low-cost Requirements: Suitable for products with certain cost requirements, such as ordinary daily skin care products, shampoos, etc.
Multi-Layer Composite Multiple Layers: Multi-layer composite consists of three or more layers of materials, including inner, middle, and outer layers, among other combinations. Enhanced Functionality: Different material combinations give multi-layer composite richer functions, such as moisture resistance, barrier properties, freshness, insulation, etc. Complex Structure: With multiple layers, more complex production processes are needed to ensure strong bonding between layers. High-end Products: Suitable for high-end facial mask products, such as essence liquids, masks with special effects, requiring higher functionality and quality assurance. Special Requirements: Suitable for products with special packaging requirements, such as those needing thermal insulation, light blocking, etc.
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Composite Technologies Hot Press Lamination: Using a high-temperature and high-pressure hot press process, the composite material layers bond more firmly and are less likely to delaminate. Material Preparation: Prepare various materials for lamination, such as polyethylene (PE), aluminum foil, polyamide (PA), etc. Coating: Apply hot melt adhesive or coating on the substrate surface for bonding the composite materials. Pressing: Stack various layers of materials together and press them using a hot press machine to ensure firm bonding between the materials. Cooling: Cool the laminated materials after pressing to cure and maintain the desired structure. Simple Process: Relatively simple operation with high production efficiency. Wide Application:Suitable for the lamination of various materials, such as PE with aluminum foil, PE with PA, etc.
Wet Lamination: In wet lamination, the adhesive coating can better bond with the material surface during the pressing process. Coating: Apply a coating on the substrate surface, which can be resin, polyvinyl alcohol (PVA), etc. Drying: Place the coated substrate in a drying chamber to slightly dry the surface. Pressing: Press the dried substrate with another material (such as aluminum foil, polyamide, etc.) using a pressing machine to form the composite structure. Smooth Surface: The surface of the composite material is relatively smooth, suitable for printing and processing. Fast Production Speed: Faster production compared to dry lamination.
Dry Laminatio: Suitable for the lamination of various materials, such as PE, PP, PET, and others. Coating: Apply a coating on the substrate surface, which can be adhesive, resin, or other adhesives. Drying: Place the coated substrate and auxiliary materials in a drying chamber to dry and solidify. Pressing: Press the dried substrate with another material (such as aluminum foil, paper, etc.) using a pressing machine to form the composite structure. Environmental Friendly: No solvents involved, reducing the emission of volatile organic compounds (VOCs), environmentally friendly. Low Cost: Lower cost compared to wet lamination, suitable for small and medium-sized enterprise production.
Co-extrusion Lamination: During the co-extrusion lamination process, all layers of material are formed simultaneously, resulting in a more uniform and stable composite. Material Mixing: Mix different types of plastic pellets together to form a mixture. Co-extrusion: Extrude the mixture through an extruder and form multiple layers through multiple extrusion ports. Pressing: Press the co-extruded multilayer boards with a pressing machine to bond them into one. Material Saving: Since the material is extruded through an extruder, material waste can be effectively reduced. High Production Efficiency: Since the material is extruded through an extruder, material waste can be effectively reduced.
Surface Treatment Techniques
Waterproof Coating Features: Applying a layer of waterproof coating on the surface of the facial mask sachets to enhance its waterproof performance and prevent water penetration. Application: Suitable for protecting facial mask products from moisture, especially for water-sensitive cosmetics.
UV Coating Features: Applying a layer of UV-curable coating on the surface of the facial mask sachets to increase its glossiness and abrasion resistance. Application: Enhances the appearance and durability of the facial mask sachets, making it more competitive in the market.
Oil-Resistant Coating: Spraying a layer of oil-resistant coating to enhance the product’s oil resistance and facilitate cleaning. Hot Stamping (Gold/Silver) Features: Using hot stamping foil to hot stamp patterns or text on the surface of the facial mask sachets, adding luxury and visual effects. Application: Commonly used in the packaging of high-end products to elevate the product’s grade and quality.
Partial UV and Embossing Features: Utilizing UV printing technology to apply UV coating selectively on the surface of the facial mask sachets to create special patterns or text, while embossing techniques add a three-dimensional effect. Application: Enhances the visual appeal and uniqueness of the facial mask sachets, making the product more competitive in the market.
Facial Mask Sachets Making Process
A. Sachets Making Equipment Types and Selection of Sachets Making Machines Vertical Sachets Making Machine: Suitable for producing small-sized facial mask sachets, simple operation, and low cost. Horizontal Sachets Making Machine: Suitable for producing large-sized facial mask sachets, fast speed, and high efficiency. Fully Automatic Sachets Making Machine: Integrates multiple functions, capable of achieving fully automated production line operation, improving production efficiency. Semi-Automatic Sachets Making Machine: Requires manual operation by operators, suitable for small-batch production.
Automation Equipment and Technology Automatic Feeding System: Sends raw materials into the Sachets making machine via conveyor belts or automatic suction devices, reducing manual intervention and improving production efficiency. PLC Control System: Utilizes Programmable Logic Controllers (PLCs) to achieve automatic control and adjustment of the sachets making machine, improving production accuracy and stability. Intelligent Monitoring System: Utilizes sensors, cameras, and other devices to monitor the production process in real-time and collect data, enabling timely detection and resolution of issues.
Sachets Making Steps Material Cutting and Forming Preparation of Printed Materials: Feed printed roll materials into the sachets making machine. Positioning and Alignment: Ensure the correct position and orientation of the printed patterns. Cutting and Forming: Cut the roll materials into appropriate-sized facial mask sachets according to design requirements and form them into sachets shapes.
Edge Sealing and Bottom Sealing Edge Sealing: Seal the side edges of the facial mask sachets through heat sealing to ensure the sachet’s closure and leak-proof properties. Bottom Sealing: Perform heat sealing on the bottom of the facial mask sachets to form a bottom seal, providing the sachets with load-bearing capacity and stability.
Processing and Fitting Processing: Perform special processing on the facial mask sachets as needed, such as zipper installation, hole punching, etc. Fitting: If necessary, perform fitting on the facial mask sachets, such as pasting zippers, tear notches, etc.
Sealing and Sealing Technologies
Sealing Equipment Heat Sealer: A heat sealer is one of the most commonly used sealing devices, which utilizes heating elements to heat the plastic sachet’s opening, melting it and bonding it together to form a seal. It is suitable for sealing most plastic sachets openings, including PE, PP, PET, and other plastic materials. Ultrasonic Sealer: An ultrasonic sealer uses ultrasonic vibration to generate heat, melting the plastic materials on both sides of the sachet’s opening together to form a seal. It does not require heating, providing strong seals suitable for applications requiring high sealing integrity. Cold Sealer: A cold sealer uses adhesive such as glue or tape to bond the plastic materials on both sides of the sachet’s opening together to form a seal. It does not require heating and is suitable for materials sensitive to temperature changes. Hot Cutting Machine: A hot cutting machine performs heat sealing while simultaneously cutting the sachet’s opening with a blade, creating neat and tidy sealed edges. It enhances the appearance quality and is suitable for applications with high aesthetic requirements. Automated Sealing Production Line: An automated sealing production line integrates various sealing devices and auxiliary equipment, achieving efficient production of facial mask sachets through automated control systems.
Sealing Processes 1. Heat Sealing: Heat sealing is one of the most common sealing techniques for facial mask sachets, using heat to fuse plastic materials together to form a strong seal. Principle: Place the sachets opening between two heated sealing bars, applying a certain temperature and pressure to melt and bond the plastic materials on both sides of the sachets opening. Features: Fast, simple, and cost-effective, suitable for most plastic materials. Applications: PE, PP, PET, and other plastic materials, suitable for conventional facial mask sachets manufacturing.
2. Ultrasonic Sealing: Ultrasonic sealing utilizes ultrasonic vibration to generate heat, melting the plastic materials on both sides of the sachet’s opening together to form a seal. Principle: Utilize ultrasonic vibration to frictionally heat the plastic materials on both sides of the sachet’s opening, melting and bonding them together. Features: No heating required, energy-efficient, environmentally friendly, strong sealing, and less prone to contamination. Applications: PE, PP, and other plastic materials, suitable for facial mask sachets requiring high sealing integrity.
3. Cold Sealing: Cold sealing bonds the plastic materials on both sides of the sachet’s opening together using special adhesive such as glue or tape without heating. Principle: Utilize the adhesive properties of glue or tape to bond the plastic materials on both sides of the sachet’s opening together. Features: No heating required, simple operation, suitable for materials sensitive to heating. Applications: PE, PP, and other plastic materials, suitable for facial mask sachets sensitive to heat.
4. Hot Cutting Sealing: Hot cutting sealing performs heat sealing while cutting the sachet’s opening simultaneously with a blade, ensuring neat and tidy sealed edges. Principle: Perform heat sealing while cutting with a blade, creating neat sealed edges. Features: Neat and tidy sealed edges, enhanced appearance quality, suitable for facial mask sachets with high aesthetic requirements. Applications: PE, PP, PET, and other plastic materials, suitable for facial mask sachets with high aesthetic requirements.
Inspection and Quality Control
1. Visual Inspection Print Quality: Check if the printing patterns, text, and colors are clear and accurate. Sealing Quality: Inspect if the sachets sealing is complete, flat, without leakage or cracking. Cutting Quality: Check if the cutting edges of the sachets are neat and free of burrs. Accessory Installation: Ensure that accessories such as zippers and pull rings are installed correctly and securely.
2. Dimension Inspection External Dimensions: Measure the length, width, thickness, etc., of the sachets to ensure compliance with design requirements. Bottom Sealing: Measure the width and strength of the bottom sealing.
3. Packaging Inspection Packaging Integrity: Check if the product packaging is intact, without damage or breakage. Labels and Instructions: Ensure the accuracy and clarity of product labels and instructions. Random Sampling Inspection: Conduct random sampling inspections on production batches to ensure stable product quality.
4. Printing Inspection Clarity of Patterns: Check if printed patterns, text, etc., are clear, without blurring or fuzziness. Color Accuracy: Check if the printed colors match the design requirements and if there are any color deviations. Ink Uniformity: Check if the distribution of printing ink is uniform and if there are any issues such as insufficient or excessive ink.
5. Material Inspection Raw Material Inspection: Conduct chemical composition analysis and testing on raw materials to ensure compliance with relevant standards. Hazardous Substance Testing: Test whether the sachets contain harmful substances such as heavy metals, plasticizers, etc.
Packaging and Logistics
A. Finished Product Packaging Bulk Packaging Packaging Method: Pack facial mask sachets in bulk according to order quantity and customer requirements, typically using cartons or sachets. Quantity Control: Ensure that the quantity of each packaging box or sachets complies with customer order requirements, voiding missing or extra packaging.
Protective Measures Moisture-proof Packaging: Use moisture-proof sachets or desiccants to protect facial mask sachets from moisture. Shock-proof Packaging: Use cushioning materials (such as foam, bubble wrap, etc.) for packaging to protect facial mask sachets from damage during transportation.
B. Logistics Management Storage Conditions Temperature Control: Ensure suitable storage environment temperature to avoid exposure to sunlight and high temperatures. Humidity Control: Control storage environment humidity to prevent facial mask sachets from getting damp.
Transportation Requirements Transportation Method: Choose transportation methods suitable for the characteristics of facial mask sachets and order requirements, such as land transportation, sea transportation, air transportation, etc. Packaging Labeling: Clearly mark product information and transportation labels on the packaging to ensure accurate identification and tracking during transportation. Protection Measures: Take necessary protection measures during transportation to avoid impact, compression, moisture, etc., affecting facial mask sachets.
Environmental Protection and Sustainable Development
Biodegradability: Priority should be given to materials that are biodegradable or bio-based, as this can reduce negative environmental impacts and alleviate ecological pressures. Recyclability: Consider selecting materials that are recyclable, such as polyethylene (PE), polypropylene (PP), etc., to reduce resource waste and energy consumption. Bio-based Materials: Choose bio-based materials sourced from renewable resources, such as corn starch, cellulose, etc., to decrease reliance on finite resources like petroleum. Environmentally Friendly Production Processes: Consider whether the production process of materials is environmentally friendly and whether energy-saving and emission reduction technologies are employed. Social Responsibility: When selecting materials, consider the social responsibility and sustainable development strategies of the supply chain, avoiding the use of materials obtained through illegal logging or labor exploitation. Certification Standards: Choose materials that meet environmental certification standards, such as FSC (Forest Stewardship Council) certification, REACH (European Chemicals Regulation) certification, etc.
In the production process of facial mask sachets, we have delved into various aspects ranging from material selection to final packaging. Whether it’s the choice of materials, the precision of printing techniques, or the perfection of sealing technology, each step is crucial in ensuring the quality of facial mask sachets. While continually pursuing quality, we should also not forget the principles of environmental protection and sustainable development. Choosing more environmentally friendly and biodegradable materials can contribute to the future of our planet!
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