Liquid Skincare Manufacturing

Twincraft Skincare has been making bar soap since 1972, but we didn’t want to limit ourselves to one product type. For the past few years, we’ve been developing and rapidly growing our liquid skincare program, making high quality, mostly natural skincare for some of the world’s best known brands.

Our liquid skincare development process starts in our 5,000 square feet state-of-the-art Innovation Center at our Winooksi, Vermont headquarters. Once a formula is approved by a customer and undergoes all required testing, we move the process over to our much larger liquids production facility in Essex, Vermont. A short drive away from our bar soap manufacturing plant, in Essex you’ll find over 70,000 square feet of production, offices, and warehouse facilities.

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Twincraft Skincare Liquid Product Capabilities

At our Essex, Vermont facility, you’ll find:

-          Four fixed, scalable, and fully jacketed vessels with full electronic remote controls

-          Three different vessels with scrape surface and tangential agitation capabilities coming in at 100, 2,000, and 4,000 liters

o   1,000 liter vessel has propeller agitation

o   4,000 liter vessel has 45 HP internal homogenizer

-          Two portable homogenizers for flexibility

-          Heating and cooling capabilities with adjustable temperature gradient for sensitive bulk

-          Two 1,000 liter mobile batch tanks with scrape surface and tangential agitation and thermal control docking station

-          An infrastructure that will handle double our existing vessel count

-          DI/UV purified water system

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Our Commitment to Hygeine, Flexibility, and Scalability

From the first day that we decided to explore producing liquid skincare in addition to bar soap, the Twincraft team has been devoted to developing a program with a commitment to the highest standards of hygiene while creating an environment that can grow and evolve with our business and the industry.

Hygiene

Our liquid product facility is home to Class 6 Cleanrooms, which are under positive pressure and undergo air changes 18 times per hour, ensuring that open product are limited in their exposure to possible contaminants.

All raw material sampling and weighing is done in a cleanroom, all containers are processed in a cleanroom, and our entire compounding area is a cleanroom as well. Our purified water system is tested and sanitized monthly, and medical-grade compressed air is used throughout the facility. We ensure that all employees adhere to the highest level of GMP requirements, and anyone who is involved in production activities is required to wear smocks, hairnets, beardnets (if applicable), and gloves.

Flexibility and Scalability

We are always adapting and evolving our manufacturing process, facility, and teams to ensure that we are performing at our best, with the priorities of each business partner in mind.

At our Essex, Vermont facility, we are prepared with our existing infrastructure to install two additional cleanrooms when the need arises. We currently place caps by hand, to intentionally allow for rapid, no-cost changeover. Our peripheral finishing equipment is mobile, which allows lines to be custom configured for each production run, adding efficiency. We pride ourselves on having in-house machine building and programming capability, as well as an on-site Quality department.

While Twincraft may only have a few years of liquid product manufacturing experience, especially when compared to all of the time that we’ve spent making bar soap, we’ve recruited some of the best, and most capable team members to ensure successful production runs. Together, they have decades of personal care manufacturing experience, and welcome each opportunity to problem solve and create with each of our customers.