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Producing Hand Sanitizers For Grab & Go Germ Protection

Disinfectants | Over The Counter | Personal Care

Cold and flu season is upon us, which means that you can find travel-size hand sanitizers attached to backpacks and stowed away in purses everywhere you go. During instances where soap and water are unavailable, customers rely on hand sanitizers to kill bacteria and prevent the spread of diseases and contamination. As a result, hand sanitizers have become a staple product available on retail shelves.

As a single-source provider, Precise Packaging understands that the formulation, delivery and packaging options for hand sanitizer solutions vary greatly. We have been working with customers for over a decade to bring both alcohol and non-alcohol, liquid or aerosol hand sanitizer options to market. Our formulation and filling specialists guide the research, product development and packaging process to deliver hand sanitizer formulations for liquid pump sprays, squeeze bottles, foaming solutions, aerosol sprays and beyond.


Traditional alcohol-based hand sanitizer formulations are the most common. As the name implies, alcohol-based hand sanitizers feature alcohol as the active ingredient, mainly in the form of either ethyl alcohol or isopropyl alcohol.

These sanitizers effectively kill germs, bacteria and most viruses. The alcohol works immediately on the skin to deliver fast-drying properties. While this is a strong selling point, frequent users such as doctors, teachers and caregivers may find alcohol solutions to be drying on their skin after repeated uses.

Non-alcohol based formulations present an attractive alternative, as they do not strip away the skin oils that retain moisture. Non-alcohol hand sanitizers feature antimicrobials, such as benzalkonium chloride, as the active ingredient for delivering effective germ protection. Beyond their moisturizing benefits, the popularity of non-alcohol hand sanitizers has recently gained traction among consumers seeking minimalist formulas that use natural ingredients.


Once the desired formulation is identified, Precise Packaging product development and packaging experts work closely with customers to determine the appropriate delivery method for the product. Due to their small size, travel-size hand sanitizers require more accurate fill weights with much tighter tolerances, as well as smaller packaging and dispensing components.

Our formulation and filling specialists advise customers on the proper components required to meet the need for packages featuring liquid fill sizes as low as 5 ml and aerosol fill sizes as low as 0.25 oz., with valve sizes from 13 mm up to 1 inch. Other important packaging considerations include the choice of appropriate caps for product protection, proper actuator selection to ensure that the packaging works with the product formulation, the presence of an expiration date to meet FDA requirements, as well as the overall packaging style and durability.

Since the majority of hand sanitizers feature clear containers, it is also especially critical to add the right type and level of additives to achieve the desired product clarity, color and formulation consistency. Additives may also be added to provide benefits such as fragrance and/or moisturizing oil to meet specifications.


Throughout the process, quality and documentation are paramount to ensuring the safety and effectiveness of OTC hand sanitizer products. As an FDA-registered manufacturer of OTC drugs, Precise Packaging adheres to strict quality and documentation standards by meeting FDA requirements for process control, documentation and testing. We also advise on factors such as the level and types of actives, selection of appropriate caps for product protection, and the use of proper actuators to ensure product safety and effectiveness.

Visit our products webpage to learn how Precise Packaging can help you to bring high quality, aerosol and liquid hand sanitizer products to market quickly and efficiently for convenient grab-and-go germ protection.

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