Lotion Bar Formulation

1. Objective:
manufacture a stable, solid, anhydrous (water-free) moisturizing lotion bar by
combining a wax, a solid fat, and a liquid oil and investigating the role of each
component in the final product's physical characteristics, specifically its hardness,
texture, and melt point.

2. Introduction:
2.1 Background / Literature Review

The Concept of a Solid Lotion Bar vs. Liquid Lotion

The solid lotion bar represents a fundamental shift in cosmetic formulation from
traditional liquid lotions. Conventional liquid lotions are typically emulsions, meaning
they are composed of a large water phase (often 60-80%), an oil phase, and emulsifying
agents to blend them. This water content necessitates the addition of synthetic
preservatives to inhibit microbial growth.

Key Types of Ingredients and Their Properties

The efficacy and texture of the lotion bar rely on a carefully balanced combination of
three primary lipid components: Butters, Oils, and Waxes. Their functionality is
determined by their respective chemical and physical properties, most notably their
melting points and their primary function as emollients or occlusive agents

Ingredient Key Function in

Physical Property Example
Type Formula

Semi-solid at room
Shea Butter,
Primary Emollient, temperature; melt near
Butters Cocoa
Texture body temperature (30C-
Butter
35C}.

Liquid at room
Liquid Emollient, temperature; contribute Coconut Oil,
Oils
Spreadability key nutrients and fatty Jojoba Oil
acids.
 Ingredient Key Function in
Physical Property Example
Type Formula

Very high melting points Beeswax,

Structural/Hardener,
Waxes (60C-80C); provide Carnauba
Occlusive
hardness and stability. Wax

2.2 Project Objective

The primary objective of this semester project is to successfully formulate,

manufacture, and analyze a functional, stable, and aesthetically pleasing solid lotion
bar ('Velour Lotion Bar'). This includes:

1. Optimizing the ratio of wax, butter, and oil to achieve ideal hardness and melt
properties but melting easily upon contact with the skin.
2. Documenting a precise, reproducible manufacturing procedure that adheres to
Good Manufacturing Practices (GMP).
3. Conducting quality control analysis of the final product, including physical
properties (appearance, texture, and melting point).

3 Materials and Equipment (The "How Much" and "What")

This section must provide a complete and precise documentation of every physical
component used in the formulation of the Velour Lotion Bar. This level of detail is
critical for the reproducibility of your experiment, a cornerstone of scientific reporting.

3.1 Materials (Ingredients)

You should list all ingredients, including active components (butters, oils, waxes),
additives (essential oils/fragrance), and any minor ingredients used for coloring or
testing (if applicable).

Function
Chemical/Common Quantity Crucial Information for
Supplier/Source in
Name Used (g) Report
Formula

Primary
Shea Butter Bulk Apothecary 45.00g Unrefined, Grade A
Emollient,
 Function
Chemical/Common Quantity Crucial Information for
Supplier/Source in
Name Used (g) Report
Formula

Texture
Base

Liquid
Coconut Oil Local Grocer Emollient, 28.00 g Virgin, Fractionated
Glide

Structural
Mountain Rose
Beeswax Hardener, 25.00 g Pellets, Block
Herbs
Occlusive

Scent,
Essential Oil / Eden Botanicals Maximum Safe Use Rate
Minor 2.00g
Fragrance - Lavender (99%)
Active

100.00 This is the basis for all

Total Batch Weight
g percentage calculations.

3.2 Equipment
All instruments, glassware, and tools used for mixing, heating, measuring, and molding
are specified below.

• Weighing:
o Digital Scale: Precision for accurate mass measurement.
o Weigh Boats/Paper: For precise measurement of ingredients.
• Heating and Mixing:
o Beakers/Jars: Heat-safe Borosilicate Glass (250 ml capacity) for melting
the lipid phase.
o Hot Plate or Water Bath: Used for controlled heating of Phase A
ingredients. Specify the method of temperature control.
o Thermometer: Digital laboratory thermometer with high Accuracy ( pm
0.1C) to monitor ingredient temperatures.
o Stirring Rod/Spatula: Glass or Stainless Steel for manual mixing.
• Specialized Equipment (Spray Dryer):
o Laboratory-Scale Spray Dryer: Model/Brand should be noted (e.g., Buchi
B-290 Mini Spray Dryer). This is required if the project involves:
 1. Microencapsulation of sensitive active ingredients (e.g., vitamins or
plant extracts) to improve stability or controlled release.
2. Creation of a specialized powdered component that is later
incorporated into the melted oils and waxes.
• Molding and Cooling:
o Product Molds: Specify the Material (e.g., Silicone) and the desired Final
Product Weight (50 g per cavity).
• Safety Equipment:
o Personal Protective Equipment (PPE): Safety goggles, heat-resistant
gloves, and lab coat.

4. Formulation and Procedure

This section provides the precise formula and the step-by-step procedure necessary for
replicating the 'Velour Lotion Bar' formulation.

C15H31 COOC30H61 + C19H21O5 + C16H20NO4 → C12H15NO5

Beewax + Shea butter + Cocunet oil → Lotion bar

4.1 Step-by-Step Manufacturing Procedure

The procedure is divided into three main stages: Preparation of the Spray-Dried
Component (Phase B), Melting the Lipid Base (Phase A), and Final Mixing and Molding.

Safety Precautions

• Personal Protective Equipment (PPE): Safety goggles and a lab coat must be
worn at all times.
• Heating: Use heat-resistant gloves when handling hot beakers and containers.
Monitor the temperature closely to prevent overheating the oils and butters,
which can degrade their beneficial properties.
• Ventilation: Ensure adequate ventilation is used during the spray drying process
and when working with essential oils.

Stage I: Preparation of the Spray-Dried Component (Phase B)

1. Preparation of Feed Solution: Accurately weigh the Lavender Essential Oil

(1.50g) and the Carrier Powder (Maltodextrin,0.50g).
2. Mixing: Dissolve the carrier powder in a minimal amount of water (50ml
deionized water) to create the feed solution. Slowly incorporate the Lavender
Essential Oil into this solution while mixing vigorously to create an emulsion.
3. Spray Drying: Transfer the prepared feed solution to the reservoir of the
Laboratory-Scale Spray Dryer.
 o Parameters: Set the Inlet Temperature to 160C and the Outlet
Temperature to 80C (adjust based on specific equipment/actives).
o Collection: Spray dry the solution and collect the resulting encapsulated
Lavender Essential Oil powder in a dry, sealed container. This powder is
Phase B.

Stage II: Melting the Lipid Base (Phase A)

1. Weighing: Accurately weigh the ingredients of Phase A: Beeswax (25.00 g, Shea

Butter (45.00g), and Coconut Oil (28.00g) into a single, clean 250ml glass
beaker.
2. Controlled Heating: Place the beaker on a hot plate or in a water bath. Gently
heat the mixture to a maximum temperature of 70C while stirring slowly with a
glass rod.
o Hold Time: Maintain the temperature at 70C for approximately 5 minutes
after all solids (Beeswax and Butters) have completely melted to ensure a
homogeneous solution.
3. Cooling: Remove the beaker from the heat source and allow the mixture to cool
down to the "pour temperature" of 40C to 45C. Continuous, gentle stirring is
necessary during cooling to prevent crystallization (graininess) of the butters.

Stage III: Final Mixing and Molding

1. Active Addition: Once the temperature of the lipid base (Phase A) reaches 45C,
carefully add the pre-weighed Spray-Dried Lavender Powder (Phase B).
2. Mixing: Stir the mixture gently for 2 minutes to ensure the encapsulated powder
is evenly dispersed throughout the molten lipid base. Crucially, do not stir too
vigorously, which could introduce air bubbles.
3. Molding: Carefully and quickly pour the liquid mixture into the designated, pre-
cleaned silicone molds. Fill each cavity to its maximum capacity.
4. Cooling/Solidification: Allow the filled molds to solidify undisturbed at room
temperature (20C-25C) for at least 3 hours. For faster results, transfer the molds
to a refrigerator for 30 minutes to promote rapid, even crystallization.
5. Demolding: Once fully solid, gently pop the 'Velour Lotion Bars' out of the molds.
 Vaseline jelly Manufacturing
[Link]

• To prep vaseline jelly are a semi-solid substance, Petroleum Jelly (Petrolatum),

by blending long-chain paraffin waxes and liquid mineral oils.
• To understand the principle of gelation—the formation of a colloidal system from
liquid and solid hydrocarbons.
• To practice controlled heating, precise blending, and controlled cooling
techniques essential for producing stable, smooth semi-solid topical products.

II. Principle and Chemical Nature

Petroleum jelly is a physical blend (a colloidal gel) of high-melting point microcrystalline

waxes and low-viscosity mineral oils. It is not formed by a chemical reaction in the
blending process.

CnH(2n+2) + CmH(2m+2) + C15H31 COOC30H61 → C25H52OOH3

• Structure: Upon heating, the wax dissolves in the oil (solvation). Upon controlled
cooling, the wax molecules solidify into a fine, microscopic, crystal lattice
structure (lamellar sheets) that physically traps the liquid oil within its matrix.
• Process: Solvation and Gelation (Physical Change)

III. Required Materials and Reagents

Approximate Ratio
Component Chemical Identity Function
(by weight)

Microcrystalline Wax or Structural Agent (Solid

CnH(2n+2) 15%
Paraffin Wax Phase)

Liquid Base/Emollient
Mineral Oil (White Oil) CmH(2m+2) 85%
(Liquid Phase)
 Approximate Ratio
Component Chemical Identity Function
(by weight)

Antioxidant, Skin
Vitamin E Oil (Optional) Tocopherol 0.1%
Conditioner

Essential
Fragrance Oil (Optional) Aesthetic properties 0.05%
Oils/Synthetic Esters

IV. Apparatus

• Weighing Balance: With accuracy to pm 0.01g.

• Heating Source: Electric Heating Mantle or Hot Plate
(with stirring capability recommended).
• Mixing Vessel: 500 mL or 1 L Beaker (preferably
borosilicate glass) or a stainless steel vessel.
• Thermometer: Range 0C to 150C (digital or glass).
• Stirrer: Glass rod or automated overhead mechanical
stirrer.
• Containers: Small, sterilized, wide-mouth jars for final
packaging.
• Safety Equipment: Lab coat, safety goggles, heat-
resistant gloves.

V. Safety Precautions

• Flammability: Waxes and oils are flammable. Never heat the mixture directly
over an open flame. Use a regulated electric heat source.
• Temperature Control: Do not exceed 130Cto prevent decomposition, scorching,
and fire risk.
• Hot Surfaces: The vessel and its contents will be extremely hot. Use heat-
resistant gloves for handling.
• Ventilation: Work in a well-ventilated area or under a fume hood.
VI. Procedure (Method of Preparation)

Step 1: Accurate Weighing and Preparation

1. Ensure all equipment is clean, dry, and sterilized.

2. Accurately weigh the required amounts of Paraffin Wax and Mineral Oil into the
mixing vessel based on the 15:85 ratio (e.g., 15 g wax, 85g oil for a 100g batch).
3. Weigh the optional additives (Vitamin E, Fragrance) separately.

Step 2: Melting and Blending (Phase A: 120C)

1. Place the vessel containing the wax and mineral oil onto the heating source.
2. Insert the thermometer to monitor the temperature continuously.
3. Begin heating and stir the mixture constantly using the glass rod or mechanical
stirrer.
4. Continue heating until the temperature reaches 120C to 125C.
5. Maintain this temperature and stirring until the mixture becomes a perfectly
clear, homogenous, single-phase liquid, indicating that all the wax has
completely dissolved in the oil.
6. Crucial Check: If any cloudiness or solid particles remain, continue heating and
stirring until they are completely dissolved.

Step 3: Controlled Cooling and Additives

1. Remove the vessel from the heat source. Immediately begin the crucial phase of
controlled cooling.
2. Continue stirring constantly. Do not stop stirring until the product begins to
thicken (around 60C). Continuous stirring ensures uniform crystal nucleation and
growth, leading to a smooth texture.
3. When the temperature drops to between 55C and 60C (the mixture will still be
liquid but slightly thicker):
o Add the optional Vitamin E Oil and Fragrance Oil.
o Stir well for at least 2 minutes to ensure complete dispersion of the
additives.

Step 4: Pouring and Final Solidification

1. While the mixture is still hot and easily pourable (above 50C), transfer it quickly
into the sterilized final containers.
 2. Allow the containers to cool completely and undisturbed at
room temperature. The process of slow cooling allows the
wax crystal network to form correctly, which is vital for the
product's stable texture.
3. Do not cap the containers until the product is completely
solidified and has reached room temperature (this prevents
condensation).
4. Once solidified, cap, label (including date and formulation),
and store the final product.

VII. Quality Control and Analysis

Parameter Method of Analysis Desired Result

Visual/Tactile check (e.g., penetration Smooth, opaque, semi-solid gel; no

Consistency
test for industrial QA) grainy or separated texture.

Visual check against a white Colorless to pale yellow (depending on

Color
background wax grade).

Bland or with the intended added

Odor Olfactory check
fragrance.

Place a sample in a 45C oven for 24 Must remain semi-solid with no

Stability
hours. separation of oil (syneresis).

VIII. Conclusion

State the quality of the final petrolatum product. Was the texture smooth and stable? If
not, suggest improvements (e.g., adjusting the wax-to-oil ratio or modifying the cooling
rate