Hand Sanitiser Formulation Development

Do you run a distillery that produces “heads” and “tails” as waste byproducts? We’ve developed a gelled hand sanitiser formula that converts that alcohol into a product with the required ethanol content — but with a smoother texture and less industrial smell than most standard grades.

The standard WHO hand rub formula produces a liquid sanitiser rather than a gel. Liquids can penetrate quickly, but gels help prevent the alcohol from evaporating too fast. The general view is that gels are the more effective and user-friendly option.

Our formulation produces a gel with clear benefits:

  • Contains a moisturising component to reduce skin dryness
  • Balanced texture — not too slimy, not too runny
  • Leaves no residue after rubbing
  • 70% ethanol content
  • Customisable essential oils to create an aroma that complements distillation heads and tails

The aroma in particular makes the product far more pleasant to use — turning a routine task into something that feels less like a chore.

The formula is effective with heads and tails that have an alcohol content above 82%, giving a gel with comfortably more than 70% ethanol. Lower alcohol content can also be used by blending with TSDA1 Denatured Ethanol. For example, a 50/50 mix of 67% proof heads and tails with 96% TSDA1 achieves the required ethanol level.

Alcohol Hand Sanitiser Bottles