Deodorant sticks are a popular personal care product used daily to reduce body odor and keep people feeling fresh. While most of us use deodorant sticks regularly, few are familiar with the manufacturing process, especially the filling techniques. In this article, we’ll break down the basics of how deodorant sticks are filled and explain the different filling methods used in production.

What is Deodorant Stick Filling?

In simple terms, deodorant stick filling refers to the process of transferring specific formulas (including active ingredients, fragrances, base oils, etc.) into deodorant containers. These materials are typically filled in a liquid or semi-solid state, then cooled or solidified to form the deodorant stick we all recognize. Depending on the product's formulation and characteristics, the filling methods can vary.

Main Types of Deodorant Stick Filling Methods

The three primary filling methods for deodorant sticks are cold filling, hot filling, and vacuum filling. Each method serves different product types and manufacturing needs.

Cold Filling

Cold filling is primarily used for products that contain heat-sensitive active ingredients. The formula is processed at low temperatures before being filled into the container, preserving the effectiveness of the ingredients by avoiding heat exposure. This method is often used for high-end products because of the strict temperature control required.

Hot Filling

Hot filling is the most common filling method and is widely used in mass production. During hot filling, the raw materials are heated until they become liquid or semi-liquid, then filled into the deodorant container. Once filled, the deodorant stick solidifies as it cools. Hot filling is efficient and ideal for large-scale production, often used for solid or gel-based deodorants.

Vacuum filling is performed in a vacuum environment to prevent air from entering the product, thus reducing bubbles and ensuring a more stable and aesthetically pleasing final product. This method is especially suitable for high-viscosity formulas or products where a perfect appearance is crucial.

Top-Fill vs. Bottom-Fill: The Technical Details of Filling

In addition to the type of filling method, the specific operation of how the material is filled into the container is also important. Deodorant sticks are generally filled either through top-fill or bottom-fill techniques.

Top-Fill

Top-fill refers to filling the liquid or semi-solid formula from the top of the container. This method is commonly used in hot filling, where the heated material is poured into the container and allowed to cool and solidify. Top-fill is simple, efficient, and ideal for automated production lines.

Bottom-Fill

Bottom-fill involves filling the material from the bottom of the container, after which the container is sealed. This technique helps control the even distribution of the material and reduces the chance of air bubbles forming. Bottom-fill is suitable for products requiring more precision, and it can be applied in both hot and cold filling processes, depending on the product’s formulation.

Steps After Filling

Once the filling process is completed, the deodorant sticks undergo cooling or solidification, after which they move to the quality control stage. Quality checks are crucial to ensure that each batch meets the necessary standards, including appearance, stability, and sealing. Products that pass the tests are then labeled, packed, and prepared for shipment.

Conclusion

The filling methods used in deodorant stick production are diverse and tailored to the specific needs of each product. Whether it's cold filling, hot filling, or vacuum filling, each method has its unique applications and ensures that the product's formula and performance remain intact. Additionally, top-fill and bottom-fill provide flexibility in the production process, ensuring both efficiency and product quality.