Herb UK Tour
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Out in the factory, our goods-in department is where all our raw materials, packaging, literature and marketing materials are received. We only use approved suppliers and hold certificates of analysis for their ingredients. Checks are carried out on the raw materials and packaging for a variety of points, such as size, colour, cap fit and label adhesion. Once approved, the items are released for manufacture or packing. |
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Our manufacturing department follows strict procedures to guarantee the quality of all our products and the safety of our employees. For example, each colour is made according to a unique formulation and the manufacturing process begins in the pigment room. This is a sealed area and our staff working in this area have to wear protective clothing including a full face mask. A mixing vessel is brought into the pigment room and the required pigments put in to it. This is the only way in which pigments are allowed to leave the pigment room. The mixing vessel containing the pigments is then brought out of the pigment room and placed onto a mixing machine. Now the rest of the ingredients are added according to the formulation. |
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During the manufacturing process, our Quality Control Manager and Quality Control Technician carry out checks on the integrity and appearance of the product mix, the pH level, peroxide content and viscosity. As a consequence, any adjustments can be made at the correct points in the process to ensure the quality of the product. Our colours are tested at the end of the process. A sample taken from the batch is mixed with activator and applied to unbleached, grey, human hair and is processed for 30 minutes at 37°C, to imitate body temperature. The sample is then rinsed and dried and the resulting colour is checked against the previous batch. If it matches, the colour is then approved. All swatches and samples are stored for the duration of the product's shelf life. Once Quality Control has approved the sample, the batch of colour is emptied into a barrel ready for filling. The mixing vessel is then cleaned and sterilised ready for the next colour. |
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Overseeing our manufacturing processes and ensuring production efficiencies are met is our Operations Manager. We have recently introduced the Lean Manufacturing concept into the factory, which falls under the Operations Manager's responsibility. |
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Once approved by Quality Control, the colour is then passed to the filling department. Here all our products are filled into the bottles and labelled. Our three filling lines can be adjusted to take any of our size of bottles. The bottles are also labelled by machine as they go down the line and the colour number and the batch number are printed on the label. The batch number allows us to trace the products, wherever they are sent throughout the world. The expiry date is also printed on the label. Finally, the bottles are automatically weighed to ensure accurate filling. On average, we can fill 12,000 bottles a day. Quality Control checks on the filling line are performed for accurate labelling, fill volume, cap and seal fit, batch codes and expiry dates. |
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Once filled the products become the responsibility of the packing and despatch departments. Some of our products such as our professional perm, Organic Curl Systems, or our retail colours, Tints of Nature, are packed into cartons, together with other items, for example, an instruction leaflet or gloves. This process is also quality controlled to ensure the correct items are in each pack. When this is completed, the products are stored in the warehouse, before being sent to customers all around the world. |
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Ensuring the smooth operation of the factory is the responsibility of our Manufacturing and Plant Manager, who with experience in all areas, is ideally placed to manage the staff and processes. The role requires constant liaison with the other departments in the company to ensure deadlines and procedures are met. Our Stores and Lean Co-ordinator's role is to insure that materials are kept flowing to different departments . |
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Health and Safety is a key concern at Herb UK and ensuring we meet all criteria in this area is the job of our QA Manager. His role also includes Good Manufacturing Practices and other standards which we follow. |