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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 Co-ordinator carries 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. |
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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. |
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We love to create great new products. In Product Formulation Development and Regulatory Affairs, products are developed from initial ideas to completed items. All products are rigorously
tested to ensure their high quality and compliance to regulations. |
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