Beauty Manufacturing Excellence
Process & Production
THG LABS highly-experienced Operations Team proudly make, fill and pack our customers’ beauty products from our 120,000 sq ft UK beauty manufacturing facility which incorporates warehousing, process and production.
Our state-of-the art site in Frome, Somerset includes process laboratories, a pilot plant, as well as a specialised support from our dedicated scale-up team. This allows us to create and refine batches using the same vessel dynamics but with less energy and materials which ensures on-going efficiencies and a seamless transition from lab to full production.
Bulk Process
Our trusted Process Operators undergo extensive training to offer customers real versatility in product format and batch size.
Our vessels range from 50 kilos to 5 tonnes to cater for batches of all sizes:
- 9 mixing vessels for detergents and emulsions
- 2 mixing vessels for alcohol and ATEX rated products (fragrances)
Expertise ranges from emulsions, detergents, oils and salts to scrubs, balms and fragrance.
Our vessels are supplied by market-leaders Ekato.
Filling
Most products are run on automated lines to ensure the most efficient route through production and we offer capabilities for a variety of formats including tubes, jars, bottles and pouches:
- Fill size ranges from 3ml – 25 litres
- 2 hot fill jar lines with in-line chiller
- 7 automated tube lines
- 6 automated bottle and jar lines (1 ATEX rated for high-volume fragrance/ alcohol filling)
- 5 hand filling lines (including 1 ATEX rated for fragrance/ alcohol filling)
We run pre-production trials so when it comes to first production, teams are familiar with new products or formats coming to line.
Our full-service flexible model also offers clients contract fill.
Safety, Quality and Transparency
THG LABS have full traceability on our process with a barcode system which tracks our beauty formulas from raw materials arriving in the warehouse through to vessel, batch, fill and final delivery to our customers. We use Marco systems as part of our process and bulk manufacturing.
Dave Fairhurst – Head of Process, THG Labs Acheson
Packing
- Auto-cartoning
- Cello-wrapping
- Single item packing
- Gift packing
In-House Engineering Team
Our in-house engineering team helps enhance our overall performance and productivity by ensuring the optimal running of all our machines.
Reducing down-time for change parts and minimising reliance on external support, our experienced Engineering team can manufacture machine parts in our on-site workshop. We also utilise our 3D printer to cut tooling costs for new projects and speed up line fixes.
Andy Mason - Feasibility Manager, THG LABS Acheson
Certifications
If a brand's brief requires their product to meet COSMOS Standards, we can work to their four core principles to help our customers achieve COSMOS certification. From delivery and storage of raw materials, through to the manufacture, labelling, handling and distribution of a customers products, there are strict operational requirements involved in manufacturing organic and natural products. Our state-of-the-art facilities and quality experts mean your COSMOS compliance is in safe hands
We support RSPO Certified customers, too.
Our factory is registered with the FDA and we also offer manufacturing from our sister operation in the US.
Electricity From Renewable Sources
THG LABS manufacturing site is fitted with solar panels and uses 100% electricity from renewable sources, generated by wind, solar and hydro assets and matched to Renewable Energy Guarantees of Origin (REGO)