Stabilizing Hypochlorous Acid at Scale: Inside HOCl Spray Manufacturing

HOCl: Small Molecule, Big Manufacturing Challenge

HOCl is naturally produced by white blood cells to fight infection. It’s also one of the most powerful and skin-friendly antimicrobial agents known today.

But creating a commercial-grade, shelf-stable HOCl spray at scale? That’s a true technical feat.

Let’s go inside the process and explore how XJ BEAUTY achieves consistent, stabilized HOCl spray production on a global level.

Step 1: In-House Electrolysis with Controlled Inputs

We start with:

• High-purity salt and RO-filtered water

• An advanced membrane electrolysis system

• Carefully calibrated voltage, current, and electrolyte ratios

This allows us to produce high-yield HOCl with low byproduct generation and precise ppm (parts per million) control.

Step 2: Real-Time Monitoring and pH Stabilization

Stabilization doesn’t happen after electrolysis—it starts during production.

• We use inline pH and oxidation-reduction potential (ORP) sensors

• A tight pH window (3.8–5.2) is maintained to ensure active HOCl content

• Excess sodium hypochlorite is separated and discarded

This yields maximum antimicrobial activity with minimal skin irritation.

Step 3: Controlled Cleanroom Bottling and Nitrogen Filling

Once stabilized, we bottle under sterile conditions:

• GMP-grade cleanroom filling

• Nitrogen flushing to displace oxygen

• Use of UV-protected, food-grade containers

This prevents HOCl breakdown during bottling, storage, and shipping.

Step 4: Customization for Skincare, Disinfection, or Medical Use

Depending on your application, we offer:

• Cosmetic-grade HOCl face mist (pH-balanced, dermatologically tested)

• EPA-registered HOCl disinfectants

• Wound care formulations for medical or professional settings

We also support private label and bulk HOCl supply worldwide.

Step 5: Quality Testing and Shelf Stability Validation

Before release, every batch goes through:

• Microbiological testing

• HOCl concentration validation

• Accelerated shelf-life simulation

This ensures our HOCl sprays stay active and effective throughout their lifespan.

Final Word: Scaling Without Sacrificing Stability

True HOCl stabilization isn’t about preservatives or fancy bottles—it’s about controlling chemistry at every stage.

Whether you’re launching a skincare brand or distributing medical sprays, XJ BEAUTY offers the science and scale to make your product viable.