The global toothpaste market was valued at about $22.3 billion in 2025 and is forecast to expand at a compound annual growth rate of roughly 3.26 % from 2026 through 2034, reaching around $29.7 billion by 2034. With nearly 3.5 billion people suffering from oral diseases globally according to WHO’s 2022 report, demand for high-quality toothpaste continues to rise.

Setting up a fully automatic toothpaste production line requires careful planning, proper equipment selection, and compliance with strict hygiene standards. This guide walks you through each step of the process.

What Is a Fully Automatic Toothpaste Production Line?

A fully automatic toothpaste production line is an integrated manufacturing system that transforms raw materials into finished, packaged toothpaste tubes with minimal manual intervention.

These systems combine multiple specialized machines into a coordinated workflow. Each piece of equipment performs specific functions, from mixing ingredients to sealing tubes. Automation reduces labor costs, improves consistency, and increases production capacity.

Modern production lines can process 60-120 tubes per minute depending on configuration. King Pack offers complete turnkey solutions for toothpaste manufacturing, providing everything from vacuum emulsifying mixers to filling and sealing machines designed for oral care products.

Recommended Reading: Toothpaste Tube Materials: A Sustainable Solution – King Pack Machinery

Overview of the Toothpaste Manufacturing Process

The toothpaste production process follows a systematic workflow that maintains product quality at every stage.

Raw Material Preparation

All ingredients must be measured accurately and prepared for mixing. Powders like silica abrasives require proper dispersion systems. Liquid components such as glycerin and water need dedicated feeding equipment.

Temperature control during preparation prevents ingredient degradation. Storage tanks maintain materials at optimal conditions before mixing begins.

Vacuum Mixing & Homogenization

This critical stage combines water-based and oil-based ingredients into a uniform paste. The vacuum environment removes air bubbles that could affect product stability and shelf life.

High-shear homogenization breaks down particles to create smooth texture. King Pack’s vacuum emulsifying mixers come in various capacities to match production requirements.

Aging & Storage

After mixing, toothpaste requires aging time for ingredients to fully integrate. Aging tanks maintain controlled temperature and gentle stirring.

This step allows viscosity to stabilize and flavors to blend completely. Proper aging improves product consistency and performance.

Tube Filling & Sealing

Automated filling machines dispense precise amounts into pre-formed tubes. Internal heating seals tube ends immediately after filling.

King Pack’s tube filling and sealing machines feature stainless steel construction and user-friendly controls. These systems minimize downtime and maintain efficient output.

Secondary Packaging

Filled tubes move to cartoning machines for individual boxing. Case packing systems bundle multiple cartons for distribution.

Optional palletizing equipment prepares products for storage automatically.This final stage completes the production cycle.

Step 1 – Raw Material Preparation System

Proper raw material handling establishes the foundation for consistent toothpaste quality.

Main Raw Materials for Toothpaste

Toothpaste formulations typically include:

• Abrasives (30-50%): Silica, calcium carbonate for cleaning
• Humectants (20-30%): Glycerin, sorbitol for moisture retention
• Thickeners (1-2%): Cellulose gums, carrageenan for viscosity
• Surfactants (1-2%): Sodium lauryl sulfate for foaming
• Fluoride (0.1-0.15%): Sodium fluoride for cavity protection
• Flavoring agents (1-2%): Mint oils, sweeteners for taste
• Water (20-40%): Purified or deionized

Each ingredient serves specific functions in the final product. Precise measurement maintains formulation consistency.Liquid & Powder Feeding Systems

Separate handling systems prevent cross-contamination between ingredient types.

Liquid feeding systems use pumps and flow meters for accurate dosing. Heated jacketed tanks maintain optimal viscosity for glycerin and similar components. Automated valves control flow rates according to batch recipes.

Powder feeding requires specialized equipment to prevent dust and clumping. Screw conveyors or pneumatic transport systems move materials from storage to mixing vessels. Weighing systems confirm quantities before transfer.

Pre-mixing and Dispersion Control

Pre-mixing disperses powder ingredients into liquids before main mixing begins. This prevents agglomeration that creates lumps in the final product.

High-speed dispersers break down particle clusters. Recirculation systems guarantee uniform distribution throughout the batch. Temperature monitoring prevents overheating during dispersion.

Step 2 – Vacuum Emulsifying Mixing System

The vacuum emulsifying mixer represents the core equipment in toothpaste production. These specialized mixers combine ingredients that naturally resist mixing. Water and oil-based components require emulsification to form stable pastes.

King Pack’s vacuum emulsifying mixers feature:

• Stainless steel construction (316L grade)
• Variable speed control for different viscosities
• Jacketed vessels for heating and cooling
• Multiple inlet ports for ingredient addition
• CIP (Clean-In-Place) capabilities

Typical batch sizes range from 50L for pilot production to 2000L for commercial operations. Mixer capacity should match your target production volume with some overhead for flexibility.

High-Shear Homogenization

High-shear homogenizers create intense mechanical forces that break down particles. Rotor-stator systems generate shearing, impact, and cavitation simultaneously.

This process reduces particle size to 1-5 microns for smooth texture. Multiple passes through the homogenizer improve consistency. Speed typically ranges from 1500-3000 RPM depending on formulation.

Defoaming Under Vacuum

Air incorporation during mixing creates foam that affects product appearance and stability. Vacuum operation removes entrained air bubbles.

Operating pressure typically ranges from -0.06 to -0.09 MPa. The vacuum pulls air from the mixture while maintaining mixing action. This process extends shelf life by reducing oxidation potential.

Heating & Cooling Control

Temperature control during mixing affects ingredient solubility and reaction rates.

Heating phases (50-80°C) dissolve thickeners and improve mixing efficiency. Cooling phases (25-30°C) stabilize the emulsion before transfer. Jacketed vessels circulate thermal fluid for precise temperature management.

Programmable logic controllers (PLCs) automate temperature sequences. This eliminates operator variation and maintains batch consistency.

Recommended Reading: What Machines Are Used to Make Toothpaste? – King Pack Machinery

Step 3 – Aging Tank & Storage System

Post-mixing storage allows formulations to reach optimal stability before filling.

Aging Tank Function

Aging tanks hold finished toothpaste batches for 24-72 hours after mixing. 

This period allows:

• Viscosity stabilization as thickeners fully hydrate
• Flavor maturation for uniform taste distribution
• Elimination of trapped micro-bubbles
• Temperature equilibrium throughout the batch

Tanks should be sized to hold multiple batches for continuous filling operations. A 500L aging tank supports production lines filling 60-80 tubes per minute.

Stirring & Temperature Stability

Gentle agitation during aging prevents ingredient separation. Anchor or paddle stirrers operate at low speeds (10-30 RPM) to maintain homogeneity without introducing air.

Temperature control prevents viscosity changes during storage. Jacketed tanks maintain 20-25°C for most formulations. Insulation reduces energy consumption for temperature management.

Hygienic Storage Design

All toothpaste contact surfaces must meet sanitary standards. Stainless steel 316L resists corrosion and cleans easily.

Sloped bottom designs facilitate complete discharge without product residue. Sanitary fittings use tri-clamp connections for tool-free disassembly. All valves and sight glasses meet GMP requirements.

CIP systems automatically clean tanks between batches. Spray balls distribute cleaning solutions across all interior surfaces. Validation confirms cleanliness before new batch introduction.

Step 4 – Automatic Tube Filling & Sealing Line

The filling and sealing stage transforms bulk toothpaste into individual consumer packages.

Tube Feeding & Orientation

Empty tubes arrive from storage and require proper positioning before filling. Automatic feeding systems:

• Load tubes from bulk hoppers or cartridges
• Orient tubes with openings upward
• Detect and reject damaged tubes
• Maintain consistent spacing for downstream operations

Vision systems inspect tube quality before filling begins. Reject mechanisms remove defective tubes without stopping the line.

Precision Filling System

Filling accuracy directly impacts product costs and regulatory compliance. Modern filling systems achieve ±1-2% accuracy across production runs.

Filling methods include:King Pack’s filling machines use servo-driven systems for precise dose control. Programmable recipes allow quick changeovers between product sizes. No-drip nozzles prevent product waste and maintain cleanliness.

Internal Heating & Sealing

Tube sealing creates airtight closures that protect product freshness. Internal heating systems apply heat directly to tube ends.

Sealing temperature ranges from 160-220°C depending on tube material. HDPE tubes seal at lower temperatures than laminate tubes. Heating time typically lasts 2-3 seconds.

Seal quality affects product shelf life and prevents leakage. Pressure controls compress tube ends during heating. Cooling stations stabilize seals immediately after formation.

Trimming, Coding & Discharge

After sealing, excess material requires removal for clean appearance. Automatic trimmers cut sealed ends flush with tube bodies.

Date coding systems print batch numbers and expiration dates on sealed ends. Inkjet or laser coders apply required regulatory information. King Pack machines integrate coding stations directly into production lines.

Discharge conveyors transport finished tubes to cartoning equipment. Accumulation tables buffer speed differences between filling and packaging operations.

Step 5 – Secondary Packaging Equipment

Secondary packaging prepares products for retail distribution and protects tubes during shipping.Automatic Cartoning Machine

Cartoning machines fold cartons, insert tubes, and seal boxes in one continuous operation. Typical speeds range from 30-150 cartons per minute.

Key cartoning features include:

• Carton magazine for blank storage
• Automatic carton forming and opening
• Product insertion with gentle handling
• Leaflet insertion for instructions
• Hot melt or tuck-closure sealing

Vision systems verify correct tube insertion before sealing. Reject mechanisms remove incomplete cartons from the line.

Case Packing & Palletizing (Optional)

High-volume operations benefit from automated case packing. These systems gather multiple cartons and pack them into shipping cases.

Robotic pick-and-place systems handle products gently while maintaining high speeds. Automatic case erectors prepare shipping containers. Tape or glue sealers close cases securely.

Palletizing systems stack cases onto pallets for warehouse storage. Robotic palletizers create stable load patterns that withstand shipping. Stretch wrap machines secure loads before transport.

Key Equipment Required for a Toothpaste Production Line

A complete production line requires multiple specialized machines working in coordination.

Essential equipment includes:

Supporting utilities include:

• Compressed air systems (6-8 bar pressure)
• Vacuum pumps (for mixing and filling)
• Chilled water systems (cooling jackets)
• Hot water/steam generation (heating and CIP)

Production line layout should optimize material flow and minimize operator movement. King Pack provides facility planning services to maximize space efficiency.

Recommended Reading: How is Toothpaste Manufactured and How Tube Filling Machines and Emulsifying Equipment are Used in this Process? – King Pack Machinery

GMP & Hygiene Requirements for Toothpaste Production

Good Manufacturing Practices form the regulatory foundation for cosmetic and drug toothpaste production.

ISO 22716 provides international GMP standards for cosmetics, while fluoride toothpaste must meet pharmaceutical GMP requirements (FDA 21 CFR 210 and 211 in the United States). Research indicates that facilities with GMP certification achieve contamination rate reductions of up to 30%.

Stainless Steel & Sanitary Design

All product-contact parts must resist corrosion and stay easy to clean. Toothpaste Manufacturing Equipment usually relies on Stainless steel 316L, with stainless steel 304 used for non-contact frames and covers. This material choice supports long service life and stable hygiene performance.

A sanitary toothpaste making machine follows clear design rules. Surfaces stay smooth and free of gaps. Piping layouts limit dead legs. Corners remain rounded. Sloped panels allow full drainage after washing. Mechanical seal areas receive special attention, since leaks or residue build-up can affect batch quality. Welds are polished to match nearby surfaces, while gaskets and seals meet FDA food-contact standards. Access points allow visual checks during cleaning validation.

CIP Cleaning System

Clean-In-Place systems automate cleaning between batches and raise production efficiency. Manual cleaning takes more time and varies by operator, while CIP delivers repeatable results.

A standard CIP cycle includes a water pre-rinse, an alkaline wash at controlled temperature, an intermediate rinse, an acid wash for mineral scale, and a final rinse with purified water from a Reverse Osmosis or RO system. Some lines add a sanitizing step. Spray balls and nozzles cover tanks, In-Line mixer housings, pipelines, and the vacuum system. Return pumps recover solutions for reuse, while conductivity sensors confirm rinse completion.

Contamination Prevention

Contamination control combines people, environment, and process management under cGMP guidelines.

Personnel follow gowning rules and hygiene routines, supported by routine GMP training. Production rooms use HVAC systems with HEPA filters, positive air pressure, and stable temperature and humidity. These controls protect sensitive stages such as Liquid Base preparation, foaming agents addition, and blending with rheology modifiers.

Process controls include validated cleaning programs, equipment qualification, and full batch records. Load cell systems track raw material dosing, while inline filters protect downstream equipment. Quality checks focus on achieving a stable, homogeneous mixture before transfer to the toothpaste filling machine.

Market studies show higher trust in certified products, making GMP compliance a commercial advantage as well as a regulatory need.

How to Choose the Right Toothpaste Production Line Supplier

Supplier choice shapes long-term output, cost control, and scalability.

Customization & Capacity Matching

Production volumes differ widely. Small producers may run pilot batches, while large brands need continuous output. A capable supplier offers multiple toothpaste making equipment sizes and adapts designs for specific formulas, from classic pastes to toothpaste tablets.

Capacity planning should include mixing time, CIP cycles, and maintenance. Modular layouts allow future expansion without replacing the full paste making machine or homogenizing paste making machine.

Automation Level & Scalability

Automation affects labor use and capital cost. Semi-automatic lines often pair manual feeding with an automatic filling machine. Fully automatic systems integrate mixing, transfer lobe pump dosing, filling station, tube filling sealing machine, labeling machines, and conveyor belt transport.

Advanced lines use PLC Controller systems with PLC touch screen interfaces or PIC-based control panel options. These setups support automatic raw material input, recipe control, and batch tracking. Scalable production designs let manufacturers add speed as market demand grows.

After-Sales Service & Technical Support

Downtime costs money. Strong support reduces risk.

Key service factors include installation support, operator training, spare parts access, and fast troubleshooting. Preventive maintenance plans help protect critical parts such as the hydraulic pump, bottom homogenizer, and Rotor/stator assembly inside a high shear emulsifier or homogenizer mixer.

Why Choose King Pack for Toothpaste Production Lines

King Pack delivers complete production technology built for real factory needs.

Turnkey Production Line Solutions

Turnkey lines simplify project management. King Pack supplies integrated systems that cover mixing, vacuum processing, filling, and packing. One supplier handles design, installation, training, and spare parts. Equipment works together from the first run, reducing startup delays.

Industry Experience & Engineering Support

With experience across industrial cosmetic manufacturing equipment, King Pack engineers focus on practical processing methods. Support includes process flow planning, utility calculations, formulation checks, and troubleshooting. Systems may combine industrial mixer units, vacuum vessels, and precise metering to suit different toothpaste recipes.

Global Installation & After-Sales Service

King Pack supports international projects through coordinated installation teams. Services cover delivery, mechanical and electrical setup, system testing, and production validation. Ongoing support includes remote diagnostics, parts supply, and scheduled service visits, helping lines run reliably across their full operating life.

Frequently Asked Questions (FAQ)

1. How does viscosity affect tube filling accuracy?

Viscosity controls flow into the tube. High viscosity can lead to short fills if dosing time is limited. Low viscosity increases the risk of splashing, air inclusion, and overfill. A stable viscosity range supports repeatable fill weights.

2. Is there a standard viscosity range for toothpaste?

No single value applies to all products. Viscosity depends on formulation, tube material, and line speed. Most manufacturers validate an acceptable range through rheology testing and filling trials rather than relying on fixed numbers.

3. Can one tube filling machine handle high-viscosity toothpaste?

Yes, if the filling system is designed for viscous products. Nozzle geometry, drive control, and sealing modules must match paste behavior. Well-designed machines can run both aluminum and laminated tubes without formulation changes.

4. Does viscosity control limit production speed?

Unstable viscosity does. When viscosity stays within a controlled range, lines can run faster with fewer rejects. Poor control usually forces speed reduction or increases waste.

Conclusion

Viscosity control plays a direct role in filling accuracy, seal quality, and overall line efficiency. As toothpaste lines move toward higher speeds and more SKUs, viscosity stability becomes a production system issue rather than a formulation detail.

King Pack Filling designs fully integrated toothpaste production lines that support viscosity control from vacuum mixing through high-speed tube filling and sealing. To discuss your toothpaste production requirements or request a line configuration, contact King Pack Filling for technical guidance and system planning.