How NSI Gels are Made - Part 2
We’ll look at how the approved base formulation is made into unique colors and packaged for shipments around the world.
Step 4: Pigmentation
If you are making any gel other than clear, you must add pigment to achieve the desired color. Gels can be heavily pigmented (opaque or cover gels) or lightly pigmented (sheer or transparent gels). NSI offers many different color options in our Balance line (50 to be exact). A color is chosen based on market needs and trends. The sales and marketing teams are always on the look-out for new and exciting possibilities.
Once a color is chosen, sales and marketing provides a control sample to the laboratory to match (this could be a photo, or a mix of several existing gels, an acrylic powder, etc.) The lab will first create a small sample for approval by using different pigments and titanium dioxide (white).
Once a color is approved, it must be tested for depth of cure, meaning that a complete cure can be achieved in a reasonable amount of time. Opaque gels require more time and UV energy to cure than sheer gels. NSI gels have cure times of 90 seconds to 180 seconds.
Step 5: Production in Large Quantities
NSI gels are manufactured in weights ranging from 5 Lb. to 50 Lb. If adding pigment, it is done while the gel is on a Lightnin Mixer to ensure the pigment is completely dispersed.
The gel then moves to Quality Control where it is tested for several characteristics to make sure the run meets the rigorous standards to NSI. Some of these characteristics include cure time, viscosity & shine.
If the gel meets all specifications, it is ready to be packaged. First, a retain sample if kept and the gel is assigned a batch number. This allows for easy tracking in the event of any quality, raw material or regulatory issue. It also ensures that if all material has shipped, we have a representative sample in house to investigate any issue quickly and thoroughly.
Step 6: Packaging
Packaging is a very important aspect of a product. It must promote product stability and be able to the rigors of many different shipping methods. Before a particular container is chosen for an NSI product, test mailings are sent around the world to uncover potential product failure.
NSI has invested in a variety of filling machines that accurately fill containers with the appropriate amount of product. It is during this stage that the containers are labeled and marked with their batch number. The finished product then gets sorted in a case-pack.
Step 7: Storage
Once packaged, NSI products are stored in a cool, dry environment. Here, it will be picked for orders, packed in boxes and shipped all over the world. Its final destination is the work station of a wise nail technician with excellent taste.