Cleaning Brush Manufacturing 2025090301455770
Cleaning brushes are a widely used tool for daily use and industrial applications. From household cleaning in the kitchen and bathroom to industrial dust removal in the manufacturing workshop and even in the medical and personal care sectors, cleaning brushes, with their simple structure, affordable cost, and intuitive results, have become a vital component of the global manufacturing and consumer goods supply chains.
However, many startup manufacturers or procurement and product managers new to the industry often focus solely on the final appearance or price of a brush, lacking a systematic understanding of the underlying production processes, key parameters, and quality control. This knowledge gap can lead to insufficient product performance, increased compliance risks, and even supply chain instability.
This article aims to help readers fully understand the process of cleaning brush manufacturing . Focusing on a “process guide,” the article will cover the process from understanding product structure, selecting process routes, raw material and incoming material inspection, to a step-by-step breakdown of the manufacturing process, quality control, equipment and tooling, EHS and sustainability, and finally, to cost, automation, and mass production milestones.
Applicable groups include:
Startup manufacturers : Help quickly establish production systems and process routes.
Quality control and process engineers : Master critical control points and defect prevention measures.
Purchasing and Product Managers : Understand cost structures and production capacity bottlenecks, and improve supply chain management capabilities.
The product coverage focuses on three categories:
Household cleaning brushes (kitchen brushes, toilet brushes, floor brushes, etc.).
Industrial brushes (dust removal roller brushes, conveyor belt cleaning brushes, deburring brushes, etc.).
Personal care brushes (toothbrushes, hairbrushes, etc., this is just a conceptual extension and no specific details are given).
Through this article, readers can gain a “panoramic view” of cleaning brush manufacturing, understand the details, and grasp the overall situation, providing guidance for product development, supplier evaluation, or production line construction.
Before going into the process, we need to first understand the basic structure, mainstream categories and process routes of cleaning brushes.
A standard cleaning brush usually consists of the following parts:
Brush handle/base : Common materials: plastic (PP, ABS, HDPE), wood, metal (aluminum, stainless steel).
Function: Provides gripping mechanics, carries hair bundles, and ensures overall strength.
Filaments/Bristles : A wide range of material options: synthetic fibers (nylon, PP, PET), natural fibers (palm, pig bristles), metal wires (copper, steel, stainless steel).
Determines cleaning ability, chemical resistance and service life.
Tufting/Fixing : Staple-set: the most traditional and widely used.
Fused: Commonly found in high-end brushes or small precision brushes.
Bonded: Suitable for specific shapes or flexibility requirements.
Flocking: used for surface softening or decorative brushes.
Accessories
It includes metal clamps, sleeves, threaded interfaces, etc., which are used to cooperate with long handles or telescopic rods.
Kitchen brush : used for cleaning tableware and pots, mostly with medium hardness brush wire.
Toilet brush : needs to be resistant to chemical corrosion, mostly made of PP or nylon.
Floor brush : The bristles are harder and the long handle makes it suitable for cleaning large areas.
Dust removal brush : used for the surface of industrial equipment, with soft brush wire and anti-static properties.
Roller Brush : Installed on the machine for conveyor belt cleaning or industrial deburring.
Different products often determine different process paths:
Wooden handle vs. plastic handle vs. metal handle : Wooden handles require woodworking line processing; plastic handles are mainly injection molded; metal handles require stamping, welding and other processes.
Pinning vs. Melting vs. Flocking : Pinning is a stable and mature process suitable for large quantities; Melting has higher requirements for materials and equipment; Flocking tends to soften the surface and be more beautiful.
Understanding these differences will help plan a reasonable production route in the early stages of product design and avoid frequent rework later.
Successful manufacturing requires thorough preparation. The design of a cleaning brush is not just about appearance; it also involves performance requirements, compliance standards, and engineering documentation.
Before designing, you need to answer the following questions:
Target surface : Is it glass, ceramic, stainless steel, or rough concrete?
Cleaning media : Are strong acids, strong bases, organic solvents, or high temperatures involved?
Lifespan : Is it for a one-time, short-term use, or will it need to withstand hundreds of cleanings?
Cost and budget : Is it positioned for mass consumption or high-end durability?
These requirements determine the subsequent material selection and process route.
In cleaning brush design, the following parameters are most critical:
Brush material
Nylon: wear-resistant and temperature-resistant, commonly used in mid-to-high-end brushes.
PP: low cost, suitable for large-volume daily necessities.
PET: good toughness and hydrolysis resistance.
Natural fiber: environmentally friendly, good feel, but poor consistency.
Metal Wire: Suitable for heavy rust removal or industrial cleaning.
Diameter and hardness
The thicker and harder the brush wire is, the stronger the cleaning power is but the more likely it is to damage the surface.
If the diameter is too small, it will be soft, but the cleaning efficiency will be reduced.
Bundle number and density
The number of bundles and the density of the arrangement determine the coverage and durability.
Appearance and mechanics
The ergonomic brush handle angle and anti-slip design can significantly enhance the user experience.
Cleaning brushes often come into contact with people or even food and must comply with relevant regulations:
Food contact safety : such as US FDA and China GB 4806 series standards.
Chemical compliance : European REACH, ROHS, restriction of hazardous substances.
Hygiene requirements : Some industries need to control bioburden to prevent bacterial growth.
To ensure smooth production, the engineering department needs to prepare complete documents:
BOM (Bill of Materials) : covers all raw materials and parts.
Process card : clearly define the parameters of each process.
Drawings and tolerances : including 2D/3D designs and critical dimensions.
Inspection specifications : determine the standards for IQC, IPQC, and OQC.
Trial production plan : small batch trial production to verify the feasibility of the process.
The first step in cleaning brush manufacturing is raw material preparation . Since the performance and durability of the brushes are highly dependent on the quality of the raw materials, establishing strict incoming quality control (IQC) is crucial.
Resin particles/wood/metal parts
Plastic: PP, ABS, and HDPE are commonly used for injection molding of brush handles.
Wood: birch, beech, etc., need to be dried and treated to prevent mildew.
Metal: Aluminum, stainless steel, for long handles or special industrial brush bases.
Brush filament spools
Material: Nylon, PP, PET, natural fiber, copper wire or steel wire.
Form: Spool packaging, convenient for use in automatic threading machines.
Adhesives/Fixers
Glue: Epoxy glue, hot melt glue, used for dispensing and fixing.
Fasteners: staples, metal clamps.
Assembly and packaging materials
Sleeve, plastic cover, threaded interface.
Packaging box, blister pack, moisture-proof bag, desiccant.
Material certificates and compliance certificates : Suppliers are required to provide RoHS, REACH, FDA or GB test reports.
Brush wire diameter and tensile strength : Use a microscope and a tensile gauge to test to avoid wire breakage and hair loss.
Moisture content and ash : Wood and natural fibers need to monitor moisture content to prevent deformation and mildew.
Odor and migration : Evaluate whether there is any odor or potential harmful substances released.
Appearance and color difference : Compare the colorimeter and the standard sample to ensure batch consistency.
IQC not only ensures product quality, but also reduces subsequent process losses , so it is often one of the most worthwhile links in the production line.
Now, let’s move on to the core of this article: the step-by-step manufacturing process for cleaning brushes . This process can be broken down into 12 key steps , each requiring specific equipment, process parameters, and quality control points.
5.1 Brush handle/base forming
Plastic injection molding
Process: Resin drying → Injection molding machine feeding → Mold forming → Demolding → Trimming.
Key controls: mold temperature, holding time, cooling rate.
Common problems: shrinkage, warping, and bubbles.
Wood Forming
Process: cutting → polishing → forming → edge banding → surface coating.
Note: The moisture content must be <10% to prevent cracking.
Metal base
Process: stamping, welding, polishing, anti-rust treatment.
Application: industrial roller brush, special high strength requirements.
Before implantation, the brush filaments need to undergo the following treatment:
Cutting : Cut the spool into designed lengths.
Combing : Ensures that the yarn bundles are flat.
Preheating/Annealing : Reduces bowing or curling.
Anti-static treatment : prevents the yarn from flying away.
Blending and color matching : match different colors or materials according to needs.
Choose different processes according to different products:
Staple-set
Process: The automatic hair transplanting machine folds the yarn bundle and nails it into the base hole.
Advantages: suitable for mass production and mature technology.
Risk: Mismatch between hole diameter and staple specifications can result in lint loss.
Fused
Process: The wire end is melted by hot plate or ultrasonic wave and directly embedded into the hole.
Advantages: No need for staples, firm and beautiful.
Disadvantages: high material requirements and narrow process window.
Bonded
Process: Dispense glue in the hole, insert the filament bundle and then cure.
Risks: Too much glue will cause overflow, too little glue will result in a weak bond.
Flocking
Process: Surface glue coating → electric field adsorption of short fibers → drying.
Application: Decorative brushes or flexible contact surfaces.
Trimming : Use a trimming knife or sanding belt to trim the outer contour to make the bristles even and neat.
Split : Through the friction of the grinding wheel, fine cracks are formed at the ends of the brush filaments, which improves the cleaning ability and reduces the risk of scratching.
Common operations include:
Sleeve/clamp crimping : Enhances structural strength.
Attaching a long handle or telescopic pole : by threading, snapping or gluing.
Printing or marking : including pad printing, silk screen printing, and laser coding.
Barcode and traceability code : facilitate quality traceability and warehouse management.
Ultrasonic cleaning/air cleaning : remove lint and dust.
Sterilization or high temperature drying : for food grade or medical brushes.
Key detection points:
Appearance defects (uneven hair bundles, hair loss, color difference).
Dimensional accuracy (brush handle, hole position, bristle length).
Pull-out force (single bundle of hair is not less than the standard N value).
Chemical and temperature resistance.
Grip torque test.
Choose different packaging according to sales channels and transportation methods:
Retail packaging : blister, color box, kraft box.
Bulk packaging : pallets, cartons, with instructions and recycling labels.
Moisture-proof measures : add desiccant or vacuum pack.
First in, first out (FIFO) : Avoid long-term detention.
Stacking strength : Ensure that the stacking does not damage the product.
Container moisture-proof and drop test : ensure export transportation safety.
Samples of each batch of products must be kept for traceability and quality review.
The sample library must be clearly marked and the batch and date must be recorded.
Process parameter regression : Optimize injection molding, hair planting, trimming and other processes through data analysis.
Yield and cycle time optimization : Improve automation rate and reduce manual intervention.
Equipment maintenance : Develop a preventive maintenance plan.
In cleaning brush production, equipment and tooling configuration directly determine production line efficiency, product consistency, and yield. Reasonable equipment investment not only increases production capacity but also reduces reliance on manual labor.
Injection molding machine/molding machine
Used for molding brush handles or plastic bases.
It has a high degree of automation and can be used with robots to pick up and stack parts.
New trend: All-electric injection molding machines, energy-saving and high-precision.
Automatic hair transplanting machine
According to different processes, there are Staple-set, Fused, Adhesive and other models.
Key performance indicators: hole positioning accuracy (±0.1 mm), speed (100–300 beams per minute).
Trimming and slitting machines
Automatic rotating trimming tool ensures uniform brush filaments.
The fork splitting equipment uses grinding wheels or chemical corrosion.
surface treatment equipment
Coating lines, drying ovens, electroplating tanks.
Equipped with exhaust gas treatment device.
Packaging line
Automatic cartoning machine, heat shrink film machine, labeling machine.
Can be connected to barcode system and ERP.
Dryer (resin pretreatment)
Cutting machines and carding machines
Air compression system and dust collection device
Automatic glue supply machine, glue dispensing machine
Tensile testing machine: to test the pull-out force of the yarn bundle.
Colorimeter: Control the consistency of plastic parts and brush wires.
Hardness tester and density tester: material testing.
Torque tester: Verifies the strength of the connection between the handle and the brush head.
Hair transplanting jig: used for small batch or special-shaped products.
Assembly fixture: ensure consistent assembly angle and force.
Testing fixtures: such as quick pull-out force test fixtures.
Cleaning brushes are daily consumer products that may seem low-tech, but to achieve consistency, durability, and safety , a systematic quality management system must be established.
Appearance : No obvious hair bundle deviation, no burrs, color difference ΔE<1.0.
Mechanical properties : Pull-out force ≥ design value (usually >20N).
Chemical resistance : Will not decompose or fade in cleaning agents or disinfectants.
Temperature resistance : no deformation at high temperature (80℃) and no brittle cracking at low temperature (-20℃).
Service life : Cyclic friction test ≥ 100,000 times.
Hair loss/loosening
Causes: The hole diameter is too large, the staple specifications do not match, and the glue is not cured enough.
Warping/deformation
Cause: Uneven cooling during injection molding and too high moisture content in the wood.
Chromatic Aberration
Cause: Inconsistent raw material batches and unstable injection temperature control.
Uneven hair bundles
Cause: The trimming tool is blunt or the fixture is poorly positioned.
Glue overflow/dirty surface
Cause: Unstable dispensing volume control and missing cleaning process.
SPC (Statistical Process Control) : Monitor key parameters such as pull-out force and size.
FMEA (Failure Mode Analysis) : Preventive analysis of potential risks.
Batch traceability : Manage raw materials and process parameters through barcodes or QR codes.
Modern manufacturing not only focuses on output and cost, but EHS and sustainable development are gradually becoming important components of corporate competitiveness.
Dust control : The slicing and trimming processes are prone to generate fine dust, and a central dust collection system is required.
Mechanical protection : Hair transplanting machines and trimming machines must be equipped with safety guards and emergency stop devices.
Noise control : Keep the workshop noise level below 85 dB and install sound insulation panels and earmuffs.
Ergonomics : Reduce repetitive labor and excessive bending.
VOC control : Spraying and adhesive processes require activated carbon adsorption or catalytic combustion.
Wastewater treatment : Wastewater from electroplating and cleaning processes needs to be neutralized and precipitated before discharge.
Waste recycling : Plastic scraps are crushed and reused, and metal nails are recycled and melted.
Use recycled plastic (rPP, rPET).
Promote biodegradable brush filaments (PLA, PBT+additives).
Designed to be disassembled for easy sorting and recycling.
Adopt variable frequency drive motor to reduce energy consumption.
Waste heat recovery system: Use the cooling water of the injection molding machine to heat domestic hot water.
Photovoltaic power generation is introduced to partially meet the electricity needs of the production line.
Although cleaning brush production belongs to the low-to-medium-tech threshold industry, cost control and production capacity optimization are particularly important due to rising labor costs and fierce market competition .
Raw material cost : accounts for about 50%-60%, with brush filaments and resin being the bulk.
Labor costs : account for about 15%–20%, and decrease with the degree of automation.
Equipment depreciation and maintenance : accounts for about 10%.
Energy and plant expenses : approximately 5%–10%.
Packaging and logistics : about 5%.
Centralized procurement and supplier cooperation : gain scale advantages.
Improve the level of automation : reduce the manual hair planting process.
Process optimization : reduce scrap rate.
Flexible production : Reduce downtime losses caused by small batch switching.
Bottleneck process
Fiber transplanting and trimming are often bottlenecks in the production line.
Solution: Connect multiple units in parallel and introduce higher-speed equipment.
Batch size management
Large quantity: reduces costs, but creates high inventory pressure.
Small batch: fast response, but high unit cost.
Capacity balance
Dynamic production scheduling through the MES system.
Ensure that the injection molding, hair planting, assembly and packaging processes are synchronized to avoid a large amount of work-in-progress accumulation.
As industries transition from labor-intensive to technology-intensive, automation and digitalization are essential for cleaning brush manufacturers to enhance their competitiveness. They not only reduce labor costs but also significantly improve consistency, transparency, and production flexibility.
Automatic threading and switching
The automatic wire feeding device can quickly switch the spools, avoiding manual wire threading.
The sensor detects the remaining amount of the wire spool, allowing replacement without stopping the machine.
Visually guided hair transplantation
A high-precision camera detects the base hole position and automatically corrects deviations.
Reduce the scrap rate caused by hole position deviation.
Robotic assembly
The six-axis robot completes the assembly of the brush head and handle, and the crimping of the sleeve.
Combined with AGV (automatic guided vehicle) to realize production line logistics automation.
Smart trimming and polishing
The cutting depth is controlled by a laser distance sensor.
The system automatically compensates for tool wear.
MES system (Manufacturing Execution System)
Collect production data (takt time, yield rate, downtime) in real time.
Dynamically schedule production lines to shorten delivery cycles.
Barcode and RFID traceability
Establish a complete traceability chain from raw materials to finished products.
Once a customer complaint occurs, the production batch and parameters can be quickly located.
SPC (Statistical Process Control) and Kanban
Automatically analyze trends in key process parameters (such as melt temperature and dispensing volume).
Provide early warning before abnormalities occur to avoid batch defects.
OEE and Maintenance Work Orders
OEE (Overall Equipment Effectiveness) = Availability × Performance × Yield.
The system automatically generates maintenance reminders to reduce unexpected downtime.
Artificial Intelligence (AI) visual inspection : Automatically identifies defects such as hair loss, color difference, and deformation.
Digital Twin : Simulate production line operations in a virtual environment to predict bottlenecks and maintenance needs.
Unmanned factory : Achieve a “dark factory” through robots, AGVs, and automatic warehousing systems.
Although cleaning brushes are consumer products, they still involve requirements such as food contact safety, chemical compliance, and social responsibility .
EU 10/2011 : Strict regulations on migration limits for plastic materials.
China GB4806 series of standards : Specifications for food contact materials.
REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) : Restriction of hazardous substances.
RoHS (Restriction of Hazardous Substances) : Electronic brushes (such as electric toothbrush heads) must comply.
SVHC (Substances of Very High Concern List) : Need to be checked one by one.
BSCI (Business Social Compliance Initiative) and SEDEX : ensure that factories comply with labor and human rights standards.
ISO 14001 : Environmental management system certification.
ISO 45001 : Occupational health and safety management.
From concept to mass market launch, a cleaning brush product typically goes through the following stages:
Used for appearance verification, 3D printing or rapid mold completion.
Check the shape, size, and grip.
Use formal technology to carry out small batch trial production.
Verify the bristle fixing strength, brushing effect and durability.
The production line is put into trial operation to confirm that the process parameters are controllable.
Evaluate cycle time, yield rate, packaging, and logistics.
Expand production capacity and gradually increase yield to >95%.
Establish a batch sample library to ensure traceability.
Appearance and size are qualified.
The pull-out test complies with the design standards.
Packaging, labels and instructions are complete.
Meet customer and regulatory requirements.
Staple-set : stapling and hair transplanting process.
Fused : Fused implantation process.
Flagging : The process of splitting the ends of the brush wire.
Nylon brush filament melting temperature : 220–260°C.
Glue curing curve : epoxy glue 80℃×30 min.
Bristle pull-out force standard : >20N (household brush); >50N (industrial brush).
IQC incoming material inspection form : material certificate, wire diameter, tensile strength.
Process inspection form : hair planting density, trimming uniformity, and hair loss rate.
OQC factory inspection form : appearance, size, and packaging integrity.
refinement, automation and greening under the promotion of modern technology, equipment and management system .
This article systematically sorts out the entire production process through fourteen chapters, from product design, raw material inspection, process details, to equipment configuration, quality control, EHS, cost planning, automation, certification and proofing and mass production.
Key takeaways:
The design stage determines the product life and market positioning.
Raw materials and IQC are the first step in quality assurance.
Process control needs to focus on three key processes: hair transplantation, trimming and final inspection.
Quality management and EHS are the cornerstones of sustainable development of an enterprise.
Automation and digitalization are becoming the core drivers of future competition.
Future trends :
New materials : Bio-based filaments such as PLA and PHA are gradually replacing traditional petrochemical plastics.
Low odor adhesive : reduces VOC emissions.
Less-manned production lines : Using robots and intelligent detection to create more efficient and environmentally friendly factories.
For start-up manufacturers, understanding the full-process framework in this guide will help them quickly establish production lines that meet market and regulatory requirements. For established factories, this foundation can further promote lean production and intelligent manufacturing , continuously improving their competitiveness.
Kelvin Liang expertise lies in navigating the complexities of international logistics, export-import regulations, and international payment methods. I am adept at managing the entire order lifecycle, from initial product sourcing and supplier communication to quality control, shipping coordination, and after-sales support. I consistently strive to mitigate risks and overcome cultural and communication barriers to guarantee client satisfaction and foster mutual growth.
I am a proactive and results-oriented professional, constantly leveraging market research and data analysis to inform strategic decisions. My goal is not just to facilitate transactions, but to create sustainable value for all stakeholders. Fluent in English and with a strong understanding of various cultural business etiquettes, I am committed to driving sales growth and expanding market share for my company on a global scale.
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