We have a very stringent work order system to ensure your order is monitored carefully throughout the manufacturing process. Our Quality control department is responsible for testing unfinished products, incoming raw materials and all in-process testing for the facility.
Receiving:
Once an order is placed by a customer, we generate paperwork to tie in
the customer order number with our automated internal tracking system.
Purchase orders are generated for all the raw materials required in the
client formula. Once an order is placed, we await materials shipment.
Measuring and Blending:
Once the work order and raw materials are released, the batching department weighs and mixes the ingredients in accordance with departmental Standard Operating Procedures and the work order specifications. The type of product, lot number and specific amount of raw ingredients are verified.
Our staff carefully labels and weighs the ingredients, and places them in individual bags to ensure the proper amount for inclusion in each container of a batch. After materials have been weighed out, each powder is screened through a mesh to ensure dispersion and size consistency, and then the ingredients are blended into the correct formula.
Agglomeration and Granulation:
After blending, some products require a change in particle size. We offer two processes for granulation. The first one utilizes a fluid bed agglomerator using water-solvent technologies. The second uses conventional alcohol solvent technologies. By using the processes, we are able to reduce the amount of excipients needed in a tablet. All in-process powder samples are forwarded to the laboratory for a special microbial analysis.
Encapsulation:
We are very versatile in our manufacturing capabilities. We have three different size machines that can produce any size capsule you require. Every 15 minutes, a staff member checks the machine to ensure capsule weights are correct, and every 30 minutes our quality assurance department verifies capsule weight and quality.
Tablet Production and Coating:
Now that the identity and specific weight of the material has been determined, the unit dose department proceeds with batch processing---in other words tablet production and coating. The batch is continuously monitored for appearance and product weight fluctuations. Every 15 minutes, a staff member checks the machine to ensure capsule weights are correct, and every 30 minutes our quality assurance department verifies capsule weight and quality. When the run is complete, the product is forwarded to inspections.
This is currently our fastest growing production area, due to the fact our high-end granulation technology has diverse coating capabilities. This technology enables us to make a variety of shapes, sizes and color coating solutions to meet unique customer needs.
Final Product Inspection:
This serves as the final check point before the product is packaged and sent to consumers. We inspect all tables and capsules manufactured at our facility. Our inspection department closely examines each capsule and tablet by hand to ensure only the highest-quality product makes it into a packaged form. Products are packaged by inspections personnel, or are forwarded to the packaging department for specialized finished product packaging.
All in-process samples are forwarded to the laboratory for microbial analysis. The results determine if the product meets release criteria prior to shipment. If contaminated, the product is placed on immediate hold until it can be cleaned or destroyed. When a material has been declared pathogen-free, it is ready to ship as per customer specifications.
Quality Control and Raw Materials Weigh-in:
Quality control is integral in each aspect of the manufacturing process, starting with the quality of the raw materials. Each raw ingredient we select requires a COFA (Certificate of Analysis) and an actual sample on-hand to help us clearly identity the appropriate ingredient. The quality control department sends a sample to our microbial lab for further testing before production. When and if a product passes quality control, it is then released for use in manufacturing the client order.
Quality Control and Raw Materials Weigh-in:
Quality control is integral in each aspect of the manufacturing process, starting with the quality of the raw materials. Each raw ingredient we select requires a COFA (Certificate of Analysis) and an actual sample on-hand to help us clearly identity the appropriate ingredient. The quality control department sends a sample to our microbial lab for further testing before production. When and if a product passes quality control, it is then released for use in manufacturing the client order.
Packaging:
We work with bottles, powder fillings, and can create unit dose packaging if necessary. Our staff can also shrink wrap in bulk, pack, or box products according to client requirements.
Packaging:
We work with bottles, powder fillings, and can create unit dose packaging if necessary. Our staff can also shrink wrap in bulk, pack, or box products according to client requirements.
Packaging:
We work with bottles, powder fillings, and can create unit dose packaging if necessary. Our staff can also shrink wrap in bulk, pack, or box products according to client requirements.
On-going Research and Development:
The R&D department is responsible for the design, control and modification of all formulas processed at our facility. R&D monitors a formula throughout each aspect of the production process, and provides insight to facilitate and improve the efficiency of production runs.
R&D begins with the very first pilot formulation. We have a miniature factory on-site, complete with miniature presses, blender and coater. Once we are assured of a tablet or capsule formulation, and confirm the weight and look is correct, we work our way up to larger batch quantities for that client formula.
This dynamic unit of Pro Pac Labs is also paving the future of the company. They are hard at work creating new formulas and expanding our private label selection.
