From formula to finished batch
Four phases. AI-planned throughout.
Submit your formula details
Upload your formula through our production intake form. Select required certifications, including organic, halal, or vegan, and provide your target batch size.
Ingredients and targets
Send the complete ingredient list, supplier specifications, target capsule and fill weights, tolerances, and known allergen declarations. Our system checks the specification against the ingredient library before placing the batch in queue.
Label and compliance needs
Identify the target market, whether India domestic, US export, or EU export, so we prepare the appropriate supplement facts format and regulatory references. Brands can add formulation review for ingredient compatibility confirmation before committing to a batch.
Quantity and delivery timing
Tell us the required quantity, preferred delivery window, and packaging limitations. For pilot runs of 500 units, the system places the batch in the next open floor slot for that dosage form.
AI batch planning
Our AI scheduler allocates floor time, minimizes changeover cost, and sequences ingredient arrivals across concurrent product queues and incompatible ingredient families.
Minimizing changeover cost
The scheduler places compatible ingredient families in shared floor windows, cutting the number of full cleaning validations required each week. On compatible equipment, a capsule batch after a powder batch may share the cleaning event, shortening turnaround by one to two days.
Ingredient timing and allocation
The schedule accounts for ingredient arrival windows. When a raw material has a 10-day lead time, the batch is scheduled after day 10. This avoids idle floor time caused by shortages and provides an accurate production start date when the order is confirmed.
Manufacturing
Robot-assisted filling, blending, and encapsulation. Human operators validate setup and handle exceptions.
Automated capsule filling
Automated machines fill two-piece HPMC and gelatin capsules to the batch target fill weight. Each batch is calibrated, while inline checkweighers continuously sample fill weights. Out-of-spec results pause the run and create a deviation log entry.
Powder blending, sachet fill
Bulk powders are blended in enclosed stainless steel vessels, with validation samples taken at the beginning, middle, and end. A separate line fills single-serve sachets with tamper-evident heat seals and inline weight verification.
Tamper-evident packaging
Finished units pass through tamper-evident banding before packing into labelled bulk containers. Lot numbers and batch codes are printed then. Finished goods remain in quarantine pending QC release.
Quality control
Weight checks run every 15 minutes. Certificate of Analysis issued per batch.
In-process weight checks
Inline checkweighers sample fill weight every 15 minutes during production. Each batch receives statistical process control charts for review before release. A deviation beyond tolerance pauses the line for human exception review.
Analytical testing
Retain samples from every batch undergo disintegration, moisture content, and microbial limits testing for TAMC, TYMC, and coliforms. Selected vitamin and mineral formulas receive potency assays by HPLC. Export-bound finished goods undergo heavy metals testing for lead, arsenic, mercury, and cadmium.
Dissolution and disintegration
Dissolution testing on retain samples verifies that the active release profile meets specification. Disintegration time is measured against USP 2040 reference standards. Results are assembled in the Certificate of Analysis before quarantine release.
Finished product, records, and delivery
Finished product arrives in labelled bulk containers with a Certificate of Analysis, batch record digest, and ingredient traceability report. We ship from Hyderabad to domestic and export destinations. Capsule runs average 4 to 6 weeks from confirmed order.