Page 22 - DHC-new 25 sept[53209]

Scaling up R&D to
commercial
manufacturing
We are embracing the best
technology and partnerships
that leverage the power of our
exemplary structure to advance
science and develop new FMCH
nutritional solutions. This means
DHC is always striving to improve
productivity, while maintaining
flexibility in production volumes
to keep costs down. So far, we have
touched millions of people across
various walks of life with our
73 World Firsts and 1500 plus
FMCH products.
Manufacturing capabilities enable the company to
provide high quality FMCH products at the most
competitive prices and in a timely manner to its
customers across the globe, thus ensuring continuous
growth and success of the company.
To overcome challenges of innovation, R&D; to
further fortify its growth and innovation capabilities,
producing effective quality compliant, consumer
friendly FMCH product the company invested in its
own FMCH product innovation & manufacturing
facility. The company’s quality FMCH product
demand is supported by modern and cost-efficient
manufacturing facility.
In 2012, DHC’s FMCH product manufacturing
facility commenced commercial production. This
manufacturing facility located in special economic
area of Uttarakhand avails special tax rebates, tax
advantages and subsidies valid unto FY 2020. DHC’s
manufacturing facility successfully complies to WHO-
GMP audit. The company’s GMP manufacturing is
qualified to export FMCH products to USA, UL and
almost every part of the globe and certified with ISO
9001:2008, FSSAI, USP certification, SGI certification,
AYUSH, German cert., among other successful
compliances.
COMPLIES WITH WHO-GMP,
MANUFACTURING UNIT
USP CERTIFICATION,
ISO 9001:2008,
GERMAN CERTIFICATION,
SGI CERTIFICATION,
AYUSH, FSSAI.
The company imported high technology equipment
and employed highly skilled manpower to produce
the best omega 3 soft gels. This plan of action for
FMCH products of omega 3 and its differentiated
formulations resulted because they are best delivered
as soft gels. The company is exalted for its superior
quality omega 3 soft gels.
The company’s manufacture portfolio includes
multiple types of dosage forms for FMCH products
that include soft gel capsules, hardgel capsules,
tablets, liquids, topical, powers and special delivery
forms.
Quality is the watchword;
process integrity is strengthened;
productivity improvement was a bonus.
Manufacturing food as pills is a real challenge and
the company has demonstrated its production ability
successfully. Our manufacturing technology supports
the innovation and makes deliverables consumer
friendly.
The FMCH product manufacturing process starts with
right quality ingredients. At the unit 4264 materials
are procured, stored and used for production. These
ingredients are classified as herbal, natural ingredients,
processed ingredients, synthetic ingredients, organic
ingredients, inorganic ingredients extracts, raw crush,
oils, flavours, taste makers, natural colours, fragrance
and packing materials. The quality parameters of
ingredients used for a product are set by R&D during
the process of development of the product are the
procurement standards.
The natural organic herbal extracts ingredients
procurement process starts from the fields. Medicinal
plants are cultivated selectively to our requirements.
We harvest and process the medicinal plants herbs
to the required level of potency and purity through a
technology share with selected channel of vendors.
These processed ingredients are procured by the unit.
The other ingredients required are mostly available in
abundance off-the shelf from vendors catering to food
industry and manufacturers of food ingredients. The
ingredients are stored in required prescribed storage
conditions at the factory.
Based on the market requirement and orders of the
finished FMCH products, the production order is released
by the unit head. The production process from here is
SOP (Standard Operating Procedures) driven. These
SOPs are designed by R&D during development and
batch scale up of the FMCH products for commercial
production. The SOP is a classified and confidential
document of the company. As per the SOP of the
product to be manufactured, the ingredients are
dispensed, under strict vigil of quality assurance,
production manager and quality control personnel.
These dispensed ingredients then move to the specific
sections where the next steps of manufacturing take
place as per SOP of that product.
Section – Soft gel: We invested in precision, state
of the art blending and encapsulation equipment
which enables us to overcome softgel manufacturing
challenges and consistently produce the finest
softgels. This dosage form is a solid dosage form
containing liquids, paste, oils and viscous ingredients
mostly with essential oils. High technology equipment
and very highly skilled workforce is essential to operate
this section. The first part of the process involves
preparation and cooking of gel mass for the shell of the
soft gel. The shell ingredients are loaded into the two
650 kg vessels which are high tech specially fabricated
cooking vessel with thermostatic control and mixing
facility of very high viscosity ingredients. The batch