Best Liquid Manufacturing Plant for Syrups & Oral Suspensions
Oral suspensions are preferred a lot by the paediatric population and a defect or unprocessed particle in the liquid syrup can land your brand in trouble. Similarly, no matter what the person’s age is, if they have difficulty swallowing or cannot handle the tablets’ bitter taste, liquid syrups come to the rescue and the overall responsibility lies with the liquid manufacturing plant behind the scenes. Thus, wisely choose a liquid manufacturing plant manufacturer in India that considers your brand’s growth as its growth. Top 10 Solutions Brought by the Liquid Manufacturing Plant The following are the top 10 common challenges and their solutions brought by the Liquid Syrup Manufacturing Plant for manufacturing oral liquids, sugar syrups and suspensions: 1. Consistency in Viscosity and Homogeneity Challenge It is not easy to achieve consistent viscosity and homogeneity in oral liquids, suspensions and syrups due to the varying properties of the ingredients in various industries. Solution The liquid or sugar syrup making machine can be customised with homogenisers and high-shear inline mixers, real-time viscosity monitoring, precision-controlled pumps, automated filling machines and temperature control systems while maintaining regulatory compliance for desired product consistency, viscosity and blending. 2. Regulatory Compliance Challenge Quality assurance goes hand in hand with following strict industry standards. For instance, Manufacturers in India follow the ISO , GMP and other national and international standards. On the other hand, The U.S. focuses on the FDA guidelines, including GMP and other standards. Solution Ensure that the liquid manufacturing plant manufacturer provides you with the machinery that meets the required national and international standards and has easy-to-clean designs, traceability systems and validated cleaning processes to follow regulatory compliance. 3. Production Efficiency Challenge You might have to optimise the production lines to improve efficiency and reduce production time, especially with complex liquid formulations. Solution The liquid or sugar syrup making machine can be customised for higher speed and automation to streamline the production process and reduce the cycle times. Similarly, efficiency and productivity can be increased via continuous processing and by adding automated filling systems. 4. Ingredient Handling and Processing Challenge Your company must be dealing with various Active Pharmaceutical Ingredients (APIs) and excipients, but do you have specialised machinery for that? Solution Get the liquid or sugar syrup preparation tank that is customised with flexible ingredient handling systems for efficiently mixing and processing ingredients with different viscosities, formulations and types (powder or liquid). 5. Maintaining Product Stability Challenge Environmental factors and ingredient interactions affect the ability of oral liquids and syrups to maintain their stability throughout their shelf life. Solution The sugar syrup mixing tank with features such as controlled temperature environments and precise mixing controls helps maintain the product’s stability. Similarly, it helps avoid the risk of segregation, sedimentation or degradation. 6. Scaling Up Production Challenge Scaling up liquid syrup production from small scale to large scale is not easy as it includes challenges such as quality consistency, equipment limitations, regulatory compliance and more. Solution The Liquid Manufacturing Plant can be designed for scalability for smooth transitions from pilot to commercial production. Similarly, the production volumes can be easily scaled with the modular components and adjustable settings. 7. Energy and Resource Efficiency Challenge High energy consumption and resource usage can affect overall production costs and environmental sustainability during the oral liquid manufacturing process. Solution Collaborate with the manufacturer to get an energy-efficient oral liquid manufacturing machine with heat recovery systems and optimised power usage that help reduce operational costs. On the other hand, environmental sustainability can be achieved via efficient resource management during the manufacturing process. 8. Precision in Dosing and Filling Challenge Inconsistency in calibration, variability in formulations, improper equipment calibration and improper measurement units can affect the precision in dosing and filling and increase waste generation. Solution Inline viscometers, advanced dosing systems with sensors, speed adjustments, real-time monitoring of temperature and more are the components of precise dosing and filling systems for accurate measurement and minimised product wastage. Automated filling machines with programmable controls enhance the efficiency and accuracy in the Oral Liquid Manufacturing Plant. 9. Cleaning and Maintenance Challenge Your machinery requires frequent cleaning and maintenance to prevent contamination and ensure product quality. However, it is time-consuming and disruptive. Solution Your Syrup Manufacturing Plant can include easy-to-clean designs and automated cleaning systems such as CIP (Clean-in-Place) for an easy cleaning process, reduced downtime, hygiene and operational efficiency. 10. Supply Chain Integration Challenge Limited production capacity, a sudden increase in demand, unsupportive suppliers, inefficient packaging and more cause a disruption in the supply chain for raw materials and finished products. This results in the need for effective coordination and tracking. Solution Your Liquid Manufacturing Plant can include integration features to be connected with supply chain management systems. Similarly, automated ingredient dosing, real-time inventory tracking and streamlined production processes help improve the coordination and overall efficiency of the supply chain. 5 Qualities to Consider in a Liquid Manufacturing Plant Manufacturer The liquid syrup manufacturing plant speeds up your work and provides a comprehensive solution because it focuses on the whole manufacturing process rather than doing just a single task. Thus, your liquid manufacturing plant manufacturer should have the following qualities: 1. Ability to Customise From gathering the raw materials to processing them as required and from automated temperature maintenance to unloading the final product, the manufacturer should be able to customise the liquid or sugar syrup making machine according to your needs. 2. Minimised Labour Costs Instead of replacing the existing workers, the machinery manufacturers should focus on eliminating the requirement of multiple workers for the sugar syrup preparation tank. Thus, single-operator machinery will be more advantageous in this case. 3. Expertise and Support Besides planning, machinery alterations and successful site installation, the manufacturer should provide after-sales support and training to the workers. For that, also look if they have a proven track record in manufacturing machinery in the industry. 4. High-Quality Material The manufacturer should manufacture the sugar syrup mixing tank with high-quality material, mostly stainless steel, that withstands higher