MANUFACTURING PROCESS:

All the production held at Getz pharma is make- to -stock that is to say 99% of their making. Whereas 1% is make -to -order for certain customized institutional orders like for instance army orders which have special labeling/carton labeling requirements. The whole production/manufacturing process at Getz may it be tablets, syrups or injections is based on production plan which is eventually based on MPS. Master production schedule is made by the supply department which is forwarded to the MATERIALS MANAGEMENT department .The job of Material Management department is to arrange the raw material for the production department well before the required time so that there are no delays in the manufacturing of the product. This plan is initially made during the plan stage. While planning production it is kept in view what resources they have with them in order to produce and what type of raw material is stored in warehouse so that according to that they make their production plan. Production plan is made on weekly bases as well as monthly bases depending upon the availability of the resources, which are required to make the required product.Then S &O P meeting is held, which is represented by two parties one from supply side and the other from demand side and production related decisions are made as per the plan.

Getz Pakistan is using BPCS system. This activity monitors the status of manufacturing department including: Tablet manufacturing Syrups Injectables

The MOs, which has been send to the manufacturing department for the finished product, are at what stage and what batches are being manufactured on which machines. As per this system, the system is programmed in such a way that only the multiples of batch size can be produced and no random manufacturing can be done that is to say if the batch size is 100 then 200 or 300 can be produced even if the requirement/demand is 125units. In order to cater the demand of 125units, 200units products need to be manufactured which will later be adjusted through the system in the coming months.

Getz Pakistan Types of ProductsTypes of Product: Tablets Liquids/Syrups/O.R.S Injectables Creams/Ointments

Main Products Multivitamins Antibiotics Anti Inflammatory Cough and Cold Haematincs Anesthetics Analgesics Anti Arthritic Antacid Anti B.P.H Anti EpilepticStandard Operating Procedures Cleaning Uniform Carefully usage of instrumentTolerance LevelCurrently +/-5% tolerance level is set but it can vary from product to product.Process Flow (Tablets)

GRANULATION

DRYING

MILLING

BottleneckBLENDING

COMPRESSION

COATING

In granulation stage the raw material is put under a process where solids are broken down into small granules. Next is drying stage where these granules are kept on large trays and passed through e certain temperature for specific period of time (varying as per the tablet). Milling process where further REFINING of this dried material is done separately and is converted into fine powder form follows this stage. Then comes blending stage where different materials are mixed together and are then passed into the compression process where a certain amount of pressure is given and the mixed material is given a tablet form (shape). Coating is the last stage where the tablets are coated with sugar and dyes/ colors (HPMC and Methocyl) in order to differentiate the tablets from other tablets available and to avoid bitter taste. The bottlenecks in the production of tablets are compression and coating.

Process Flow (Syrups)

The processing of syrups is done in huge tanks, which are already filled with water (as per the requirement/specifications). Raw materials and glucose are added in the tanks, certain material are also dissolved separately in other small tanks or large beakers etc and dissolved solution is then added to the tanks along with glucose etc. the solution is heated at a very high temperature usually (varies as per different syrups). The sample is then passed to QA for testing and once the tests are approved the packaging of these syrups starts.

Packaging Process (Syrups)

FILLING

SEALED

STERILIZED

LEAK TEST

RELEASED

Process Flow Injectibles

The processing of injectables is done in beakers with a capacity of 50 liters. The materials are mixed in that beaker in the form of a solution. If large amount of injectable is required then large pressure vessel containers are used for mixing and making the solution. Keeping a PH check and PH adjustments is the most important factor during this process. The filtration of the solution should be 0.2 microns.

Process Flow (Pedialyte)

SOLUTIONMANUFACTURINGBottleneckBOTTLE FEEDING & WASHINGFILLINGSEALINGLEAK TESTCAPPINGSterilization

SKILLETING & TROLLY TRANSFER

AUTO CALVEUNCAPPEDPackaging Line

LEAK TESTER

CAPPING

OPTICAL

LABELLING

SKILLETING & LSPC SEALING