Include tablet, capsule, and syrup; drop, vial & soft gel capsule production lines.

A) Tablet production line

This line includes powder production sections, in which beside mills, granulators & mixers, there are fluid bed driers, tray driers, pasters & blenders. These sections together can produce at least 500 kg of tablet powder in each work shift. The most advanced machinery's of the pharmaceutical industry are selected and installed in this part of the line.

The pressing section has two pressing machines (Model P 3102), which are equipped with the latest computerized facilities, which are nearly unique in their kind. Each of these machines can produce up to 400,000 tablets per hour while continuously measuring their weight, thickness and pressure during the production process. In addition, pressing is performed inside the machine and the resulted dust is conveyed into dust collectors,

which are installed out of production space. During the production process, in addition to the controls, which are performed by the pressing machine, sensitive scales and sclerometers check itself, hardness and weight of the tablets.

The coating section has two coating devices made by Manesty Company, each of which are able to coat (film coat, sugar coat or drogue) more than 140 kg of tablets. All steps are performed automatically and without any human intervention.

Two sorting devices, made by Company, perform sorting of tablets by size and form, if needed.

This section is equipped with two blistering and cartooning machines, made by Uhlmann Company (Model; LIPS2), each of which can blister and pack (including printing of expiry date and batch number) up to 180000 tablets per hour in a fully automatic manner. These machines are equipped with control systems, which prevent empty blisters to be packed. This line is also one of the fully automatic lines of production in our plant.

B) Capsule:

This line includes powder production sections, which make powders suitable for capsules, fluid bed driers, mixers, pasters, mills, granulators, blenders and powder conveyor devices.

The filling section has two filling machines (MG2) with a filling capacity of 100,000 capsules per hour. These are very advanced machines, which in addition to filling the capsules can sort out the defective ones and then dust and polish the intact capsules.

The packaging section includes two blistering and packing machines (Uhlmann) each of which can blister and box more than 150,000 capsules. These machines automatically control the blisters and prevent empty blisters to be packed. Expiry dates and botch numbers are also printed automatically on each blister and box.

Both tablet and capsule production lines have tablet counters and capping devices, which automatically count the tablets or capsules to be packed in a container and put them inside the container and then cap it.

C) Ampoule:

In this unit 1, 2, 3, 4, and 5 ml vials are produced, and the unit consists of the following:

1 - Preparation:

     This section has two distillers, which produce distilled water needed for preparing    vials. Each of these distillers can produce 300 liters of distilled water. In this section there is a 2000-liter tank, which is used to preserve distilled water at high temperature.

      The preparation process is carried on in two layered stainless steel tanks of various capacities in a completely clean environment. Contents of the vials are passed through 0.45 and 0.22 filters to be completely decontaminated. This section has a very advanced type of autoclave, which is completely programmable, and equipment and instruments in this section are fully sterilized before entering the vial filling section.

 To sterilize the shells, a programmable sterilizer is used. Its internal temperature   reaches up to 300 C to dry - sterilize the shells.

 2 - Filling section:

This section is equipped with 4 B & S advanced filling machines, each of which can fill 2000 vials per hour. This section, space is completely decontaminated and all entering equipment pass through 2 programmable B & S autoclaves to be sterilized.

      These autoclaves vacuum test the filled vials to sort - out cracked ore broken vials, and if necessary wash or heat the filled ones.

 3 - Visual control:

      This section is equipped with 2 visual control instruments each of which can check 18000 vials per hour, these equipment can identify the vials which contain microscopic particles (e.g. for example broken glass) and sort them out.

4 - shell printing:

      In this section there is a shell-printing machine, which can print the desired data (to mark the contents known) on the shells. These data may include batch number and expiry date, if necessary.

5 - Blistering & cartooning:

      This section has 2 Uhlmann blistering and cartooning machines, each of which can package 4200 vials per hour.

      Checked vials enter this machine to be located in specially formed P.V.C containers in groups of 5 vials and then the cartooning machines pat them in a box and prints batch number and expiry date on the box.

D) Soft gel capsule:

This is a unique production line in the Middle East and can produce soft gel capsules in various sizes, forms and colors. This line includes:

1 - Gelatin production:

      This section has two 500-liter gelatin preparation tanks, which can provide the desired condition to prepare various kinds of gelatin. The process is performed in vacuum and appropriate temperature, and the blades in the tank can move in different directions with variable speeds to prepare the gelatin in the best possible way. Once the gelatin is prepared it is transferred to portable two layered tanks, which can preserve it in a predetermined temperature until filling time.

2 - Liquid preparation:

      Various kinds of liquids are prepared in this section under appropriate light in stainless steel tanks, which can provide the desired temperature for preparing the liquid. The liquid is then transferred to portable tanks to be used when necessary.

3 - Filling:

      In this section the gelatin capsule is filled with liquid using a special technology by the filling machine. This section should have certain conditions in terms of temperature and humidity. This section has 3 filling machines, each of which can, depending on the product’s form, fill up 300,000 capsules per working shift.

      While being filled, sensitive scales check the quality of capsules, in terms of gelatin and liquid contents weight, and attachment of two parts of the filled capsules is regularly checked by microscope.

      These machines have a tumbler section, which can use airflow to dry and harden the capsules while turning and tumbling them in various stages and different baskets.

4 - Soft gel capsule washing:

      This section has a special washing machine that removes all remains of fats or drugs from the surface of the filled capsule.

5 - Drying:

      After being washed, the capsules soften, and have a gelatinous consistency, and therefore are transferred in special trays to the drying room, which has appropriate temperature, humidity and airflow, to reach the desired hardness and dryness.

6 - Blistering & cartooning:

      In this section all capsules are automatically blistered and packed by an advanced blistering and cartooning machine, which also prints expiry date and batch number on each blister and box. In addition to the existing machine, two new ones have been purchased and one being installed.

E) Ware houses:

     ZAHRAVI Co. has various warehouses for storing primary substances, packaging materials, technical items and finished products.

      The primary substances warehouse has separate sections for inflammable substances, capsule shells, active components and cold room for storing substances with various storing conditions.

      All items in our warehouses are transferred by advanced lift - trucks, side - trucks and palette trucks with electrically powered engines with a considerable maneuverability, and the existing space is sufficient to contain all needed items easily. The automatic fire extinguishing system of the warehouses give warning in case of fire and locates it precisely . The system breaks the connection of the fire location with neighboring spaces by automatically putting mobile walls between them.