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Design and Commissioning of a Nutraceuticals Manufacturing Plant in Indore, India

1.Challenge

An Indore-based e-commerce company, founded by a team of young and energetic management graduates, had built a successful nutraceuticals business selling on platforms like Amazon and Flipkart.

Their portfolio included over 250 SKUs, all sourced through third-party manufacturing.

With annual sales of approximately USD 6 million, they now aimed to bring production in-house to:

  • Gain control over quality, compliance, and timelines

  • Reduce long-term costs

  • Build a facility aligned with US GMP standards for future exports

  • Set up an integrated warehouse, packaging, and e-commerce dispatch center

Key challenges included:

  • Convincing first-time manufacturers to invest in a GMP-compliant plant

  • Designing a facility for multiple dosage forms and packaging formats

  • Educating owners on equipment, instruments, and compliance requirements

  • Recruiting and training technical and operational staff from scratch



2. Project Objectives

  • Design and commission a manufacturing facility compliant with FSSAI and US FDA guidelines

  • Enable in-house manufacturing of tablets, capsules, powders with packaging in bottles, sachets, and blisters

  • Create a well-organized warehouse and dispatch center to manage inventory and e-commerce packaging

  • Recruit and train a skilled workforce

  • Obtain statutory approvals to initiate commercial production

3. Our Approach

A. Facility Design & Space Optimization

  • Created URS (User Requirement Specification) and DQ (Design Qualification) documents

  • Calculated equipment capacity for each dosage form and aligned operations accordingly

  • Due to space constraints on the ground floor, a mezzanine level was designed to house QC labs and administrative offices

B. Equipment Selection & Installation

  • Guided procurement of Indian and imported manufacturing & packaging machines

  • Managed challenges related to installation and qualification of Chinese-sourced equipment

  • Ensured timely qualification of all systems and utilities

C. Manpower & Training

  • Recruited production, QA, and warehousing staff

  • Delivered detailed training on SOPs, GMP guidelines, and daily operational practices

4. Final Results

  • Facility construction and partitions completed in 6 months

  • Equipment installation, qualification, and utility setup completed by month 9

  • Received all statutory clearances within 12 months

  • Seamlessly transitioned 250+ SKUs to in-house production

  • Improved turnaround times, cost efficiency, and quality control

  • Fully compliant with FSSAI and aligned with future US GMP expectations

5. Key Learnings



  • Even compact projects demand deep technical planning and regulatory foresight

  • Effective coordination with HVAC, lighting, plumbing, and civil teams is essential for GMP compliance

  • Local FSSAI and FDA authorities were surprisingly cooperative, supporting faster approvals and local employment

  • The experience, though small in scale, broadened our expertise in nutraceutical regulations and operations

  • Most rewarding of all: the young client team was delighted with the quality, timeline, and readiness of the facility


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