Turn-Key Services

Technophar offers complete turnkey plant systems for both hard and soft gelatin capsule plants. Part of this turnkey program will include all the necessary auxiliary equipment which Technophar sources and supplies to the customer for Gelatin Preparation, Medicine Preparation, In-Process control, Inspection, Packaging, AC/Dehumidification, Purified water systems, etc. Part of this program includes our technical services which consists of the following:

PRELIMINARY FACTORY DESIGN

It is a collection of documents specifically developed for the project, presented in a manual containing construction and technological information necessary to the customer to finalize the Detail Factory Construction Design, using local architectural and engineering firms, familiar with the site building codes and requirements. This manual is to be provided to the customer not later than 5 to 6 weeks after the project was launched, internally, in Technophar. It includes:

Process description
Facility requirements
Equipment requirements
Raw materials requirements
Utilities requirements
Employees requirements
List of equipment
Electrical power chart
Building design guidelines with room finishes and door-window schedules
Drawings:
capsule plant equipment lay-out
building room lay-out
building typical cross sections
capsule plant utilities piping lay-out
capsule plant climate control requirements
capsule manufacturing product flow chart
capsule manufacturing employees flow chart
capsule machine lay-out
capsule machine trimming collecting system (hard)
gelatin melter lay-out
melter installation and utility hook-ups
melter platform lay-out
production area air-flow diagram
production area suggested ductwork lay-out
de-humidification diagram
de-humidification equipment lay-out
de-humidification equipment suggested ductwork lay-out
chiller lay-out
air conditioning equipment lay-out
air conditioning equipment suggested ductwork lay-out
chilled water system diagram
hot and cold water system diagram
steam system diagram
compressed air diagram

ENGINEERING SPECIFICATIONS

Technophar will assist the customer in the procurement of equipment that the client decided to purchase directly. In this respect Technophar will provide suggestions, recommendations and specifications related to this equipment. This information shall be forwarded to the customer along with the Preliminary Factory Design Manual. Technophar will provide the customer with a series of manuals containing information about the capsule plant equipment supplied by Technophar. The manuals will be shipped along with the equipment or, upon specific request by the customer, by courier prior to the equipment dispatch. The manuals will contain:

Equipment assembly drawings c/w dimensions and weights
Bills Of Materials (BOM)
Recommended spare parts
Technical specifications and performances
Utilities requirements
Installation instructions
Operation instructions
Maintenance instructions

INSPECTION OF EQUIPMENT

It shall be performed by Technophar qualified engineer/technician, upon receipt of the equipment by the customer. The purpose of this inspection is to establish if the equipment shown on the package lists has been received and whether or not the equipment was damaged during transit.

FINAL BUILDING INSPECTION

It shall be performed by Technophar qualified engineer/technician, upon receipt of notification from the client that the capsule manufacturing facility is ready for inspection. The purpose of this inspection is to determine whether or not the building is ready and suitable for the installation of the equipment supplied by Technophar. Focus will be on the following:

Building to be constructed according to the industry requirements and as per Technophar specifications
Air conditioning system
Technological utilities
Equipment positioning
Equipment storage

SUPERVISION AND TECHNICAL ASSISTANCE

It shall be performed by Technophar qualified engineers/technicians upon the equipment supplied by Technophar being installed, tested and started-up. The scope and extent of such assistance is to be defined in the Purchasing Agreement.

TRANSFER OF TECHNOLOGY

Manuals and documents supplied by Technophar enabling the customer employees to handle properly the process. They contain: instructions, procedures, formulas, etc.

TRAINING

It shall be performed by Technophar qualified engineers/technicians on the customer technicians, prior to the equipment installation and start-up. The scope and extent of such assistance is to be defined in the Purchasing Agreement. Typically this training takes place at Technophar's equipment manufacturing facility in Canada. It consists of:

Prior to equipment shipment, the buyer's technicians will visit Technophar facility for a period of one month. During this time they will be trained in the following areas: mechanical, electrical, maintenance, troubleshooting, adjusting, settings of the capsule machine. They will witness the actual disassembly for the shipment.
In addition, training on other equipment, not manufactured by Technophar, but supplied by Technophar may be arranged through the equipment manufacturer representatives.

ON SITE TRAINING

It shall be performed by Technophar qualified engineers/technicians, at the buyer's factory, during installation, start-up and production test run. The scope and extent of such assistance is to be defined in the Purchasing Agreement. It may consist of:

Upon arrival and positioning of the machinery and equipment in the buyer's capsule production facility, Technophar's team (typically 3 technicians: mechanical, electrical, production) will come to the plant to initiate capsule production and begin training for a period of 2 weeks by each technician; it is possible that the proposed schedule for the 3 technicians be carried over a period of a total of four weeks, with mechanical and electrical specialists starting on week 1 and ending on week 2 and production and quality specialists starting on week 3 and ending on week 4. Areas of training:
Recommendation and specifications for materials acquisition including: gelatin, dyes, opacifants, additives, shipping containers, etc.
Gelatin processing including mixing, blending, melting, formulae for various capsule colors, proper viscosity; preparation of various additives, preservatives, dyes and opacifants
Instructions in the operation of the environmental equipment and controls; this will include fine tuning and maintenance of optimum temperatures and precise humidity levels in the production spaces
Procedures in the proper operation of the gelatin melting system
Training program for proper operation of the capsule machine including: adjustments for various product specifications; knowledge of the PLC controls; procedures for changing sizes of capsules to be produced.
Quality control program to ensure that outgoing capsules meet international standards for color, moisture content, size, wall thickness, brittleness, and overall visual quality. This will include training in sorting, inspection, capsule printing and counting equipment. Also, recommendations will be made for proper storage and shipment.
Scrap recovery program (hard)
In addition to the program detailed above, Technophar personnel will train the buyer's staff in equipment troubleshooting and maintenance. This will include the following:
Instructions in determining diagnosis of capsule defects and training for quick and efficient rectification
Preventative maintenance for all equipment
Troubleshooting instructions to quickly finding out the source of problems with the equipment and enable quick correction
Normal maintenance
Lubrication
Procedures for proper cleaning of the equipment
Procedures for repairs

SPECIAL ON SITE SERVICES

On particular projects Technophar may be able to provide continuous technical assistance, on site, starting with the design of the building and continuing with the actual construction of the facility. The scope and extent of such assistance is to be defined in the Purchasing Agreement.