Ointment Preparation Plant

The Ointment Manufacturing Plant by Gansons is meticulously engineered to serve the pharmaceutical and cosmetic industries, supporting the production of a wide range of products, including ointments, creams, lotions, and toothpaste. The facility is designed with a strong emphasis on minimizing manual handling and maintaining consistent vacuum levels during mixing and blending, ensuring superior product quality.

Operational Efficiency

Closed-Circuit Processing: Wax and water phases are heated and vacuum-transferred through a conical filter into the manufacturing vessel to ensure a sterile, contained environment.
Automated Emulsification & Transfer: An integrated Ointment Transfer Pump handles both product recirculation during emulsion and final discharge into the storage vessel.
Optimized Resource Management: The streamlined system allows for single-operator control, significantly improving manpower utilization and lowering operational costs.

Compliance and Quality Assurance

The Gansons Ointment Manufacturing Plant adheres to Current Good Manufacturing Practices (cGMP), featuring paint-free construction and high-quality materials. All contact parts are made of stainless steel (SS 304), with SS 316 available upon request. The plant includes features such as:

Compliance and Quality Assurance

The Process

The Gansons Ointment Manufacturing Plant operates as a closed circuit manufacturing facility, ensuring efficient and hygienic production of ointments and creams. Below is a structured breakdown of the system’s key components and processes.

Feeding of Wax/Water Phase

Materials Used: Wax and water.
Temperature Control: Both wax and water are heated to the required temperature before transfer.

Transfer to Manufacturing Vessel

Method: The heated wax and water are transferred to the Manufacturing Vessel or Planetary Mixer.
Vacuum Transfer: This transfer is achieved through a vacuum system using a conical filter, ensuring contamination-free movement of materials.

Storage Vessel Operations

Fixed Position: The Storage Vessel remains fixed in place after filling.
Connection to Filling Area: It is connected to the Ointment Transfer Pump for further processing.
Transfer to Filling Machine: The pump transfers the ointment from the Storage Vessel to the hopper of the Ointment Filling Machine.

Emulsion Formation

Recirculation: During the emulsion formation process, the product is recirculated through the Ointment Transfer Pump.
Discharge: The pump also discharges the emulsified product into the Storage Vessel.

Automation and Control

Gansons equipment is available with an integrated intelligent automation platform. Key features include:

PLC/SCADA-based control with touch-screen HMI
Centralised recipe management with role-based access control
IoT enabled for remote monitoring and pre-emptive analytics
Integrable with any site architecture including MES, ERP, and LIMS
Customised reporting and smart graphs for lot reproducibility
Industry-leading IPC processors for fast, reliable control performance
21 CFR Part 11 compliant automation available as an add-on for regulated pharmaceutical facilities
GAMP 5-aligned computerised system validation documentation supplied with 21 CFR Part 11 configurations

Installed in facilities regulated by US-FDA, UK-MHRA, EMA, WHO-GMP, Japan-PMDA, TGA, SAHPRA, MCC, and health authorities in 40+ countries. CE, UL, ATEX, ISO, and IEC configurations available on request.