An Oral Liquid Manufacturing Plant is a specialized facility used in the pharmaceutical, nutraceutical, cosmetics, and food industries to produce liquid dosage forms such as syrups, suspensions, elixirs, oral drops, expectorants, and antacid solutions. These plants are designed to ensure high-quality output by minimizing manual handling of liquids, maintaining strict cleanliness, and complying with international standards like cGMP, WHO, USFDA, and MHRA guidelines.
These plants address two critical factors affecting product quality: effective control over sugar and water processing, and seamless integration of mixing, filtration, and transfer processes. They often incorporate automation features like SCADA systems for monitoring temperature, pressure, agitation speed, and levels, reducing human error and enhancing efficiency.
Oral Liquid Manufacturing Plant Video
Key Components of an Oral Liquid Manufacturing Plant
A typical plant consists of interconnected vessels and equipment for a streamlined workflow. Here’s a breakdown:
1. Sugar Melting Vessel:
- Jacketed cylindrical tank with torispherical ends and a propeller-type stirrer. Made from SS316L material for corrosion resistance.
- Dissolves sugar in water using steam/electric heating. Handles initial syrup preparation.
2. Pre-Filtration Unit (Sugar Filter):
- Small tank with mesh or basket filter, often inline between sugar vessel and main manufacturing vessel.
- Filters undissolved particles from sugar syrup to ensure clarity and prevent contamination.
3. Manufacturing Vessel:
- Jacketed/limpet coil cylindrical vessel with torispherical ends, equipped with high-shear homogenizer, anchor agitator, or propeller stirrer. Variable speed for low- to high-viscosity liquids.
- Main mixing and homogenization of ingredients. Supports heating/cooling for uniform blending and lump reduction.
4. Storage Vessel:
- Jacketed tank with stirrer, similar to manufacturing vessel but for holding finished product.
- Stores filtered liquid temporarily before transfer to filling lines; maintains stability.
5. Transfer Pumps:
- Twin-lobe or centrifugal pumps.
- Vacuum-assisted or pump-driven transfer of liquids to minimize exposure and manual handling.
6. Inter-Connecting Pipeline & Work Platform:
- SS304/316 piping with sanitary fittings, valves, and a raised platform for operators.
- Facilitates sterile transfer; platform aids access and cleaning.
7. Optional Add-Ons
- CIP/SIP (Clean-in-Place/Sterilize-in-Place) systems, vacuum loading for powders, SCADA automation panel.
- Ensures hygienic cleaning, automation, and integration with filling/packaging lines.
Manufacturing Process
The process follows a “three-tank” or integrated flow for efficiency and sterility:
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Sugar Syrup Preparation: Load sugar and water into the sugar melting vessel manually or via vacuum. Heat and agitate to dissolve sugar at controlled temperatures (e.g., 80-100°C). Filter through the pre-filter to remove impurities.
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Premixing and Main Manufacturing: Transfer filtered syrup to the manufacturing vessel. Add active ingredients, flavors, and excipients from a premix vessel. Use high-shear mixing/homogenization for uniform suspension or emulsion. Cool if needed via jacket circulation.
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Filtration and Transfer: Pass the mixture through a final basket or cartridge filter for clarity. Pump to the storage vessel under vacuum to avoid air incorporation.
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Filling and Packaging: Transfer from storage to filling lines (not always included in the core plant). The entire process ensures zero hold-up of unfiltered liquid, with single-pass filtration for time and cost savings.
The workflow is often automated, requiring only one operator and one helper, with features like reverse flow for complete recovery of samples—no scavenging needed.
Design and Components
We have made this plant to help you streamline your productions. So, we have integrated multiple components to boost the machine’s productivity. They include:
Sugar Syrup Vessel: This component is basically a melting vessel. Here, sugar and water can be mixed, heated, and prepared to form syrups.
Prefiltration Unit: The sugar syrup made in the vessel passes through an online prefilter. This helps remove impurities.
Manufacturing Vessel: This is where the main production happens. This vessel comes with agitators, which guarantee that the formula is properly mixed.
Storage Vessel: Once produced, the final product reaches this vessel, and then it either moves to the filling area (for smaller capacity) or stays as it is (for larger capacities).
Vacuum System: A vacuum system is integrated into the machine. It helps transfer sugar and sugar syrup and makes the process contamination-free. In larger models, this vacuum system helps transfer sugar directly from the storage area to the vessel.
Transfer Pumps: These pumps help transfer sugar syrup between various stages. This helps control the flow of the product through the manufacturing process.
Advanced Features and Functionality
Our oral liquid manufacturing plant has some advanced features. For instance, it employs a closed circuit system to prevent contamination and uphold product integrity. Next, we equipped the plant with an inline homogeniser or transfer pump. This component recirculates the sugar syrup to form emulsions precisely.
For temperature control, we have used limped coils. These coils can better control the temperature when mixing and producing syrups.
The agitator system also deserves attention. They are mounted at the bottom of the vessels. And that’s why it works differently from the traditional side or top-mounted agitators.
The entire plant is constructed adhering to the cGMP standards. We have built all vessels from stainless steel. Plus, we have incorporated food-grade silicon gaskets to keep the contact paths crevice-free and stabilisable.
Efficiency and Automation
These manufacturing plants are automated. Plus, we have kept it user-friendly. All vacuum or transfer pumps handle material transfers. That way, we have eliminated the need for manual intervention.
Additionally, the system has a control panel. Your operators can keep an eye on it and take necessary actions when required. The mechanical aspects of the plant (propeller, agitators, transfer systems, etc.) are built to prevent wear and tear.
Customisation Capacity
Our oral liquid manufacturing plant comes in different capacities. They range from 50 – 50000 litres. So, you can use it for small-scale and large-scale production. Since the plant is customisable, you can tailor it according to your production needs. If you are looking for added efficiency, you can get it equipped with additional features like in-line emulsifiers.
The vessels can handle internal pressure of up to 1kg/sq. Cm. So, you can sterilise them and keep the entire production process contamination-free.
To book your unit, please drop us an enquiry.
* Power voltage can be adjusted as per customer’s domestic power voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.
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