Syrup Manufacturing Plant

A Syrup Manufacturing Plant is a specialized facility designed primarily for the pharmaceutical industry to produce oral liquids, such as cough syrups, antibiotic syrups, suspensions, and other liquid formulations. These plants ensure high-quality output by minimizing manual handling of liquids, maintaining strict hygiene standards, and complying with Good Manufacturing Practices (cGMP). They are engineered to handle key factors like sugar dissolution and water integration efficiently, often featuring automated or semi-automated systems for precision and scalability. Plants typically range in batch capacity from 10 liters (for lab/R&D scale) to 10,000 liters, making them versatile for small-scale testing or large-volume manufacturing.

Syrup Manufacturing Plant Video

Key Components of a Syrup Manufacturing Plant

These plants operate as closed-circuit systems to prevent contamination, integrating several interconnected units. Below is a table summarizing the core components and their functions:

• Sugar Syrup Vessel/Melting Tank: A jacketed, insulated tank with high-speed stirrers for dissolving sugar in heated water. Capacities vary; includes vacuum or mechanical loading for ingredients. Ensures uniform melting and prevents air incorporation.

• Prefiltration Unit: Filters the melted sugar syrup to remove impurities like undissolved particles. Often includes a transfer pump for seamless movement to the next stage. Tri-clover joints facilitate easy cleaning.

• Syrup Manufacturing/Mixing Vessel: Main processing tank with agitators for blending sugar solution with active ingredients. Supports homogenization for uniform suspensions; optional inline homogenizer for finer mixing.

• Storage Vessel: Insulated holding tank with gentle agitation to maintain product stability before filling. Keeps the syrup under controlled conditions for further processing or packaging.

• Transfer Pumps and Piping: Sanitary pumps and stainless steel pipelines with tri-clover connections for hygienic transfer between units. Supports vacuum or gravity feeding.

• Control Panel and Automation: Microprocessor-based PLC/HMI system for automated operation, monitoring temperature, speed, and flow. Optional for semi-auto models; ensures precise control and data logging for compliance.

Salient Features of Syrup Production Plant

• The Plant is designed to be operated only by one operator and one helper.

• All material transfer are done by vacuum or by transfer pumps.

• All the vessels are CGMP (paint free construction)

• The gaskets used are of silicon (food grade).

• All contact parts are of S.S. 304 quality material (SS316 provided on demand) & finished to class 4B (mirror) finish and are crevice free.

• The entry of stirrer & high speed emulsifier are from top. In – line Emulsifier (as per customer choice) provided on demand. (Optional)

• All vessels are suitable for internal pressure of 1 kg./sq. cm. and hence can be sterilized.

• All pipes, pipe fittings and valves are of SS304 / SS316 (as per customer requirement) seamless quality, internally electro polished, with tri-clover ended joints.

• The entire plant is equipped with CIP & SIP connections, so that customer can use these facility, if have CIP & SIP equipment.

• All values of temperature & time of the plant are indicated digitally on the control panel. Ampere indicates on Ampere meters.

• A micro processor based automatic operating plant can be designed as per requirement. (Optional)

• All the inlet & outlet connections are provided with tri clover joints, which are very easy for cleaning & replacement.

Process Operation of Syrup Manufacturing Plant

• This system consist of a closed circuit manufacturing facility feeding of Sugar/Water Phase to loading the Volumetric Liquid Filling Machine.

• The Sugar and Water, are load with vacuum system or by mechanical system or manually.

• The Sugar Syrup Vessel is supplied with high speed stirrer & electrical heating (In small model) / steam heating facility (in bigger size model). The sugar syrup is prepared at required temperature & are transferred to Manufacturing Vessel by vacuum or by transfer pump.

• The product during emulsion formation is recirculated through In-Line Homoginizer or Liquid Transfer Pump. (Optional Facility)

• The Pump also discharges the product in the Storage Vessel.

• The Storage Vessel is then taken to the filling area (if it is small capacity) and is connected to again Liquid Transfer pump. Or Storage Vessel remain fixed (in bigger size) & pump transfer the Liquids in the float tank which is connected with filling machine.

• The entire plant can be operated by centralized operating panel by one operator

• The plant is equipped with an electrical control panel with digital temperature indicators / controllers and digital timers.

• Minimum two batches per shift of the same product can be assured in this plant.

• This plant conforms to CGMP standards (paint free Construction).

Liquid Manufacturing Plant consist the following equipment’s and accessories:

1. Sugar syrup vessel
2. Filters press
3. Manufacturing vessel
4. Transfer pump
5. Storage vessel
6. Transfer pump
7. Piping to connect all above equipment’s.
8. Working platform.
9. Control panel

Optional Features of Syrup Manufacturing Plant

• Parts made of SS304/SS316/SS316L/as per customers’ requirements.

• Top entry or Bottom entry Stirrer & Emulsifier can be provided.

• Fittings and valves can be offered SS304 / SS316.

• CIP & SIP connections for cleaning after each batch with control from the Panel Board.

• Connections with tri clover joints for easy cleaning & replacement.

* 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.