MANUFACTURING PROCESS:

All the production held at Getz pharma is make- to -stock that is to say 99% of their
making. Whereas 1% is make -to -order for certain customized institutional orders like for
instance army orders which have special labeling/carton labeling requirements. The whole
production/manufacturing process at Getz may it be tablets, syrups or injections is based on
production plan which is eventually based on MPS. Master production schedule is made by the
supply department which is forwarded to the MATERIALS MANAGEMENT department .The
job of Material Management department is to arrange the raw material for the production
department well before the required time so that there are no delays in the manufacturing of the
product.
This plan is initially made during the plan stage. While planning production it is kept in
view what resources they have with them in order to produce and what type of raw material is
stored in warehouse so that according to that they make their production plan. Production plan is
made on weekly bases as well as monthly bases depending upon the availability of the resources,
which are required to make the required product.
Then S &O P meeting is held, which is represented by two parties one from supply side and the
other from demand side and production related decisions are made as per the plan.
Getz Pakistan is using BPCS system. This activity monitors the status of manufacturing
department including:

Tablet manufacturing

Syrups

Injectables

The MOs, which has been send to the manufacturing department for the finished product,
are at what stage and what batches are being manufactured on which machines.
As per this system, the system is programmed in such a way that only the multiples of
batch size can be produced and no random manufacturing can be done that is to say if the batch

size is 100 then 200 or 300 can be produced even if the requirement/demand is 125units. In order
to cater the demand of 125units, 200units products need to be manufactured which will later be
adjusted through the system in the coming months.

GETZ PAKISTAN TYPES OF PRODUCTS

TYPES OF PRODUCT:

Tablets

Liquids/Syrups/O.R.S

Injectables

Creams/Ointments

MAIN PRODUCTS

Multivitamins

Antibiotics

Anti Inflammatory

Cough and Cold

Haematincs

Anesthetics

Analgesics

Anti Arthritic

Antacid

Anti B.P.H

Anti Epileptic

STANDARD OPERATING PROCEDURES

Cleaning
Uniform

Carefully usage of instrument

TOLERANCE LEVEL
Currently +/-5% tolerance level is set but it can vary from product to product.

PROCESS FLOW (TABLETS)

GRANULATION

DRYING

MILLING

BLENDING

BOTTLENECK

COMPRESSION

COATING
In granulation stage the raw material is put under a process where solids are broken
down into small granules. Next is drying stage where these granules are kept on large trays and
passed through e certain temperature for specific period of time (varying as per the tablet).
Milling process where further REFINING of this dried material is done separately and is
converted into fine powder form follows this stage. Then comes blending stage where different
materials are mixed together and are then passed into the compression process where a certain
amount of pressure is given and the mixed material is given a tablet form (shape). Coating is the
last stage where the tablets are coated with sugar and dyes/ colors (HPMC and Methocyl) in

order to differentiate the tablets from other tablets available and to avoid bitter taste. The
bottlenecks in the production of tablets are compression and coating.

PROCESS FLOW (SYRUPS)

The processing of syrups is done in huge tanks, which are already filled with water (as per the
requirement/specifications). Raw materials and glucose are added in the tanks, certain material
are also dissolved separately in other small
tanks or large beakers etc and dissolved
solution is then added to the tanks along with
glucose etc. the solution is heated at a very
high temperature usually (varies as per
different syrups). The sample is then passed
QA for testing and once the tests are
approved the packaging of these syrups starts.

PACKAGING PROCESS (SYRUPS)

to

FILLING

SEALED

STERILIZED

LEAK TEST

RELEASED

PROCESS FLOW INJECTIBLES

The processing of injectables is done in beakers with a capacity of 50 liters. The materials
are mixed in that beaker in the form of a solution. If large amount of injectable is required then
large pressure vessel containers are used for mixing and making the solution. Keeping a PH
check and PH adjustments is the most important factor during this process. The filtration of the
solution should be 0.2 microns.

PROCESS FLOW (PEDIALYTE)

BOTTLE FEEDING & WASHING

SOLUTION
MANUFACTURING

FILLING
SEALING
Sterilization

LEAK TEST
CAPPING

SKILLETING & TROLLY TRANSFER

PACKAGING LINE
AUTO CALVE

UNCAPPED

LEAK TESTER
CAPPING

OPTICAL
LABELLING
SKILLETING & LSPC SEALING

BOTTLENECK