Batch production is manufacturing a similar or identical product in individual controlled stages. Manufacturing in batches increases the number of quality control checkpoints to reduce waste and cost. It also provides greater production flexibility for final product modification.
Manufacturers use batch production to produce everything from packaged food to clothing to dietary supplements to automobile parts. Working in small batches improves efficiency and control of production over mass and continuous production models.
Batch Production in Dietary Supplement Manufacturing
Manufacturing dietary supplements in batches involve:
- Supplement Formula: The research and development team works with a client to formulate a supplement recipe.
- Testing: Laboratory identity and public safety consumption testing is conducted on all raw ingredients.
- Batching: Trained employees measure, sift, and join together individual ingredients according to the developed recipe.
- Mixing: The combined ingredients are mixed and blended in hoppers to produce a fully blended bulk powder.
- Adding Extras: At this point, the base powder can be divided to add different flavors or additional ingredients. And then blended again to obtain a uniform powder.
- Supplement Form: The powder mix is divided and shaped into the desired form for a single serving. Supplement forms include tablets, capsules, chewable tablets, powder, or a mix of options.
- Laboratory Testing: Extensive laboratory testing is conducted on individual supplement serving sizes to determine the supplement nutrition label and ingredients list as required by the Food and Drug Administration (FDA).
- Supplement Packaging: Depending on the supplement form, packaging options include bottling, sachets, stick packs, bulk tubs, single-serve pouches, or a mix of packaging options.
- Labeling: Packages are labeled with brand product design, nutritional facts label, ingredients list, appropriate certifications, and any other required information per FDA regulations.
- Group Packaging: Single serving packaged items can be further grouped into a box or bag packaging for convenient marketing.
Advantages of Batch Production of Dietary Supplements
Increased Quality Control: Batch production allows for precise quality control measures for each stage of product development.
Improved Accuracy: Working in batches improves the measuring accuracy of individual ingredients.
Flexible Sampling: Minuscule doses of micronutrients or sensitive ingredients contained in a supplement can clump together or get lost when blended with macronutrients. Batch Production allows the manufacturer to pre-blend these components and then sample at various times and hopper locations to determine optimal mixing time for uniform blending. This ensures the complete mixing of all ingredients to meet label claims for individual nutritional components.
Reduce Waste: With quality control measures in place at every step of batch production, problems in production are quickly identified and resolved. This prevents a bad batch from moving forward in the production process and reduces the amount of product wasted.
Efficient and Flexible Product Production: A supplement that contains the same nutritional ingredients, but comes in different flavors can be initially mixed together. The mixed batch is then divided according to the number of desired flavors. For each flavor, additional ingredients are added and then re-blended.
Fewer Risks: The ability to produce small batches decreases the monetary risk of developing new supplements to meet specific demands or niche markets.
Disadvantages of Batch Production of Dietary Supplements
Cost: Just like buying food items at the store, the per-cost unit is higher for smaller batches of supplements. Manufacturing larger batches of supplements is more cost-efficient per unit volume.
A Little Too Easy: Batch Production may make it too easy to modify or over-collect samples for quality control. These things may add cost without adding value to the final product.
Additional Cleaning: Smaller batches equates to more time spent cleaning production equipment to prevent contamination between batches.
Origin Nutraceutical is a full-service dietary supplement manufacturer located in Spanish Fork, Utah. We bring vast experience to help clients develop and manufacture high-quality supplements using batch production methods.
We operate in full compliance with the FDA’s current good manufacturing practices (GMP) with GMP certification from NSF International. We also maintain Organic, Kosher, and Halal Certification. (link 4 main types of quality certification article.)
Our Research and Development Team works closely with clients to formulate supplements and create tasty flavors. Our manufacturing teams are highly trained and efficient in batching, blending, forming, and packaging supplements.
We know developing, manufacturing, and packaging supplements is only half of the equation to put your supplement in consumers’ hands. Origin has developed partnerships with other companies to provide clients with the tools they need to efficiently get their product on the market.
Are you looking to start a supplement brand? Do you have an existing brand, but you have had problems with your supplement manufacturer? Contact Origin Nutraceutical today! And discover why our motto is “Customer Service is the Origin of Success.”
The content of Origin Nutraceutical’s website is for information only, not advice or guarantee of outcome. Information is gathered and shared from reputable sources; however, Origin Nutraceutical is not responsible for errors or omissions in reporting or explanation. No individuals, including those taking Origin Nutraceutical products, should use the information, resources, or tools contained within to self-diagnosis or self-treat any health-related condition. Origin Nutraceutical gives no assurance or warranty regarding the accuracy, timeliness, or applicability of the content.
Martin, Patrick. “Technologies to Improve Batch-Production Probability, Consistency, and Traceability.” PharmTech. 2007. https://www.pharmtech.com/view/technologies-improve-batch-production-profitability-consistency-and-traceability
Gemma. “Advantages and Disadvantages of Batch Production in Manufacturing.” LAC Conveyers and Automation. 2019. https://www.lacconveyors.co.uk/batch-production/
LaDoux, Mark. “The Proper Role of Pre-Blend of Nutrients in Production of Dietary Supplements.” Natural Product Insider. 2019. https://www.naturalproductsinsider.com/contract-manufacturing/proper-role-pre-blends-nutrients-production-dietary-supplements