Manufacturing

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Manufacturing

This facility has a commercial capacity of 3 billion units. Our FDF business moves us forward on our vision to become a leading player in offering integrated solutions to the global market.

Our Dosage Productions

Oral solid dosage forms

Tablets
1800 million tablets per annum

Capsules

450 million Hard Gelatin capsules per annum
300 million Soft Gelatin capsules per annum

Oral liquid dosage

Clear Liquids & Suspensions
30 million bottles per annum

Ointments and creams

30 million tubes per annum,
size range up to 20 gm

Injectables

15 million vials per annum
30 million ampoules per annum

Infrastructure

Esjay Pharma India, with its state-of-the-art Pharmaceutical facility, is unique and one of such kind in India. The Advanced Facility possesses comprehensive dosage forms for the US, EU and Sime-regulated Markets under one modern facilitated roof. Covering 21,030 square meters, our Manufacturing facility comprises dedicated sections, including efficient Production, precise Quality Control, cutting-edge R&D, and specialised Microbiology Areas. Each space is meticulously crafted to uphold our pharmaceutical excellence standards.

With precision engineering at its core, our facility features 68 installed AHUs, ensuring controlled area segregation for all dosage forms and zero cross-contamination. With a 400 KL total water storage capacity, loop system, and stringent pipeline standards like stainless steel construction, electro-polishing, and boroscopy-tested joints, water quality is paramount. Purified water circulates at room temperature, while water for injection is closely maintained at 80°C. Our commitment to quality shines through in every detail, including zero dead leg valves at all user points.

Salient Features

  • Rapid Speed & High Capacity Machinery
  • PLC control and Data Loggers in place
  • Automatic Machinery
  • Box in Box Type design
  • Material Handling within a Sealed System with Localized Dust Extraction
  • All the Equipment has a CIP (Clean in Place) system
  • Less Labor intensive
  • Machinery is 21 CFR compliant
  • Installed BMS-controlled System for Temperature, Humidity, Pressure differential and Access Control

Zoning & Prevention Measures For Cross Contamination

  • Closed Material Handling in OSDs
  • Access Control System in place in the production area
  • CIP (Clean in Place) system implemented and local dust extraction
  • Charging of materials in Ointments, Creams, Liquids and Injectable
  • Terminal HEPA filters (99.97% efficiency) and low-level return ducts in operational areas
  • The pressure differential between the rooms and corridor is maintained
  • Wash areas for granulation are attached to the granulation area
  • Limiting movement of Dust-Laden Equipment & accessories in the corridor
  • Proper GMP Primary and Secondary gowning procedures
  • Customized AHUs ensure precise air changes, avoiding cross-contamination risks
  • Unidirectional flow of Men and Material
  • Proper segregation of the Area and zoning concept in place