Contract ManufacturingYour product in safe hands

Drying.

Spray Granulation.

Agglomeration.

Instantization.

Coating.

Blending.

Co-Packing.

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Your product in professional hands. Economical solutions in excellent quality.

Foreword

Since production started, SternMaid has grown

to become one of Europe’s leading contract

manufacturers. In nine construction phases,

earnings have been continuously reinvested,

capacities enlarged and the latest technologies

acquired. Our key competence is customized

production of food supplements and premixes

for further processing in the food industry.

SternMaid’s management team:Torsten Wywiol (left), Mark Riemer (right)

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Food supplements

• Dietetic drinks • Dietetic soups• Protein preparations• Dry beverage bases• Products for athletes• Base powder

Premixes for• Bakery mixes• Bakery products• Snacks• Dairy products• Deli foods• Beverages• Sweets

Special applications• Microencapsulated

products• Agglomerated products • Instantized products • Granulated products • Coated products

In the contract manufacturing sector we carry out the following processes:

• Drying • Spray granulation • Blending • Agglomeration • Instantization • Coating • Grinding • Fractionation • Co-packing

We can offer you the

whole service chain.

Or just the components

you need. To outsource part of the production chain is a ma or decision for any company. SternMaid is aware of this and helps with the decision- making process. We do everything possible to ustify

the confidence our custom-ers place in us with greater quality, care and safety. So cooperation with Stern-Maid will ensure you flexible and reliable production now and in the future.

Pharmaceuticals

• Excipients

The SternMaid Service Chain

Help in developing new products

Help in procuring raw materials

Compounding and processing

Quality assurance and quality control

Filling or refilling of large containers

Filling of retail packs

Warehousing, logistics and

delivery

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SternMaid sets standards in blending. Consistent quality – from 1000 kg to 500 tonnes.

Blending

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Counter-current blending unit

Checking the results of cleaning

Over the years, SternMaid has acquired an excel-

lent name for itself in compounding substances in

powder form. With passion, skill and state-of-the-

art technology we meet even the most demanding

challenges.

Plant configuration as

required by the product Four flexible blending units are available for small orders, and large orders are carried out e ciently on four further, fully automated blending lines. For highly sensitive applications we also have a counter-current container blending unit designed to pharmaceutical standards, installed in a completely separate and independent part of the plant.

Flexible production of

medium-size orders Orders between 1,000 and 10,000 kg are carried out on the four semi-automated production lines. Besides the usual blending quality of up to 1:100,000, these lines permit fast setup times and flexible filling of containers such as sacks, fibreboard boxes, drums, FIBCs etc.

Efficient compounding

of large quantities On four other fully automated production lines operated by means of a central process control and visual display system we blend formulations of many di erent kinds. As many as 15 di erent raw materials can be weighed and fed in automatically. It goes without saying that an unbroken chain of docu-mentation is ust as impor-tant as adherence to formulations and safe and reliable processing.

Pharmaceutical

and other sensitive

applications The counter-current container blending unit installed in a separate part of the plant is qualified according to Part II of the EU GMP Guide. The wet cleaning process is certified. An o cial GMP certificate has been issued for both. The free-fall method is the most gentle blending procedure and can be intensified with a cutter head if necessary. This o ers ideal conditions for sensitive applications and

special requirements such as blends of pharmaceutical active ingredients and excipients, allergen-free products, premixes for baby food and micronutrients. All the steps in the process such as delivery of the raw materials, depalletizing, weighing, feeding, blending, filling and palletizing take place in separate rooms designed for wet cleaning and exact separation of batches.

Dosing of liquid

substances On all the lines, liquid components can be applied to the powder homogeneously by means of special nozzles. Microcomponents such as flavourings, oils, emulsifiers etc. can be distributed as extremely fine droplets through these atomizing spray nozzles. Large percent-ages of fats and highly viscous liquids can be worked in too.

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Blending

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For solutions, emulsions, suspensions or pastes: make use of our special plant for liquids.Different types of plant are available, depending on the task in hand.

We can fill quantities ranging from 100 to 1,000 litres into bottles, cans or IBCs.

Facts about powder blending technology

• Batch-by-batch documentation of setpoint/actual values in weighing • Computer-aided, operator-controlled hand weighing system for micro-ingredients and raw materials not capable of automatic conveyance • All blending units with cutter heads • Extremely fine, homogeneous distribution of ingredients under gentle production conditions. Blending accuracy as high as 1:100,000 • Possibility of working in liquid substances through special nozzles as 0.01 to 60 of the formulation • 4 blending lines for quantities from 1,000 to 10,000 kg • 4 blending lines for quantities from 1,000 to 10,000 kg • Feeding and processing technology with the latest process control and visual display systems • 4 fully automated blending lines for orders over 10,000 kg, with automatic feeding of the mixers within very narrow tolerances or even accurate to the gram. • 1 GMP-certified counter-current container blending line for extremely sensitive applications

Blending plant for oily

or aqueous solutions A unit with a batch size of 800 litres is available for oily or aqueous solutions. A propeller or cup mixer is used.

Blending plant for stable

viscous solutions This plant has a heated outside tank with a mixer

which can be filled from a road tanker. Powdered raw materials can be worked in homogeneously with an

tron system. Suspensions are made up e ciently without the inclusion of air. Heated processing and filling containers are fitted with mixers to permit the addition of further liquid components.

Qualified blending plant for

sophisticated products This area is qualified in accordance with Part II of the EU GMP Guide/ICH . The 1,500-litre mixing vessel can be heated to a tempera-ture of 90 C. For special blending applications a et mixer is used. Solids are worked in gently by means of an anchor agitator.

High-pressure homo-

genizer for stable

emulsions This plant is used for processing oils and also high-melting fats. With the two-stage homogenizer, O/W and W/O emulsions can be produced at up to 350 bar pressure.

Cutter heads All the blending lines are frequency-controlled and make up their products gently in short mixing times. For more intensive mixing or rubbing, cutter heads are available which can also be used for working in liquids or dissolving any lumps.

Batch sizes from

50 to 4,000 litres Whatever the size of your order, you are always in good hands with SternMaid. We make up batch sizes from 50 to 4,000 litres that corresponds on average to 25 to 2,000 kg. For premixes and trial blends, too, we have ust the right techno-logy and the necessary know-how.

Breaking up and

grinding Product mixtures with an uneven consistency can be broken up and homogenized with the hammer and knife mills. The rotor can be reversed so that the prod-ucts can be reduced in size either by the hammers (impact side) or by the knives (cutting side). The mill is especially suitable for crushing hard, crystalline or fibrous products and for applications in which a fine grain ( 200 m) is essential.

Filling or refilling

products Fibreboard boxes, sacks, drums or FIBCs: we will fill your product ust as you wish, whether o the production line or as an order for refilling alone.

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Fluid-Bed Processor

Fluid-bed technology opens up new perspectives for your products.Soluble, free-flowing, dust-free, tablettable, masked, or with protection for the active

ingredient: we will design your powdered or granulated product and solve your problem.

Competence and

technology Our customers benefit by the competence in process technology we have demon-strated for years in all manner of di erent applications. Our experts help to develop production processes for new or modified formula-tions. With our pilot fluid-bed processor we will make up trial quantities and subse-quently prepare the product step by step for full-scale production, in consultation with you.

Uniform drying with

customized properties Process-air temperatures from 20 to 130 C permit flexible ad ustment of the

drying conditions to the requirements of the product, e.g. gentle drying of enzymes or microorganisms.

Fluid-bed processor • Drying, agglomerating,

instantizing, coating• Gentle process for

thermosensitive products• Continuous or batch

operation• Evaporation capacity

500 l/h• Process air temperatures

from 20 to 130 C• Operating volume 300

to 1,600 litres• Premises and equipment

qualified prospectively according to Part II of the EU GMP Guide/ICH

Pilot plant • Process and product

development in the technical trials department

• Upscaling• Evaporation capacity

up to 5 l/h• Operating volume 2.5

to 10 litres

Multifunctional fluid bed processor

In coating, a layer or film is applied to existing particles (e.g. salts, granulates)

• Production of the layer, e.g. from melted fats or substances dissolved in water

• Inertization of the surface, e.g. to mask a taste• Functional surfaces protect the core, e.g. against moisture,

acids (gastric uices) or oxidation, and permit controlled release of the active ingredients (retarded delivery)

• Application of varnishes or colours to design the surface

Coating

100 % CoatingLayering

Spraying Coating Solidifying Protected particle

Powder particles

Agglomeration

Powder particles Liquid bridge “Blackberry” structure

In drying/spray granulation, liquids are dried to form powders or granulates

• Very good dispersibility in liquids• Very good free-flowing properties• No separation of the individual components• Very little fine dust• Narrow range of particle sizes • High bulk density

Spray granulation

“Onion” StructureLayer build-up

Spraying Growing Drying Granulate

Powder particles

In agglomeration, fine powder particles are bonded together with a liquid to form larger particles

• Instantizing of powders• Better flow properties• Less tendency to separate• Smaller proportion of fine dust• Better tablet formation• Low bulk density

Spraying Bonding Drying Agglomerate

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Co-Packing

1110 111111

Filling of large containers• Sacks• Fibreboard boxes• Drums• FIBCs• Cans• IBCs

Filling and refilling of large containers. Flexible, clean, and on time. SternMaid can carry out different orders for filling or

refilling quickly and simply. We fill products into large

containers exactly according to your specifications.

Sacks, fi breboard boxes, drums, FIBCs or a silo: we can transfer products from any initial container into any other, ust as you wish. And naturally we will meet your deadline as well as adhering to quality and safety criteria such as sifting and metal detection.

Attractive and efficient – filling of retail packs.Our small-pack lines fill cans and tubs, Doypacks, tubular and block-bottom

bags and folding boxes in sizes from 50 to 5,000 g.

Filling small packs• Cans and tubs• Doypacks• Tubular and

block-bottom bags• Folding boxes

An attractive pack is an important criterion for the success of any product. The pack must be eye-catching and assert itself against

similar products in the trade. But it is ust as important for the packaging process to be cost-e ective. If you don t fi nd the type and size of

pack you are looking for on these pages, ust let us know. We are constantly adding new types of packaging to our range.

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You will find our current certificates in the download centre of the SternMaid website.

www.sternmaid.com

Quality Control

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Life science or foods – leading manufacturers confirm that where quality is concerned we make no compromises.Today’s safety requirements in the life science sector and the food industry

are stricter than ever before: even the smallest omissions may have immense

consequences for a company’s reputation. We are aware of this responsibility

and take every precaution in order to ensure you the greatest possible safety.

Quality assurance and

quality control There is no way quality can be tested into a product or service quality has to be lived. All our employees keep this fact in mind, led and supervised centrally under our quality manage-ment system.

The measures include documentation according to stringent A criteria, regular auditing and em-ployee training. In this way we ensure that all products leaving our factory are in top condition.

We meet the growing demands of food safety and quality with Standard FSCC (Food Safety System Certification), recognized by the GFSI and valid worldwide.

Whatever the require-

ments: we meet them. SternMaid meets the latest requirements in the field of allergen management and kosher, halal or organic standards as well as complying with the current regulations on hygiene and food safety. Our production areas are air-conditioned and can only be entered through a hygiene air lock.

But however high our safety standards may be, we make constant e orts to improve them. When new require-ments come into force, we make no compromises: we invest in technology that conforms to the new standards. That is part of our service strategy. And service is something we take very seriously.

The standard is made up of DIN EN ISO 22000, ISO/TS 22002-1 and thus combines the advantages of a manage-ment system and a food safety system.

Certifications/standards

• FSSC 22000 (Food Safety System Certification)

• Certification according to Part II of the EU GMP Guide

• Allergen management• Kosher and halal management• “Bio” seal for organic products

Quality assurance measures

• Automatic standard control sifting from 0.5 to 5 mm, depending on the product attributes

• Metal detection• Easy-to-clean plant ensuring

maximum quality and flexibility• An unbroken chain of

documentation• eliable traceability of batches

of raw materials and packaging• egular employee training

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Raw Materials ServiceWarehousing/Logistics

Food

Denny WergerPhone: + 49 (0)3 88 52 / 666-508dwerger sternmaid.de

Pharmaceuticals/Food supplements Frank HellerungPhone: + 49 (0)3 88 52 / 666-501fhellerung sternmaid.de

Your Contacts:

We will be pleased to take on your warehousing and logistics.

Use our knowledge of raw materials to achieve first-class results.

Potential savings in

costs and CO2 Whatever we process for you can also be stored with us. In times of cost pressure and the need to reduce CO2

emissions, thought should be given to every consign-ment of goods. That is why we have enlarged our warehouse capacity to accommodate 20,000 pallets. Many of our customers supply their own customers directly from our warehouse.

Level of quality and

service All goods are stored in pallet racks without direct contact with the floor. Besides the usual separation of packag-ing materials, raw materials and finished products we

Comprehensive range

of raw materials and

packaging SternMaid has about 800 di erent raw materials permanently in stock. This may well lead to synergisms in purchasing, so that we can o er you these raw materials on favourable terms. But we will also be pleased to buy

Learn what your individual production system could be like with SternMaid

• Which components of our service chain would you like to use

• How would our range of services fit neatly into your production system

• Are you interested in short-term production capacity• Do you need regular help

We are looking forward to hearing from you.

have further zoning systems that take allergens, tempera-ture specifications etc. into account. Of course our monitoring system for pests includes the warehouse too, with non-toxic mouse boxes, pheromone traps and UV light traps. By means of pallet barcodes and WLAN scanning of all pallet movements we can tell at any time where each individual pallet is. The final scan takes place on the outgoing goods ramp when the products enter the HGV. The delivery note can only be printed out if all the pallets making up the consignment have been recorded that excludes any risk of incorrect loading.

Temperature zones Well insulated halls ensure narrow temperature ranges which are recorded with data loggers. The 25 C mark is never exceeded, even in long periods of summer heat. For extremely sensitive goods there is a separate storage area with a temperature of 8 C and another area regulated to 18 C.

Logistics and customs

clearance Of course we can also take on the whole logistics chain to meet your requirements from choice of a forwarder through customs clearance to ust-in-time delivery to your customers. Whether the goods are to be shipped within Germany or world-

wide: our international experience enables us to o er almost any form of transportation and see to the relevant formalities. We have an open customs warehouse and take part in active processing.

Optional minimum stock

administration We o er our customers a minimum stock adminis-tration service at the warehouse. In this way we ensure that goods are reordered automatically if the quantity in stock falls below a certain level.

according to your specifica-tion and from your stated suppliers. This method simplifies the procedures within your company, since you only have to keep the finished product on your books. Naturally we will also be pleased to work with the raw materials supplied by you.

We also stock a compre-hensive range of neutral packaging materials in good quality. This is only an optional service too, of course, but it ensures trouble-free processing.

SternMaid: Contract Manufacturing Service

Come and see our modern production plant in Wittenburg!We are looking forward to a visit from you.

Errors and modifi cations are expressly reserved. Organic Control Number: DE-ÖKO-001

Year of establishment• 1996

Number of employees• 300

Location• Wittenburg (Mecklenburg-West Pomerania)• Direct connection to the A 24 motorway• No more than 1 hour by car from Hamburg

Business fi elds• Contract manufacturing of premixes, food ingredients, food supplements and active pharmaceutical ingredients and excipients• Co-packing

Range of services• Drying• Spray granulation• Blending• Agglomeration• Instantization• Coating• Grinding• Fractionating• Co-packing

Process technology• 4 fully automated, multifunctional blending lines• 4 semi-automated multifunctional blending lines• 1 qualifi ed counter-current container blending unit • 4 blending lines for liquids• 1 pilot fl uid-bed processor• 1 qualifi ed fl uid-bed processor• 2 grinding stations• 1 fractionation plant (tumbler screening tower with up to 3 decks)• Various packaging lines

Certifi cations / standards• FSSC 22000 (Food Safety System Certifi cation)• Certifi cation according to Part II of the EU GMP Guide• Allergen management• EU health mark for dairy products• Licence for the production of dietetic foods• “Bio” seal for organic products• Kosher and halal management

Filling of industrial packs• Sacks• Fibreboard boxes• FIBCs• Cans• IBCs

Filling of retail packs• Cans• Doypacks• Tubular and block-bottom bags• Folding boxes

Logistics • Barcode-controlled high-bay warehouse and wide aisle warehouse with space for 20,000 pallets• Computer-aided real-time recording of all movements of goods

Area of the site• 60,000 m²

Area of buildings • 20,000 m²

Production capacities• 50,000 tonnes p.a.

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Drying.

Spray Granulation.

Agglomeration.

Instantization.

Coating.

Blending.

Co-Packing.

SternMaid GmbH & Co. KG Am Mühlenberg 419243 Wittenburg, GermanyPhone: + 49 (0) 3 88 52 / 666-60 Fax: + 49 (0) 3 88 52 / 666-66info@sternmaid.comwww.sternmaid.com