operational plan for vitex nutrition ltd....
TRANSCRIPT
Operational Plan
For
VITEX NUTRITION LTD.
September 2018
1. Summary
This operational plan addresses the on-site business in accordance with the Business Plan. The business will
start up and grow for the GMP compliant production of oral dosage products, plus packaging. Basic
elements (personnel, facility, equipment, process, quality system, GMP programs) are proposed in
detail.
Introduction of VITEX NUTRITION LTD (VITEX). (vision, mission)
2. Objectives and Strategies
2.1 Objectives /activities
VITEX is performing the following activities that are subject to Establishment/Site Licensing in Canada:
Fabricating of oral dosage (Vegan soft capsule, DR caps, (delayed release vegan hard capsule),
tablet, powder) NHP, dietary supplement and drugs
Packaging/Labelling (powder, bottle, blister) of oral dosage products
Importing and exporting of oral dosage products
2.2 Strategies
Initially, VITEX will produce product in accordance with the Vitex Business Plan. VITEX will
establish a quality system, submit regulatory licensing or certificates, pursue compliance
approval/recognition along with setting up of manufacturing for NHP supplement products.
Additionally, VITEX. will provide contract manufacturing and packaging service to the public, with
in-house process scale-up or improvements that are necessary. VITEX will also upgrade its quality
system and pursue licensing to cover drug product manufacturing/packaging business.
3. Personnel
VITEX’s team is made up of qualified individuals to be responsible for jobs that support the
corporate mission and objectives. On-going training will be held periodically to ensure occupational
safety, hygiene, GMP compliances and technical competence of the team.
3.1 Organizational Chart.
See attachment 1
3.2 Job description.
See attachment 1a
To start up, key personnel (e.g. encapsulation operator, QC associate, QA manager, packaging,
inspection technician) are required to establish the production lines, quality system and initiate
GMP programs.
4.Premises and Equipment
4.1 Canadian site
The proposed GMP manufacturing facility is a 35,000 sq. ft commercial building consisting of two floors. The facility is built with air-conditioning, supply of power (110v, 220v), water (city water) and waste disposal service. Additional utility requirements may include: HVAC, Pressure zoning, Purified water, Compressed air, Nitrogen gas, Vacuum system.
Proposed Details
Main Floor 25,000 sq. ft. Mezzanine 10,000 sq. ft. Total Area 35,000 sq. ft.
Value of building @ $300.00 sq. ft. $ 10,500,000
Down payment (25%) $ 2,600,000
3.72% 10-year term mortgage on $7,900,000 {30-year amortization} Principle & Interest (monthly) $ 37,306 Maintenance + taxes @ $3.65 sq./ft. $ 10,646
Monthly payment $ 47,952
NOTE: Building is custom built to GMP specifications to facilitate full manufacturing requirement.
4.2 Foreign sites
Foreign sites are pharmaceutical or nutraceutical firms that are qualified as per US or Canadian
GMP regulations. Foreign sites support manufacturing or packaging operations for the Canadian
site.
4.3 Process flow
A day-by-day production operation covering work order, production through to finished product
release is illustrated in a Process Flow Chart. See attachment 2.
4.4 Equipment list
Table 2 lists equipment needed for manufacturing, utility, or QC activities.
5 Production Process for oral dosages
5.2 Blending, granulation
5.3 Encapsulation
5.4 Tablet pressing
5.5 Coating
5.6 Packaging-bottle packaging
5.7 Supporting activities
6 Quality System
Based on the philosophy “Quality should be built into the product and testing alone cannot be relied on
to ensure product quality”, a quality system addresses the goal of providing a high-quality drug/NHP
product to patients and prescribers.
A quality system will be coupled with manufacturing process and product knowledge and risk
management practices, to ensure cGMP compliances and to guarantee the quality, safety, and efficacy of
products. A well- built quality system will reduce the number of (or prevent) recalls, returned or
salvaged products, and defective products entering the marketplace.
6.2 Quality unit
Quality unit is responsible for quality work, and generally divided into Quality Control (QC) and Quality
Assurance (QA) functions.
QC usually involves (1) assessing the suitability of incoming components, containers, closures, labeling,
in- process materials, and the finished products; (2) evaluating the performance of the manufacturing
process to ensure adherence to proper specifications and limits; and (3) determining the acceptability of
each batch for release.
QA primarily involves (1) review and approval of all procedures related to production and maintenance,
(2) review of associated records, and (3) auditing and performing/evaluating trend analyses.
Quality unit represents the authority to create, monitor, and implement a quality system. Such activities
do not substitute for, or preclude, the daily responsibility of manufacturing personnel to build quality
into the product.
6.3 Certifications, licensing, and compliances
Regulatory Affair (RA) and QA oversee the quality system and ensure its compliances with regulations.
Compliances status that will be represented by licensing, or certification granted by national authorities,
or by 3rd party inspecting institutes, including:
NHPD site licensing, ITC for GMP Compliance, Canada
NHPD product licensing, Natural Product Number (NPN),
Canada Drug Establishment License (DEL), Canada
Drug Identification Number (DIN), Canada
US Food and Drug Administration (FDA) oversees
current good manufacturing practices (cGMP) for
Foods as per requirements of 21 CFR Part 110
Supplements as per requirements of 21 CFR Part 111
Pharmaceuticals as per requirements of 21 CFR Part 211
The Natural Products Association (NPA) is a third-party
providing certification for FDA GMP requirements of 21
CFR Part 111
The National Sanitation Foundation (now NSF
International) is a third-party providing certification, e.g.
NSF supplement GMP registration program
Quality Assurance International (QAI) is a USDA-
accredited organic product certifying agency serving US
and Canada.
US Department of Agriculture (USDA) National Organic
Program issues organic labeling certifies organic products,
and claims
Islamic Society of North America (ISNA®) is a certifying
agency certifying foods, drinks that conform to the Halal in
Islam
Kosher certifies foods that conform to the regulations of
kashrut (Jewish dietary law).
SO (International Organization for Standardization) is a third-
party providing certification. ISO 9001:2008 sets out he
requirements of a quality management system
6.4 GMP programs
Good Manufacturing Practice (GMP) ensures that products are consistently produced and controlled to
the quality standards appropriate to their intended use and as required by the marketing authorization or
product specification.
Good Manufacturing Practice is concerned with both production and quality control. The basic
requirements of GMP are that:
All manufacturing processes are clearly defined, systematically reviewed in the
light of experience, and shown to be capable of consistently manufacturing medicinal
products of the required quality and complying with their specifications;
Critical steps of manufacturing processes and significant changes to the process are
validated;
All necessary facilities for GMP are provided including:
6.4.3.1 appropriately qualified and trained personnel;
6.4.3.2 adequate premises and space;
6.4.3.3 suitable equipment and services;
6.4.3.4 correct materials, containers, and labels;
6.4.3.5 approved procedures and instructions;
6.4.3.6 suitable storage and transport;
Instructions and procedures are written in an instructional form in clear and
unambiguous language, specifically applicable to the facilities provided;
Operators are trained to carry out procedures correctly;
Records are made, manually and/or by recording instruments, during manufacture
which demonstrate that all the steps required by the defined procedures and instructions
were in fact taken and that the quantity and quality of the product was as expected. Any
significant deviations are fully recorded and investigated;
Records of manufacture including distribution which enable the complete history of a
batch to be traced, are retained in a comprehensible and accessible form;
Distribution (wholesaling) of the products minimizes any risk to their quality;
A system is available to recall any batch of product, from sale or supply;
Complaints about marketed products are examined, the causes of quality
defects investigated, and appropriate measures taken in respect of the defective
products and to prevent re-occurrence.
The quality unit implements the following on-going programs to support/ensure GMP compliance.
GMP training
Pest control
Sanitation/hygiene
Preventive maintenance
Calibration
Change control
Change control is another well-known CGMP concept that focuses on managing change to prevent
unintended consequences. It regards creating a regulatory environment that encourages change towards
continual improvement that empowers effective activities (e.g., quality planning and control of revisions
to specifications, process parameters, procedures)
Validation
Documentation
Specification, standard operational procedures (SOP), batch production record (BPR) are basis for a
controlled, trackable documentation that support GMP requirements.
DIR review
Deviation requires timely investigation and review via a collaborative effort between initiator and the
quality unit.
CAPA
To follow up a DIR, corrective and preventive actions require planning, execution, and documentation.
Complaint, Return, Recall
Quality of a product should cover its life cycle from manufacture to expiry date. Client’s complaint and
the subsequent return or recall of product challenges the quality system, and should be dealt with
internally, or as per regulation.
Stability
Authority/Contractor audit/inspection
Regulatory inspection/audit
Projects that implement operations
Project name Year 1 Year 2 Year 3
Site renovation ○ ○ ○
Recruiting personnel ○
Equipment ○ ○
Quality system ○ ○ ○ ○
Licensing ○ ○ ○ ○ ○ ○
Trial runs ○ ○
GMP programs ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Commercial runs ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Marketing/Sales ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
2
Diagram 5: EQUIPMENT PURCHASES
VANGUARD Tablet/Capsule Bottle Filling Line
Price
(60-90 Counts – 50-60 Bottles per min.) $US $CDN
VL 1000 (39”) Bottle Infeed Turntable 4,600
VSL-16 Automatic Counter and Filler (2 Heads) 79,600
VSZ-3 Automatic Desiccant Inserter 22,500
VSZ-2 Cotton Inserter 22,500
Bottle funnels for 3 different size 2,400
VSG-200 Automatic In-Line Capper 38,900
Cap feeding System 6,500
VFL-2000 Automatic Induction Sealer 12,800
VTP-200 Automatic Labeler 23,000
Foil Detection System/Rejection 1,750
VA 1000 Accumulating Turntable 4,500
Thermal Ribbon Printer 3,900
12 Meters Conveyor and Drivers Integration 15,000
Crating and Onsite setup and training 15,000
TOTAL 249,050
327,058
V-35 V BLENDER 35 cu ft 35,800
316 Upgrade Contact Parts 10,500
Stainless Steel Ladder 4,500
Wooden Crating 1,500
TOTAL 52,300
69,560
VANGUARD CAPSULE FILLING MACHINE
VAF 900C Auto Capsule Filler - 54,000/hr. 61,200
VAF-900C Change Parts (#1, #0, #00) 27,000
PCX-3 Capsule Polisher & Sorter (150,000 capsules per hour)
7,900
I-500 Inspection Machine with 60 L Volume Hopper 27,800
Set of Spare Parts 2,300
Crating and training (3 days) 3,050
TOTAL 129,250
172,330
LABORATORY EQUIPMENT 300,000
400,000
Sub Total (Phase 1) 730,600 974,109
VANGUARD TABLET PRESS
VRP-1124A Rotary tablet press 24 station (106,000 tablets per hour) 65,600
Stainless Steel Upgrade 2,000
Round shape tablet tooling (24 x 165) 3,960
Other shaped tablet tooling (24 x 295) 7,080
VSZ-800B Uphill Tablet Deduster 10,500
Industrial Dust Collector 6,900
Crating and Training (3 days) 3,050
TOTAL 99,090 132,087
FILM COATING
VSB-150E Film Coating System w/Siemens Touch Screen control 115,900
Electrical Heating Integration 6,000
Three Head Coating Solution Pump System 3,700
Swing Arm Touch Screen Control 3,700
Solution Mixing Tank (Heated Jacket & Mixer Mounted) 5,700
Wooden Crating & 2 Tech onsite set-up & training (5 days) 15,000
TOTAL 150,000 200,000
IR520 CHILSONATOR FULL SYSTEM WITH RECYCLE 483,550
OPTIONS 56,405
Crating 4,685
Setup & Training (5 days) 7,800
TOTAL 552,244 736,568
Sub Total (phase 2) 801,133 1,068,443
TOTAL (Phase 1 & 2)
1,531,733
2,042,301
Examples of production equipment (not necessarily the exact ones Vitex will use)
150 kg aqueous film coating machine
V Blender
Capsule filling machine
Tablet pressing machine
Chilsonator roll compacting machine
ER-Kang StarchGel™
First to market with Non-GMO products
100% Vegetarian Source from cassava root; Halal and Kosher certified; No risk of animal-
transmitted diseases.
No cross-linking reaction
Tapioca is stable and has no cross-linking reaction with filled material.
Better thermal stability
Non-sticky/ Minimum deformation/Global shipping.
Good at 50 ℃ and RH 75% for 19 hours.
Quick response & full on-site production support
We are always there to deliver fast service and offer on-site technical support to our clients
global wide.
StarchGel™ is a revolutionary product developed by Er-Kang Pharmaceutical through a
significant technical breakthrough in starch film forming process. This vege-based durable
softgel brings your products to a new level by offering the above advantages.
Proposed building details.
Main Floor 25,000 sq. ft. Mezzanine 10,000 sq. ft. Total Area 35,000 sq. ft.
Value of building @ $300.00 sq. ft. $ 10,500,000
Down payment (25%) $ 2,600,000
3.72% 10-year term mortgage on $7,900,000 {30-year amortization} Principle & Interest (monthly) $ 36,434 Maintenance + taxes @ $3.65 sq. ft. $ 10,646 Monthly payment $ 47,080 Lease: Long term lease rate @ 1.00 / sq. ft. per month $ 35,300 Maintenance + taxes @ $3.65 sq. ft. $ 10,646 Monthly payment $ 45,946
NOTE: Building is custom built to GMP specifications to facilitate full manufacturing requirement.