Batch Size
100 L to 10,000 L
Syrup & Liquid Oral Manufacturing Plant
Complete, GMP-compliant turnkey solutions for pharmaceutical syrups, suspensions, and oral liquids. Gem Pharma Machineries designs, manufactures, and integrates high-efficiency production lines — from sugar syrup preparation to bottle filling and labelling. Every system is built with SS316/SS304 contact parts, automated controls, and a compact footprint to maximise your yield and regulatory compliance.
Cough Syrups
Antacid Suspensions
Vitamin & Mineral syrup
Herbal Oil liquids
Paediatric Drops
Nutraceutical Food Syrup
Typical Syrup Manufacturing Process Flow
Sugar Syrup Preparation
Sugar charging system, transfer pump, and heating vessel with high-speed stirrer to dissolve sugar in DM water.
Syrup Filtration
Inline cartridge filtration (0.45/0.2 micron) or sparkler filter to remove undissolved particles. Pre-filter and polishing filter assembly.
Manufacturing & Storage
Jacketed manufacturing vessel with top/bottom entry agitator, active ingredient addition hopper, and recirculation loop. Intermediate storage tank with level sensors.
Filling & Capping
Volumetric piston/servo filling machine with 2 to 16 heads. Automatic screw capping or press-on cap system. Integrated gassing (nitrogen) if required.
Labelling & Packaging
Automatic sticker labeling machine, thermal inkjet coder, induction sealing (optional), and bottle collating for secondary packing.
Complete Equipment List (Turnkey Scope)
Our turnkey package includes everything you need to start production – from vessel to packed pallet. The exact specification is finalised after a thorough discussion of your product characteristics and desired output (bottles per minute).
Weighing & Charging
Pharma-grade platform balance / load cell system: Accuracy 0.1%, SS304 platform, digital indicator
Sugar feeding station with magnetic sieve: SS304 hopper, 1 mm mesh, 316 rare‑earth magnets
Syrup Preparation
Sugar melting vessel: Jacketed, SS316L, anchor agitator, 2–5 KL
Syrup transfer positive displacement pump: Lobe type, 316L, 3–15 m³/h, with VFD
Inline sparkler/cartridge filter housing: 5–20” x 5 cartridges, SS316, 0.45+0.2 µm
Manufacturing vessel (main preparation): Jacketed, dual agitation (paddle + high‑shear), 500–5000 L
Storage & Transfer
Product holding tank: Insulated, conical bottom, spray ball, level transmitter
Nitrogen blanketing system: Pressure reducing station, sterile filter, relief valve
Transfer panel with manifold valves: SS316L diaphragm valves, orbitally welded
Bottle Handling & Filling
Bottle unscrambler: Rotary, 30–150 bottles/min, with ionised air rinse
Air washing / rinsing tunnel: HEPA H13, 0.3 µm retention
Servo volumetric filling machine: 4–12 heads, 30–250 ml, ±0.25% accuracy
Laminar air flow unit (LAF): ISO 5, horizontal/vertical flow, covering fill zone
Automatic screw capping machine: Single or multi‑head, torque control
Sealing & Coding
Induction sealing machine: Water‑cooled, 2–8 kW, conveyor integrated
Sticker labelling machine: Wrap‑around, ±0.5 mm, with date coder
Thermal inkjet / laser coder: Inline, with vision verification system
Utilities & Controls
Clean‑in‑place (CIP) system: Single tank, SS316, heat exchanger, spray balls
Central control panel with PLC-HMI: Siemens S7‑1200/1500, WinCC, 21 CFR Part 11
Advanced Automation and Regulatory compliance
Every Gem Pharma syrup plant is built around a robust PLC‑HMI control architecture. The system offers:
Recipe Management: Store unlimited recipes with step‑by‑step production parameters (temperature, agitation speed, time, pH set‑points). One‑touch batch start.
Sequential Batch Control: Automated interlocks prevent valve mis‑routing; the PLC manages transfers, heating, cooling, and CIP cycles.
Data Acquisition & Reporting: Real‑time trend curves for temperature, pressure, and pH. Batch reports with electronic signatures, compliant with 21 CFR Part 11 and EU Annex 11.
Alarms & Safety: Alerts for filter blockage, high temperature, low product level, and pump faults. Password‑protected access levels (operator, supervisor, admin).
Remote Access: Ethernet/IP and OPC‑UA connectivity allow integration with your plant SCADA or remote diagnostics (optional and with customer approval).
Proven Performance
One of our recent installations for a leading paediatric cough syrup brand achieved:
Output: 120 bottles per minute (100 mL PET) using a 12‑head filler and 6‑head capper.
Filling Accuracy: 100 mL ± 0.2 mL, validated over a 500,000‑bottle run.
Product Yield: >99.5% after CIP recovery.
Regulatory: Successfully passed a US‑FDA pre‑approval inspection within 6 months of commissioning.
- Our engineering team can share more case studies during technical discussions, aligned with your product viscosity, bottle geometry, and speed requirement.
Compliance & certifications
GMP compliant
FDA 21 CFR Part 11
ISO 9001
EU GMP Annex 11
ATEX / FLP rated
Gamp5
Documentation
- User Requirement Specification (URS)
Functional Design Specification (FDS) & Hardware Design Specification (HDS)
Design Qualification (DQ), Factory Acceptance Test (FAT), Site Acceptance Test (SAT)
Installation Qualification (IQ), Operational Qualification (OQ), Performance Qualification (PQ) protocols
Standard Operating Procedures (SOPs) for operation and cleaning
Material certificates (EN 10204 3.1), weld inspection reports, surface finish certificates, and calibration certificates