MG2 in India: one billion capsules per year, no problems

18.12.2013

Over the last two years MG2, world leader in the design and marketing of dosing machines for hard shell capsules and end-of-line solutions, has deeply strengthened its presence on the Indian market,  also thanks to the successful cooperation with Zydus Cadila.

Over the last two years MG2, world leader in the design and marketing of dosing machines for hard shell capsules and end-of-line solutions, has deeply strengthened its presence on the Indian market,  also thanks to the successful cooperation with Zydus Cadila, an important organization taking care of research, production and marketing of pharmaceuticals, even in outsourcing.

It is a story of great success, that  between Zydus Cadila and MG2, which brought many advantages to both companies. The first one, an innovative pharmaceutical organization which operates at a global level, has found a partner able to perfectly meet its requirements in manufacturing huge quantities of capsules, and today it entrusts part of its production to two capsule fillers mod. G250 equipped with in-process NETT weight control system. For the Bolognese company, the partnership with the Indian firm has become the “bridgehead” for an important expansion on the local market, which is  strongly rising. In fact, India hosts many contractors and branches of multinational Companies, which dislocated their production sites on this area. Actually, they are companies which invest and export to more developed countries, such as the United States. As for Zydus Cadila, almost 40% of its turnover comes from these areas. That is why it is very important to get good manufacturing quality.

Big production batches or flexibility

From a technological point of view, the Indian market mostly requires two kinds of solutions. The first one prefers big production batches and requires very performing machines, often mono-product. In the second case, the production capability is a secondary issue, while it is very important to have a high flexibility level. For example, the active principle is often delivered as micro-tablets, which are combined in different quantities inside the capsule, in order to get different dosages. The wide range of solutions offered by MG2 allows to satisfy both requirements, but in this specific case Zydus Cadila needed to have machines suitable to handle high production volumes. We are talking of an estimated production of one billion capsules per year. In order to face these volumes, the best solution for Cadila was to get  two G250 capsule fillers equipped with in-process NET weight control system.

The technical solution

G250 continuous motion capsule filler is a high performance machine, suitable to reach a production speed of 200.000 capsules/hour, the ideal solution for medium and high productions. The machine can dose different kinds of products such as powders, pellets, microtablets, tablets and low dosages of powder even without compaction, as in the case of powders used in medical devices for the treatment of asthma. G250 can carry out different dosing combinations inside the same capsule (ranging from size 000 to 5,  including tamper-proof capsules), moreover it can be fitted with some accessory devices, such as product loader, empty capsule feeder and selector, to work without the assistance of operators.

G250 as well can be equipped with SWC, Pre-weight and NETT weight control systems, such as the one installed on Zydus Cadila’s machines. The NETT system, which is covered by an MG2 patent, has gained the market approval as the most reliable solution to check in-process the net weight of each capsule; this system is constantly supported and updated by the engineering team of the Bolognese company. MG2 after sales service is another point of strength which Zydus Cadila appreciated; the service is not only focused on the assistance, maintenance and eventual upgrade of the machines installed, but it follows the customer onwards, with periodic visits of skilled technicians, both Italian and Indian. In this way, operators working on the machine are always trained and updated and it is possible to schedule the production activities.