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Manufacturing

cGMP Manufacturing

We’ve made a very wide variety of Consumer Healthcare products in our state-of-the-art cGMP facilities over the years, so we probably have direct experience that is applicable to your project. And if we haven’t made something similar before, then great! Few things excite us more than tackling a challenge, and we solve problems that seem unsolvable at the time. 

Integrated Optimization

We offer cost-effective manufacturing from lab-scale up to full commercial production, whether your project is a completely new product or a reformulation to improve an existing line. If you are already selling your product, we can ensure that it is manufactured in the most thoroughly compliant and high-quality manner possible.

Packaging is seamlessly integrated into our production process, and we are ready to take on any challenge. We currently have the following capabilities:

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Processing Capabilities

Our full range of processing capabilities is supported by our leading-edge packaging technologies, which enable us to develop the optimal solution for your product’s application. No matter the complexity of your ingredients or intended scale of distribution, we will guide you down the path toward commercial success.

  • Flexible batch sizes
    (25 to 3,500-gallon scale)
  • High alcohol
  • High viscosity
  • Powder suspension
  • Gas emulsion
  • Foams
  • Aerosol sprays
  • Bag-on-valve
  • Cryogenic cooling systems
Container closure systems

Airless Container

  • Dispense product with minimized risk of air exposure or cross-contamination
  • Premium metered control ensures the same dose every time
  • Empower the user with greater control over product distribution
  • >99% product evacuation
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Airless Pump Bottle

Airless Pump

When repeatedly depressed, the pump creates a vacuum that draws product from the bottle, which is expressed through the pump's exit orifice.

Product

The base formula intended to be dispensed.

Plate

A disc that is drawn up and follows the product as it’s dispensed, allowing near-complete evacuation and preventing air from commingling with the formula.

Air Intake

A small hole in the bottom of the bottle that allows for air to pass as product is dispensed and the plate moves up.

CONTAINER CLOSURE SYSTEMS

Pressurized Containers: Aerosol

  • Create a more convenient application experience
  • Optimize formulations that would otherwise be difficult to apply
  • Gentle application for sensitive or irritated skin
  • Expanded breadth of formulation possibilities
  • Seamless application and even coverage
High Solids Powder Spray Platform: ZnOSprayTMLearn More
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Aerosol System

Can

Holds and preserves the pressurized contents of the package system.

Valve

Crimps to the can to effectively seal the pressurized system. When depressed, the valve opens a fluid channel to allow product to flow to the actuator.

Dip Tube

Creates a fluid channel for product to travel from the can to the valve assembly.

Actuator

When depressed, the actuator activates the valve, allowing for product to flow out of the pressurized package, often in a stream, mist or foam.

Formula Concentrate

The base product formula intended to be dispensed from the package.

Propellant

A volatile liquid or compressed gas that, upon actuation, exerts positive pressure on the package system to drive product through the dip tube, valve and actuator.

CONTAINER CLOSURE SYSTEMS

Pressurized Containers: Bag-on-Valve (BoV)

  • Dispense product in any direction
  • Maintain product integrity by preventing air exposure
  • Hydrocarbon propellant-free system
  • Suitable for both liquid and viscous products, including gels, creams and ointments
  • Optimal solution for sterile and oxygen-sensitive products
  • >99% product evacuation
  • Bag-on-valve manufacturing suite featuring 4 lines

Whipped Delivery Platform: eN2fusedTMLearn More Icewhipped Delivery Platform: cryO2fusedTMLearn More
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Pressurized Bag-on-Valve System

Bag-on-Valve

A multi-laminate foil bag is affixed to a valve system, which is crimped to the can to effectively seal the pressurized system. Product is filled through the valve into the bag, which expands and conforms to the can shape. When depressed, the valve opens a fluid channel pathway, allowing product to flow to the actuator.

Product

Suitable for liquid as well as viscous products, such as gels, creams and ointments in a number of application areas. Optimized for oxygen-sensitive and sterile products.

Propellant

Rests between the can and bag to exert pressure on the system and drive dispensing. The propellant can comprise a variety of compressed gasses (including ambient air), or volatile liquids.

Actuator

When depressed, the actuator activates the valve, allowing product to flow from the pressurized package, often in a stream or mist, or, when combined with a viscous formula, a dollop or foam.

Can

Holds package system under pressure.

The Bag-on-Valve Filling Process
Step 1

Placing of valve and bag inside the can

Step 2

Crimping and under-cap pressurizing

Step 3

In-line pressure testing

Step 4

Product filling into the bag and in-line target weight verification

Step 5

Actuator and cap placement

Semi-solids & Liquids

Tubes

  • Laminate
  • Aluminum
  • Extruded
  • Oval/round
  • Flat/contoured seal
  • Applicator options
  • Tube filling suites with 7 lines

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The Design a Seal (DAS) system

In Consumer Healthcare, product packaging matters. It can help differentiate you in a sea of competitors, solidify your brand equity and even convey your commitment to quality through attention to detail. In response to market demand for flexible tube customization, we are proud to offer Design a Seal (DAS). DAS is a system that allows for custom shaping of sealed-end flexible tubes, resulting in consumer-friendly products that are as unique as the carefully crafted formulas within. All tooling is customized and designed specifically for your unique application.

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SEMI-SOLIDS & LIQUIDS

Samples

  • Single-dose wipes – 2 or 4 panel fold configurations
  • Single-dose sachet – up to 1 million centipoise in viscosity
  • 1g sample tubes
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Liquid Filling

  • Rollerball
  • Tottle
  • Bottle
  • Jar
  • Pumps
  • Other
  • Filling capabilities range from 1g to bulk container and 300 units to 25,000 units per hour
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Secondary Packaging

  • Straight tuck
  • Glued
  • 4/5 panel
  • Custom cartoning applications
  • 80,000-square-foot container and packaging warehouse
  • 100,000 square feet of climate-controlled warehouse – outbound goods
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