Liquid additive manufacturing technologies: how to ensure quality and stability

The high quality and stability of liquid additives is guaranteed by the use of cutting-edge production technologies. This article will outline the principal stages of production of liquid additives and the technologies employed in the process.

Major steps in the production of liquid additives

The production of liquid dietary supplements is a complex, multi-stage process that requires the use of high-tech equipment and modern technologies. Let us examine the principal stages involved in the manufacture of biological supplements.

Base ingredients selection. The first step is to select suitable raw materials for further use in the manufacture of liquid additives. The selection is conducted in several stages:

• the quality and purity of raw materials is verified and the presence of pesticides and other harmful components is inspected;
• the supplier of the raw materials is assessed, data on the origin of the primary ingredients, the place and peculiarities of cultivation of plant components, and the conditions of production of other ingredients are studied;
• compliance of raw materials with international quality standards and availability of certificates is verified;
• biological activity is screened to ensure proper effectiveness of the dietary supplements.

The selection of suitable base materials involves the choice of not only active ingredients but also secondary components such as solvents, emulsifiers and preservatives.

Mixing of ingredients. Once the base ingredients have been selected, the Liquid Supplement Manufacturing begins. The initial stage involves preparing the correct formulation to ensure the supplements are as useful and effective as possible. Subsequently, the pre-dispensed components are blended to form a homogeneous mass in specially designed large containers. 

Homogenisation. The homogenisation process guarantees the uniform distribution of all components in the mixture, preventing the inclusion of particles that are too coarse for the finished liquid supplements. This process guarantees the stability of the finished product, optimises its efficacy and enhances its absorption by the body. There are three methods of homogenisation:

• High-pressure pumping is the procedure of pumping fluid for dietary supplements through narrow passages with high pressure, which effectively pulverises all particles contained in the solution;
• mechanical mixing — the liquid is agitated using automatic industrial mixers and dispersants until a homogeneous consistency is achieved;
• the use of ultrasonic waves allows for the creation of a finely dispersed emulsion through the process of ultrasonic homogenisation.

Homogenisation is a mandatory process that eliminates the risk of ingredient breakdown and ensures homogeneity, thus guaranteeing the quality and safety of the final product.

Pasteurisation. The application of temperature treatment to liquid supplements enables the elimination of vegetative forms of microorganisms. It is essential to pasteurise liquid supplements to prevent these organisms from disrupting the structure of the product and posing a threat to consumer health. Furthermore, the pasteurisation process extends the shelf life of the finished product. The pasteurisation of dietary supplements is typically conducted at temperatures below 100 degrees Celsius. A variety of pasteurisation techniques are employed in the production of dietary supplements:

• continuous, in which the products are treated at 65 degrees Celsius for about 40 minutes;
• rapid, whereas processing is carried out at 90 degrees Celsius for 1 minute;
• instantaneous, in which the food is treated at 98 degrees Celsius for a few seconds.

Filtration. The most common use of automatic or semi-automatic filling lines equipped with filtration and sterilisation systems is for filtering liquid dietary supplements. The filtration process is designed to remove any harmful or extraneous impurities.

Packaging. At the final stage of the production process, finished goods are packed in hermetically sealed containers to eliminate the risk of ingress of oxygen, microorganisms and other substances that can affect the state of active components. It is essential that packaging complies with the relevant product safety standards. The most common packaging material used by manufacturers is the bottled container, which is used for the dispensing of liquid additives.

Labelling and transport. It is imperative that the packaging is accurately labelled to match the contents. Once the products have been labelled and packaged in accordance with the aforementioned requirements, they are ready for transport. It is of the utmost importance that the recommended temperature regime is adhered to at all times.

It is essential that each step is subject to quality control in order to guarantee the safety and efficacy of the final product.

Choice of ingredients for liquid additives

The selection of ingredients is a critical step in the production of liquid supplements. The correct formulation and high-quality ingredients provide the supplements with their key characteristics:

• balanced composition, thanks to which dietary supplements are highly effective and have a complex effect on the consumer’s body;
• minimisation of the risk of adverse side effects due to the use of natural components without chemical additives;
• high level of bioavailability, so that the body absorbs the active components of the composition at a faster rate;
• by using quality products, one can guarantee the safety of the goods and the preservation of their properties until their final expiry date.

To ensure the finished product meets the highest quality standards, Liquid Supplement Manufacturing must consider a number of key factors when selecting ingredients.

Natural origin. Natural ingredients of dietary supplements are better absorbed, have minimal contraindications and side effects.

Supplier reliability. When selecting a supplier of ingredients for the development of dietary supplements, it is essential to consider the reliability of the supplier. It is advisable to select suppliers with certification confirming the quality and safety of their wares.

Compatibility of components. It is recommended that manufacturers have their own laboratories to study the interaction of the mixture constituents and to make the appropriate formula selections.

Accuracy of proportions. To ensure the highest standards of product safety and efficacy, it is essential to select the correct ratio of each ingredient in the composition.

Ensuring product stability

The stability of active ingredients in dietary supplements is a critical factor in ensuring the safety and efficacy of the product throughout its stated shelf life. Manufacturers may employ a variety of techniques to ensure the stability of active ingredients. We will now examine the most popular of these methods.

Sustaining optimum temperature and humidity levels. It is essential that base ingredients and goods are stored in a way that optimises their performance:

• temperature up to 20 degrees Celsius;
• relative humidity level not exceeding 60 %.

Protection from direct sunlight exposure. It is important to note that photodegradation occurs when the active ingredients of supplements are exposed to light. Therefore, it is essential that they are stored in closed, opaque containers to ensure their efficacy and safety.

pH monitoring. It is essential to maintain constant vigilance over the pH level and ensure it remains within the normal range. Any deviation from the normal pH range can result in hydrolysis and other chemical reactions, which in turn affect the properties of the active ingredients and impair their effectiveness.

Hermetically sealed storage containers. It is essential that packaging prevents contact between active ingredients and moisture or oxygen, in order to maintain the stability of the active ingredients.

Test execution. Testing of liquid additives is an essential stage of the manufacturing process. Such testing may include accelerated ageing techniques and stress testing. Testing is an essential part of the product development process, enabling the selection of optimal storage conditions and the determination of product shelf life.

Addition of antioxidants and preservatives. Antioxidants are used to prevent the risk of oxidation of the active components of dietary supplements. Preservatives are used to prevent the proliferation of microorganisms in the liquid. Furthermore, these ingredients prevent the decomposition of active substances, thereby extending their shelf life.

Quality control at all stages of production

It is the responsibility of Liquid Supplement Manufacturing to conduct regular quality control at all stages of supplement creation in order to ensure the safety of the goods.

Upstream quality control. The quality control process commences even before the final ingredients are combined. It is essential that primary materials are sourced from reliable suppliers and subjected to rigorous checks for authenticity, purity and efficiency. It is equally important to ensure that all equipment meets the required standards and is fit for the task:

• compliance with sanitary norms;
• correct operation;
• absence of energy and functional losses due to equipment condition defects. 

It is imperative that all devices used in the manufacture of dietary supplements undergo a comprehensive cleaning, testing and setup process prior to launch.

Quality control during the production process. During production, regular checks are conducted to ensure that the batch volume is stable and that the proportions of the ingredients are correct. Furthermore, the AQL and a number of tests are carried out:

• the stability of the temperature regime required at each stage;
• degree of contamination;
• pH level.

In the event of any irregularities being identified, further inspections are conducted with the objective of rectifying any issues that may have arisen during the manufacture procedures.

Post-production quality control. It is essential to conduct quality control on the final product even after the manufacturing process of dietary supplements is complete. This entails a number of different types of testing:

• microbiological tests;
• assessment of the composition of finished liquid supplements, inspection for excessive impurities and harmful substances;
• verification of the accuracy of information on the label and compliance of dietary supplements with the specified nutritional value;
• inspection of packaging quality for integrity, impermeability and compliance with safety standards.

Certificates and record keeping. All products must comply with the relevant international quality standards. The high quality and safety of the dietary supplements are confirmed by ISO 9001 and ISO 22000 certificates, as well as NSF and GMP certification. In addition to production, research must be conducted to develop optimal formulas and proportions. All tests, studies and inspections must be documented in accordance with the relevant procedures.

It is essential that quality control is conducted by both the company’s in-house laboratories and external third parties. This approach ensures the manufacture of effective and safe goods, as well as ongoing enhancements to their quality.

Conclusion

The production of liquid supplements necessitates the utilisation of a range of technologies, including homogenisation and pasteurisation, to ensure the preservation of product properties and safety. It is only through the use of these technologies that manufacturers are able to develop goods of the highest quality and efficacy.