Guayama Packaging & Warehouse Overview
In the last four years, approximately $22M USD has been invested in packaging equipment and $14 M USD in facility upgrades. There are 5 bottle lines with speeds ranging from 200 to 300 BPM and bottle sizes ranging from 60 to 750cc. The packaging facilities have full environmental control and the packaging lines include desiccant placers, metal detectors, check weighers and rotary labelers with full inspection technology. The case packaging features on-line printing and a verification systems. The plant features the industry’s most advanced vision technology filler design with 100% accurate counting, foreign tablet inspection and individual, traceable tablet rejection. Other features include a quick change-over design coupled with variable data downloading and line management through a SCADA system.
All of the above make use of central dispensing and warehousing. The HVAC is segregated using quality based management systems and personal protective equipment. The detailed capabilities and capacity of the packaging operations are shown below. The capacity will vary depending on product mix and can increase by 50 percent, or more, with a product mix that is predominantly high volume products. The demonstrated capacity is 12B SDUs with 229 current SKUs. The design capacity is over 18 million SDUs.
Product exposed areas are physically segregated (All Bottle Lines, 3 Blister Lines and
1 Single Unit Dispenser Line)
Individual enclosed gowning areas and material airlocks are in place for 2 Bottle Lines,,
1 Blister Line and 1 Single Unit Dispenser line.
The warehousing function has demonstrated flexibility in supporting new product transfers and shift pattern changes over recent years. As well as handling multiple product movements, the complexity of the business requires the handling of large numbers of material codes on a daily basis. Refrigeration capacity is also available for materials and products which require storage at controlled, low temperatures.