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Challenging the Brands

Growth of the Super-Manufacturer

Traditionally brands within industries such as food and pharmaceuticals have manufactured their own products. This gave companies the control they need to ensure brand standards and specifications are maintained.

Alongside the brand manufacturers, contract manufacturers produce own-label product for retailers and other higher volume, lower margin suppliers.

This is where it gets interesting! The demands made by the supermarkets for high, consistent quality at low prices have driven the contract manufacturers to invest in the best possible equipment from the development lab through to the factory. This enables them to deliver consistent, scalable quality across the board ensuring that the specification developed in the lab is sustained through to the high volume manufacturing that delivers the economies of scale which help to drive down cost.

To maximise production volume and plant efficiency, contract suppliers manufacture for a range of customers and, as production switches from customer A to customer B, it is vital there is zero cross-contamination. Production lines must be thoroughly cleaned and prepared – but in the shortest possible time.

Downtime costs money!

Meeting these combined objectives has seen the emergence of the Super-Manufacturer, a high efficiency, high quality, low cost manufacturer who can produce a range of product to the tightest specification at remarkably low costs

Challenging the brshutterstock_55787002ands

Historically, premium products have been manufactured in-house. The cost of lower volume, in-house manufacture is offset by the guarantee of consistency and the maintenance of brand value.

This is how it used to be!

With the emergence of the Super-Manufacturer, the landscape has changed…

The Super-Manufacturer produces consistent product to the tightest specification – exactly what the brand manufacturers are doing; but the scale of the Super-Manufacturer means they can deliver versatile, validated quality at lower costs than the brands.

Brand Quality at Value Manufacturing Costshutterstock_161094461

If you can’t beat them….

Of course the brands are fighting back. Several leading brand manufacturers are now migrating their production facilities into separate subsidiaries and investing in the best available plant and machinery. Just like the Super-Manufacturers, these new generation brand manufacturers need volume to run efficiently. They too are starting to take on sub-contract manufacture for private label brands.

Read more at Validation & Scalability

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Validation & Scalability

How do you guarantee scalable production volume and a validated process?shutterstock_21104719

Greaves has the knowledge and expertise to succeed

To deliver at a guaranteed high standard to multiple customers relies on two pivotal factors:

  • The knowledge and equipment to meet a wide spectrum of different needs, ranging from small-volume lab testing to full-scale mass production
  • The ability to switch between these varying processes cleanly and efficiently.

Joshua Greaves & Sons Ltd is perfectly placed to work with manufacturers to achieve the best possible results on both counts.

Consistency. From Lab…

“Scalable, flexible machines are the hot topic,” says Sales Director Edward Greaves. “Faultless, pinpoint accuracy, whatever the scale, with reliable validation at every stage, is critical to the success of this kind of multi-product, high-volume manufacturing. The exact requirements of each product for each client must be guaranteed.

…to volume production

Greaves has extensive experience in a key area where extreme precision is paramount; We know how to design and build mixers that operate consistently to very tight specification and tolerance”.

All models of Greaves mixers are available from Laboratory to pilot scale through to lower then high volume manufacture. Greaves are ahead of the game in incorporating the key design elements including:

  • Impeller geometry
  • Impeller-to-tank-diameter ratios
  • Flow rates
  • Peripheral speeds
  • Vacuum pressure

The balance and relationship between each of these factors is crucial for achieving the desired levels of consistent scalability.
Greaves also understands importance of matching the best speed with pharmaceutical-grade thoroughness in cleaning machinery after its use in one production process as the same equipment is prepared for a new production run. Every minute of unnecessary downtime in the site operation costs money but avoiding any risk of cross-contamination is essential.

In our drive to deliver end-to-end mixer performance, Greaves has used our expertise in machinery design to develop PortaCIP the ultimate, portable clean in-place system. The PortaCIP system practically addresses the real-world implications design factors including:IMG_7604DoubleBallCoverage_Diagram

  • Nozzle flexibility
  • Area coverage
  • Vessel geometry
  • Internal surface roughness,
  • Crevices and residue traps (including) nuts, bolts and securing devices.

Ever aware of the importance of cost-efficiency, PortaCIP also includes a system for the efficient use and reuse of cleaning fluids

To get the best from your mixer investment, call us.