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We offer a wide variety of products and services to meet your needs

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Product Development

Product Development – Technical Support – R&D Lab

ProTab Laboratories offers an in-house Research and Development Lab, which is dedicated to working with our customers to help create formulations that meet or exceed their product specifications. Our R&D Lab allows us to develop formulations using laboratory size equipment and then scale up to production size batches formulating on a lab and pilot scale prior to processing a production batch. This ensures that production runs will be successful and minimizes loss of material during the development stage. We can offer our customers help in both developing new products and formulations as well as solving existing problems. Assisting customers in developing exacting specifications that can be reproduced in a manufacturing environment is of primary importance to our R&D effort.


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Granulation – Tray Drying

When tray drying is needed, the liquid is added to the material in a planetary mixer. The moistened material is then spread onto trays and the trays are loaded in our high capacity Gruenberg Ovens for drying. When the required moisture level is reached the material is screened to collect the proper mesh size and oversize and fine material is further processed.

Product Development



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Product Development

Granulation – Fluid Bed

Our large capacity fluid bed dryers are used to produce a wide range of granulated materials. Liquids are introduced into the chamber with a spray system while the product is being moved by heated air to create the granulation. When the product has been dried to the required moisture level it is milled and screened to collect the desired mesh size.


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Chilsonation

ProTab offers Chilsonation systems that are used to create granulated products when no liquid can be added to the raw material. Raw material is passed between high-pressure rollers to form a sheet of material that is processed through a Fitzpatrick Mill that grinds the product into a granular form. The ground material is then screened to collect the desired mesh size.

Product Development


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Product Development

Mixing

ProTab Laboratories has several style mixers to accommodate custom blending requirements. The variety of mixers available allow ProTab the flexibility to process high and low capacity batch sizes. All material is passed through a screen as it is loaded into the blender to ensure that no foreign material or objects are introduced to the mixture. All weighing is verified in accordance with our quality control procedure to ensure that the proper amount of each raw material is added to the blend.


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Bi-Layer Tableting

ProTab Labs has expanded on the range of tablet form manufacturing services available by now offering Bi-Layer Tablet Form technology.

Bi-Layer Tablet technology offers a variety of applications including Extended Release and Immediate Release delivery systems for greater consumer benefits.

Ideal for formulations that contain ingredients which may go into dissolution too quickly to receive the adequate dosage for optimum benefit, Extended Release assists in providing delivery of the active ingredient over an extended period of time. For formulations which contain active ingredients that are more effective when delivered quickly, Immediate Release assists in providing delivery of the active ingredient with an immediate release to dissolution for faster benefits.

Product Development


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Product Development

Tableting

ProTab has a variety of tablet presses with both B and D tooling to offer a wide range of shapes and sizes to our customers. Types of tablets that we can offer include chewable, coated, enteric, slow release, bi-layer and sublingual. In accordance with our quality control procedures, all tablet production is carefully monitored to ensure that correct size, weight, hardness, friability and dissolution are maintained through each individual production
batch manufactured.


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Encapsulation

ProTab Laboratories facility is equipped with high-speed automatic and semi-automatic encapsulating machines with capabilities to produce two-piece hard shell gelatin and vegetarian capsules in sizes including 0, 00, and 1. The fully automatic machines can produce at a high rate of production per hour to offer a high yield capacity per shift. Our semi-automatic encapsulating machines offer additional flexibility to manufacture large or small batch sizes based on the product needs of our customers.

Product Development


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Product Development

Powders

All raw materials are blended in stainless steel tanks and manufactured under rigid quality control standards to provide a homogeneous blend and a high degree of product uniformity. The variety of blending equipment at ProTab Laboratories accommodates small and large batch sizes for optimum efficiency. Ideal for Sports Nutrition and Protein Powder formulations.


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Packaging Services

PROTAB LABORATORIES offers the convenience of in-house packaging services for finished product in Tablet, Capsule, Powder Form as well as Blister Packaging Services. We can offer faster turn around times with our new packaging facility equipped with the latest high speed automated equipment designed to provide Premium Quality cGMP packaging to our customers.

  • New Packaging Facility with the Latest High Speed Automated Equipment.
  • Fully compliant with Certified cGMP Standards.
  • Tablets & Capsules: Automated Bottle Fill, Automated Cotton Inner Fill, Automated Capper, Heat Induced Foil Inner Seal, Tamper Evident Outer Safety Seal, High-Speed Automated Pressure Sensitive Label Application, Video Jet Lot Coding.
  • Powder Processing Lines: Dual Auger Fillers, Check-Weighers, Automatic Cappers, Heat Induction Seal, Video-Jet Lot Coding, Interchangeable Labelers for both Roll-Thru and Pressure Sensitive Labels, and Unscrambler Tables for Packing.
  • ProTab Laboratories can produce most types of standard blister packs as well as custom card layouts.
  • Blister Packaging is the ideal option for individually packed units or products that need individual protection and a premium quality appearance.
  • Blister Packaging is available in a wide variety of styles, shapes and sizes.
  • Strict Quality Control Standards.
  • Automated Quality Control Sensors throughout the entire Packaging Process.
  • On-time delivery.
  • ProTab Laboratories has the resources to offer complete all-in-one manufacturing services to meet all your final product specifications.
  • Compliant with Good Manufacturing Practices (cGMP) established.
Product Development


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Product Development

Probiotic Formulations

ProTab Laboratories offers a wide variety of manufacturing services from our facility in Rancho Santa Margarita, CA. for all tablet, capsule, & powder form products. We strive to provide industry leading service levels and quality control standards that meet all cGMP standards at highly competitive pricing.

To reinforce our commitment, ProTab Labs will be expanding to a new 80,000 sq. ft. state-of-the-art facility by early 2014! We will be dedicating a large portion of our new manufacturing operation to climate control, humidity control clean room production capacity. Recognizing that Probiotic tablets, capsules, and powders must be produced and packaged under the most stringent, environmentally controlled conditions, ProTab Labs new facility is being specifically designed to ensure the stability of all probiotic products manufactured.

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