16 Spray March 2020
customers to work side-by-side with
scientists and chemists to innovate.
The lab increases overall I&D bandwidth
and will allow for significant
increases in I&D staffing.
Additional lab expansions have allowed the firm to
grow its quality control, product release and microbiology
lab footprint by 40%. The space features a
newly expanded, dedicated micro-testing suite and
an upgraded product release suite, all supported by
a dedicated USP water system to meet specific U.S.
Pharmacopeia standards. This allows higher turnover
in the releasing of finished products and enables inhouse
micro-media to be manufactured onsite.
In addition, a new 30,000 gallon tank was installed
in Formulated Solutions’ aerosol propellant farm
expansion that increases the variety of on-site gas
options.
The company also recently completed the installation
of three new natural gas-powered generators
capable of producing 3 megawatts of power for office,
lab and production space, as well as the expansion
of Blending Suite 1 to include a new, 2,000 gallon
vacuum-rated blending vessel. This new addition
includes side sweep action and possesses high speed
in-tank mixing and homogenization to increase
overall emulsion and non-flammable bulk formula
production capacity.
Other completed projects include the expansion
of Blending Suite 3 to increased pilot and small-scale
blending capacity in an XP (explosion proof) environment
and the installation of site-wide radio frequency
tracking of pallets, containers and other assets.
Looking ahead, Formulated Solutions will be commissioning
a brand new aerosol filling line that will
represent a 200% increase in aerosol manufacturing
capacity. Key features will include fully-automated
production, including pack-out; dual propellant filling
capability; high viscosity formula filling capabilities;
continuous recirculation pump and filling system to
keep product in constant movement prior to filling,
allowing for homogenous filling of powder-containing
formulations; quick changeover automation and a
separately contained ISO-rated filling suite.
“In 2020 we will begin build-out of a new, two-story
30,000 square foot expansion,” explained Carpenter.
“This space will include a new front office, additional
warehouse space and increase the footprint of
our headquarters location to approximately 250,000
square feet. We will also be installing a totally new
emulsion and non-flammable blending suite that
will include three new 2,000 gallon blending vessels,
expandable to four.
“Of course, with growth comes increases in staffing,”
said Carpenter.
“In 2020, we will be terraforming the majority site
footprint, with significant increases in parking, the
creation of better traffic flows for both employees and
deliveries and installation of a dedicated guard house.
Within the next few months, we will increase our
USP water generation capacity, critical to the creation
of water-based formulations, by an additional 100%.”
Carpenter concluded that in 2019 and 2020
Formulated Solutions did/will play a significant role
in the introduction of new powder sprays, dry sprays,
Lidocaine sprays, pressurized cryogenic systems,
whipped delivery systems and formulas driven by
Honeywell Solstice propellants. In addition to celebrating
its 20-year anniversary, the company recently
completed its third consecutive Federal Railroad
Administration (FRA) drug audit with zero violations.
Various ISO certifications are under way and expected
to be completed by mid-year.
Aerofil invests in the future
In February of 2020, Aerofil Technology, Inc., Sullivan,
MO, commissioned a new high-speed Beauty
& Personal Care product aerosol filling line: Aerosol
Line 8. Due to unskilled labor shortages, an increasingly
diverse consumer base, rising SKU counts and
the need for shorter run sizes, Aerofil saw the need
to design “the line of the
future.” When planning the
line, each equipment center
was evaluated based on efficiency,
quality, automation
and flexibility.
Aerosol Line 8 is rated for
more than 200 cans per minute.
Other features include:
• Robotic can depalletizer:
Robotically offloads
can frames and cans one
layer at a time and eliminates
operator intervention.
The equipment is
designed to handle all
Expansions,
Mergers
and more…
Left to right: Formulated Solutions’ new warehouse; three new natural gas-powered generators capable of producing three megawatts of
power.; a new 30,000 gallon tank installed in Formulated Solutions’ aerosol propellant farm.
Aerofil robotic depalletizer