Batch cards, press settings, punch sets, blister counts and yield in one plant system.
Run a tablet plant from the dispensing booth to the dispatch bay: master formulas, batch cards, rapid mixer granulation, compression, film coating, blister and bottle packing, yield reconciliation and contract client orders. Operators post readings at the press. Nothing waits for a clerk. Quality staff review a complete batch record before release.
- Formulas and punch sets keyed as they stand
- Open batches, ingredient lots and clients migrated
- Release rules agreed with your quality unit
Plants that dispense, granulate, compress, coat and pack tablets hold master formulas, batch cards and dispatch records in one system that GullySystem configures for the site. Every pack traces to its press run. Yield is reconciled before review.
What goes wrong before the software.
How the work flows through it, step by step.
- 1
Batch card and dispensing
A batch card is issued from the master formula, and ingredients are weighed against it with lot numbers and a second check at the dispensing booth.
- 2
Blend and granulate
Blending, granulation, drying and sizing parameters are recorded, with samples taken for loss on drying and blend uniformity before the lot is allowed to move on to the press hall.
- 3
Compress
Press settings and periodic weight, thickness and hardness readings are posted, with the punch and die set used for the run.
- 4
Coat
Pan load, spray rate, inlet air temperature and weight gain are recorded for film coated products, and the coating step is skipped entirely for the uncoated lines on the same floor.
- 5
Pack
Blister or bottle lines record counts, rejects, batch coding and the carton artwork in use, after a signed line clearance.
- 6
Reconcile and release
Tablets in and packs out are reconciled. The record then goes to quality review and release.
What is inside.
Every module can be switched on, left out or changed to match how your team already works.
The business modules it is built from.
Each one is also available on its own, or inside a system built for you.
- Bill of Materials
Each formula lists ingredients, quantities and overages, and the dispensing card is issued from the revision in force on the day of the batch.
- Batch and Serial Tracking
Every ingredient lot weighed into a batch is recorded with a second check, so one excipient lot recall reaches every batch that used it.
- Quality Control
Weight, thickness and hardness readings are checked against limits, and drift is shown early enough for the operator to adjust the press.
- Production Planning
Batches are scheduled by machine and product, so mixer granulation, fluid bed drying and compression follow in the order the plan sets.
- Work Order Management
Each packing run is tied to its batch with counts, rejects and batch coding, and closes only when tablets in and packs out reconcile.
- Asset AMC Tracking
Punch and die sets are tracked with the tablets made, so inspection and replacement follow use and not guesswork.
- Barcodes and Labels
Cartons and labels are scanned against the batch at the line, so a wrong carton is stopped before a blister goes into it.
- Order Management
Contract client orders are held by brand and pack, then flow into batches and dispatch with the client’s own documents and printed names.
How we would put it in.
Setup, data migration, integrations and anything built on top.
One system, each person sees their part.
For production managers
See batches by stage, running lines, open reconciliations and punch sets due for inspection at a glance, before the morning meeting starts.
For compression operators
Post press settings and checks beside the machine. Drift shows early, so the press is adjusted before a whole drum of tablets is rejected, and the shift lead can see which limit was crossed.
For packing supervisors
Record counts, rejects and clearance. The correct carton artwork stays on screen.
For quality reviewers
Review the full batch record and reconciliation, then release.
The numbers the owner asks for.
- Batches by stage and product
- Weight, thickness and hardness trends by run
- Tooling sets and tablets made
- Yield and variance by batch
- Rejects by cause and line
- Contract orders by client and status
- Dispatches by batch number
Who this is built for.
- Makers of uncoated and film coated tablets
- Contract manufacturers that produce tablets under client brands
- Companies packing tablets in blisters and bottles
- Producers of nutraceutical and vitamin tablets
- Plants running granulation, compression and coating lines
When it is not the right choice.
- An API plant will find API Manufacturer Management Software closer.
- A pharmacy counting tablets needs a pharmacy tool.
Adapted to your business before it goes live.
You are not handed a login and left to it. The product is set up around your records, your people and the tools you already use.
Works alongside
- Weighing scales
- Barcode and label printers
- Batch coding printers
- Accounting export
Questions owners ask before a demo.
What does the operator enter at the press?
Press settings, and the weight, thickness and hardness readings at set intervals, with rejects and samples logged on the same screen beside the limits so that nothing is lost.
How does it reconcile yield?
It sums tablets compressed, rejected, sampled and packed, and flags any difference beyond your limit before the record goes to the reviewer. A gap shows before the foil is sealed.
Can we see which tooling set ran a batch?
Yes. Each compression run records its punch and die set, so a set’s history and the batches it produced are linked.
Can contract clients have separate documents?
Yes. Brand, pack and documents stay apart for each client, and printouts carry that client’s name only.
What about line clearance?
Before a granulation or compression batch starts, the operator signs a clearance check on the press, and that signature is stored with the batch.
Is it validated?
Not by itself, because validation is planned with your own quality staff. We supply the system and its supporting documentation.
How do we see it before deciding?
A demonstration on one of your formulas comes first. The quote follows from the headcount using the system and the number of presses and coating pans you run on the floor.
Can the data be exported?
Yes, batches, checks, tooling and orders export to spreadsheet and document files in a format that the agreement sets out, so that auditors and clients can open them without our software.
Wondering what it would cost? Share your requirements and an engineer will come back with a scope.
Businesses that use this.
See Tablet Manufacturer Management Software with your own data.
Tell us how you run things today. We’ll show you the parts that matter to you and say plainly what would need changing.
- No obligation
- A reply within one business day
- Your details stay private
Start with your requirements
Seven short steps that tell us what you need. An engineer reads them before getting in touch.
Share your requirements