Nagaraju G

General Manager-SCM

Encompassing varied therapeutic segments, the cap­sule manufacturing sector in India has been expand­ing steadily. According to various research studies and industry veterans, the demand for capsules, particu­larly empty capsules, is attributed to factors such as the growth of oral dosage forms and adoption of nutraceuti­cals, primarily among the aging demographics. Invest­ments from both the government and private entities are also playing a catalytic role in the development. Needless to say, this has created a multitude of opportunities for many businesses to burgeon into and disrupt this niche in­dustry. But, given the proliferation of manufacturers, it is imperative for a customer to collaborate with companies distinguished for a consistent track record of delivering high-grade solutions, research and development (R&D), technology usage, and firm adherence to quality and reg­ulations. Headquartered in Hyderabad, Gelcaps Industries is one such venture that offers the best of all the aforemen­tioned elements.

Gelcaps Industries was founded in 2013 and officially started its commercial production in 2016. Today, boasting nine fully-automated manufacturing lines and a production capacity of over 6 billion capsules per year, Gelcaps Industries stands unparalleled in providing premium and BSE/TSE-free empty hard gelatin capsules to its customers, comprising leading pharmaceutical, nutraceutical, and dietary supplement-making companies. Highly recognized for its quality standards and constant innovation, the company operates with a focus on offering safe, effective, and distinctive solutions, which are reflected in its complete manufacturing process and product range of hard capsules.

In order to address the long-standing scarcity of pharmaceutical gelatin in a fluctuating market like capsule manufacturing, fraught with escalating raw material costs, Gelcaps Industries has employed a lucrative strategy in which it has established long-term volume and rate agreements with its gelatin suppliers. Furthermore, the venture gains an additional edge by importing 50% of its gelatin materials internationally. The company also stands out with its portfolio of customizable capsules. “Upon receiving an inquiry, we provide customers with a capsule development form, covering integral aspects like the desired color, size, formulation compositions, print specifications, and target market. However, some customers also allow us to use our creative competencies in formulating the capsules. Subsequently, we generate and share a composition shade card with the customers for further review and approval,” explains Nagaraju G, General Manager-SCM, Gelcaps Industries. The adept team then develops a sample formulation, incorporating all the changes recommended, and submits them for evaluation by the customers' R&D team, after which an order is placed. In addition, the entire process is online, which empowers the company to stay current with contemporary trends in manufacturing.

The Pillars of Excellence

The notable factor of Gelcaps Industries lies in its advanced manufacturing practices, in which quality and safety are upheld in each facet of the process. Certified by WHO-GMP, US DMF-Type IV, ISO QMS, EMS, and OHSAS, the methodologies at Gelcaps Industries are driven by a robust quality control and assurance system designed to detect quality deviations and achieve consistency in delivering excellence, right from screening raw materials for impurities to regular visual inspection, sampling, and testing to meticulous handling of documentation vital for aspects like GMP and SOP. The system also includes data integration to enable efficient workflow. The frequent supplier audits held in its supplier manufacturing units, on the other hand, help the company identify and mitigate potential risks.

For Gelcaps, maintaining a hygienic environment across all its manufacturing lines is also of paramount importance. While the team makes sure to constantly monitor temperature, pressure, and relative humidity, its state-of-the-art, fully-automated high-speed line needs no human intervention in the entire production cycle, from the initial mixing phase to the final finishing. The company also prioritizes air quality within its manufacturing facility, employing HEPA filters to prevent air contamination. This proactive approach underscores the company’s compliance to stringent rules laid out by regulatory bodies while also laying equal emphasis on environmental protection. “There are minimal environmental concerns in the capsule manufacturing domain, one of the ‘orange industries’. However, our facility is engineered so as to comply with the customs of the pollution control board,” adds Nagaraju. The company continuously strives to enhance energy efficiency, which is exemplified by its manufacturing lines, which has made Gelcaps Industries a pioneer in India for utilizing energy-efficient air-handling units. Besides, the company has also deployed multiple measures for proper waste disposal and sewage and water treatment.

Currently engaged in improving the energy consumption ratio, Gelcaps Industries plans to incorporate solar energy with a capacity of nearly 1 megawatt in the next financial year. Registering a CAGR of 25–30 percent growth, Gelcaps Industries is seeking to double its growth by increasing its production capacity. The company aims to achieve this by launching a new unit in Hyderabad next year, equipped with quality certifications and cutting-edge facilities to produce the same quantity, slated to begin in 2025. The company is claimed to be the sole manufacturer in India, catering to only regulated markets, predominantly the US market. Looking ahead, the company also wishes to expand its footprint to the European market in the upcoming financial year, adding flesh to its vision of becoming a globally recognized organization.

Nagaraju G, General Manager-SCM

Nagaraju G is a seasoned professional with a wealth of experience in supply chain management and all of its aspects, including sales, marketing, procurement, imports, logistics, production, CRM, and maintenance operations. Throughout his career, he has been instrumental in delivering significant cost savings through his strategic, analytical, and negotiation prowess while serving in key leadership and managerial positions in eminent companies like MRF, BIOGENEX, and Indian Immunologicals, along with Gelcaps Industries.