Arya Vaidya Sala manufactures more than 500 classical
formulations. The manufacturing activity takes place
at two centres, one at Kottakkal and the other at
Kanjikode near Palakkad. Both Factories operate on
manufacturing license issued by the Drugs Controller
of the State and both possess GMP (Good Manufacturing
Practices) certificate issued by the Government.
The important feature
of the two Factories is the fact that the basic principles
and practices of medicine manufacture are still based
on the specifications in the classical text books.
At the same time, extensive mechanisation has taken
place as a necessary consequence of adapting industrial
methods. This change is essential when scaled up and
bulk level production of medicines becomes necessary.
All the processing
activities are done in pharmaceutical grade stainless
steel vessels. There are several electro-mechanical
equipments which are employed for achieving efficiency
in production. Major areas where mechanisation has
been incorporated are: Fire wood has completely been
replaced by boiler generated steam for boiling purpose.
There is 15 tons/hr and 6 tons/hr steam generating
capacity at Kottakkal and Kanjikode respectively.
Major functions like disintegration, sifting, filtration,
concentration, incineration, compression, filling,
blistering, packing, etc are done with the aid of
heavy equipments. The introduction of modern dosage
presentation forms of tablets and capsules has also
necessitated the incorporation of modern pharmaceutical
machinery like punching machine, mass mixer, granulator,
drier, blender, encapsulation equipment, blister packing
Both the Factories
work round the clock in three shifts. More than 600
personnel are engaged in manufacturing activity including
work-men, and supervising, clerical and support staff.
Every Section of the two Factories is managed by qualified
and trained Physicians under the overall control of
a Factory Manager and Production Manager.
The production activity
is scheduled by the Production Planning Unit. It draws
up annual / monthly / weekly / daily production schedule
by taking into account the requirement of the Marketing
Department and by maintaining close association with
the Materials Department, Factory Managers and Finance
Department. The operations of the Factories are supported
by Personnel Department, QA Department and Engineering
takes care of human resources development related
matters. There is a Labour Welfare Officer who works
closely with the recognised Unions of the workmen
and associates with the Personnel and Production Departments.
QA Department has
a well-equipped laboratory and trained chemists. They
carry out regular analytical tests to ensure the quality
of raw materials as well as that of finished products.
Issue of a Quality Certificate is a necessary step
for accepting every item of raw materials. Standards
specified by the Bureau of Indian Standards (BIS)
are generally followed in the QC Laboratory. The QC
Certificate issued by the QA Department forms an integral
part of the Batch Manufacturing Record (BMR) of every
product. In the case of finished products, the Pharmacopoeial
Standards specified by the Government of India are
followed. A high level Quality Control Cell comprising
senior physicians examines samples from every batch
looks after procurement, installation and maintenance
of the plant and machinery of the Factories. Under
the control of Sr. Manager (Engg.), there are electrical
/ mechanical / classical Engineers and a Maintenance
Engineer looking after the functions of the Department,
which are manned by about 70 skilled and professionally
qualified workmen. Additionally, there is Civil Engineering
Department under the control of an Executive Engineer,
which looks after the civil construction and maintenance
There is heavy
transfer of information and data between different
Sections of the Production Units as well as between
different Departments and the Factories, which crucially
influence the speed and correctness of Factory operations.
Appropriate software for information / data transfer
and for passive control of work have been specially
got prepared for this purpose. A full-fledged IT Department
maintains the database in addition to designing/upgradation
of software as per the changing requirements.