New Zealand’s pharmaceutical and nutraceutical processing and manufacturing sector operates under some of the most stringent regulatory and quality requirements of any processing industry. Production environments must demonstrate compliance with current Good Manufacturing Practice (cGMP) standards, maintain strict controls on contamination and particle size, and provide full process traceability. The equipment used in these environments must meet or exceed the requirements of regulatory bodies including Medsafe, the FDA, and applicable international standards such as ATEX, EHEDG, and 3-A.
Advanced Packaging Systems (APS) supplies processing and packaging equipment to pharmaceutical and nutraceutical manufacturers throughout New Zealand and the Pacific, representing a portfolio of specialist international partners. This article outlines the key process stages in pharmaceutical and nutraceutical production and the equipment APS supplies at each stage.
Russell Finex Grading Sieve
Milling and Particle Size Control
Achieving a defined particle size distribution is a critical step in pharmaceutical and nutraceutical processing. Whether reducing an active pharmaceutical ingredient (API), an excipient, or a botanical raw material, consistent milling is directly linked to downstream processing performance, dissolution behaviour, and final product quality.
The Hanningfield Uni-Mill conical screen mill is designed specifically for pharmaceutical and nutraceutical applications. Contact parts are manufactured from 316L stainless steel (EN 1.4404) with FDA-compliant seals and gaskets. Hanningfield holds ATEX/Ex-proof accreditation enabling self-certification of the Uni-Mill for Zone 0/20 explosive atmospheres — a relevant consideration when milling fine combustible powders such as nutraceutical extracts or organic pharmaceutical raw materials.
No metal-to-metal contact occurs within the milling chamber, eliminating the risk of metallic contamination and limiting heat generation during processing. The Uni-Mill can be specified with CIP (Clean-in-Place) and WIP (Wash-in-Place) capability, and the detachable mill-head supports autoclaving where sterility requirements apply. Inlet and outlet configurations accommodate closed process integration via vacuum transfer, tri-clover fittings, and bespoke connectors. The low heat and low noise profile suits thermally sensitive materials, including heat-labile APIs and botanical extracts.
Hanningfield Uni Mill
Powder Screening and Containment
Screening of pharmaceutical and nutraceutical powders serves two primary functions: removing oversize particles or agglomerates that would affect dosing accuracy and product uniformity, and providing a containment barrier to protect operators from exposure to potent or hazardous compounds.
Russell Finex has supplied sieving and separation equipment to the pharmaceutical industry for over 90 years, with customers including Pfizer, GSK, Wyeth, and Sanofi-Aventis. Their equipment is built to comply with cGMP, HACCP, FDA, and USDA standards.
The Russell Compact Airlock Sieve™ is an enclosed vibratory screener designed for operations where operator protection from potent compounds or airborne pharmaceutical dust is required. The sealed construction provides total containment, and the unit supports tool-free disassembly for cleaning and changeover between batches or products.
For pharmaceutical powders prone to mesh blinding during sieving, the Vibrasonic® ultrasonic deblinding system applies high-frequency ultrasonic energy directly to the sieve mesh, preventing particle adhesion and maintaining consistent screening rates without interrupting production. For liquid pharmaceutical streams, the Russell Finex Liquid Solid Separator™ removes suspended solids from process liquids, while Russell Finex self-cleaning filters provide continuous-duty liquid filtration with automated cleaning cycles.
Russell Finex Ultrasonic Mesh Screens
Powder Blending
Once milled to the required particle size, pharmaceutical and nutraceutical powders typically require blending to achieve a homogeneous mixture of active ingredients and excipients. Blend uniformity is a critical quality parameter — particularly in solid dosage forms where each tablet or capsule must contain a consistent dose.
The Dinnissen Pegasus® Batch Mixer is a multifunctional paddle mixer suited to pharmaceutical and nutraceutical powder blending applications. Its twin counter-rotating paddle shaft design achieves a homogeneous blend quickly and without product damage, handling a wide range of particle sizes and bulk densities. Contact surfaces are manufactured from stainless steel and finished to minimise product retention, supporting full cleanout between batches and reducing the risk of cross-contamination in multi-product facilities.
The Pegasus® range holds ATEX Zone 20 (internal) type approval, covering batch, continuous, and vacuum mixer configurations, making it suitable for use in facilities processing combustible fine powders such as APIs, nutraceutical extracts, and vitamin premixes. For operations requiring validated batch traceability, the Pegasus® Batch Mixer supports recipe-based processing with accurate batch tracking. A continuous mixer variant is also available for high-volume operations running a fixed formulation, providing sustained output without batch interruption.
Pegasus Hygienic Batch Mixer
Mixing, Dispersion and Emulsification
Liquid mixing in pharmaceutical and nutraceutical production encompasses a wide range of applications: dispersing APIs in suspension, emulsifying active ingredients into creams, gels, and ointments, dissolving excipients in liquid bases, incorporating powders without agglomeration, and homogenising formulations to specified particle size and uniformity.
Silverson high shear mixers are widely used in pharmaceutical manufacturing globally. With more than 60 years of experience supplying the pharmaceutical industry, Silverson has developed a range of Ultra Sanitary mixers with crevice-free construction designed for CIP and SIP operations. Mixers can be supplied with hygienic single or double mechanical shaft seals suitable for pressurised flush, and Silverson provides IQ/OQ documentation packages to support validation requirements for FDA and Medsafe submission.
The Silverson Batch Mixer (BX range) suits pharmaceutical and nutraceutical batch processes, providing rapid dispersion and homogenisation across a range of batch sizes. For continuous production, the Silverson Inline High Shear Mixer delivers consistent processing without large mixing vessels, with flow rates scalable to production volume. For research, development, and scale-up work, the Silverson L5M-A Laboratory Mixer applies the same high shear mixing technology at bench scale, allowing direct process transfer to production equipment and reducing the risk of variability between development and commercial-scale manufacture.
Silverson Inline Mixer
Capsule Filling
Hard capsule filling is one of the most common dosage forms in pharmaceutical and nutraceutical production. Capsules are versatile, widely accepted by regulatory bodies, and compatible with a broad range of fill materials, including powders, pellets, mini-tablets, liquids, and capsule-in-capsule combinations.
Harro Höfliger designs and manufactures capsule filling equipment for pharmaceutical and nutraceutical manufacturers. Their Modu-C HS high-speed system uses a patented rotary platform with interchangeable dosing trolleys, enabling rapid changeover between filling materials and dosing methods without extensive machine reconfiguration. Output capacity reaches up to 200,000 capsules per hour, making the system suitable for commercial-scale pharmaceutical and supplement manufacturing.
The modular dosing station architecture accommodates a wide range of fill formats — powder, pellets, tablets, mini-tablets, liquids, and combinations — within a single machine platform. This supports product portfolio flexibility for manufacturers producing multiple capsule products without requiring separate filling lines for each dosage form. Harro Höfliger’s process expertise spans the full development-to-production pathway, from early-stage feasibility through to high-volume commercial manufacturing.
Harro Höfliger Modu-C LS Capsule Filler
APS as a Pharmaceutical and Nutraceutical Equipment Supplier
The APS partner portfolio spans the key process stages in pharmaceutical and nutraceutical manufacturing — from raw material milling and powder blending through to screening, liquid mixing, homogenisation, and final capsule filling. All represented partners have established pharmaceutical industry credentials and offer equipment built to the regulatory and hygiene standards these sectors require. APS provides local support from Auckland, with direct access to partner technical teams for equipment specification, integration, commissioning, and ongoing service.
For pharmaceutical and nutraceutical manufacturers evaluating processing or packaging equipment, contact Advanced Packaging Systems to discuss your specific requirements.
