By using the latest technology and automating and robotizing processes, we ensure impressive production efficiency. With the implementation of three-shift manufacturing, we are able to make nearly 40,000 product items per day, or more than 9 million items per year.
The production of dietary supplements is a complex process involving many steps. Fitness Authority® is committed to ensuring consistent, superior quality throughout the manufacturing process.
We have tailored our production to meet customer expectations and the standards of even the most demanding markets. The plant meets the highest standards in the areas of production process safety (GMP), quality assurance (HACCP), hygiene (GHP), food safety (IFS) and Halal. In addition, we are FDA-certified by the U.S. Food and Drug Administration, confirming that our products are safe, meet high quality requirements and have no negative health effects.
Before a batch of a given raw material is purchased, a sample of it is sent to the technology department along with the required quality documentation from the supplier, including certificates of analysis, other certificates and declarations. In order for the purchase to be completed, the sample must receive a positive qualitative and technological assessment.
Raw materials are also inspected upon acceptance of delivery. At this stage, the quality assurance department takes reference samples from each batch. In the company's physical and chemical laboratory, quality tests are carried out to determine compliance with specifications and comparative evaluation with previously sent samples. Only those raw materials that received a passing grade in the tests are qualified for the next stage of production.
Fitness Authority® employees undergo thorough training in order to consciously and effectively ensure the quality of the manufactured product, at every stage of its creation. Any deviation from the standards is immediately reported to the quality service, in order to implement adequate corrective actions.
Thanks to the use of a precise ingredient weighing system, we are guaranteed that the right raw materials in strictly defined proportions go into the product. After all the ingredients are mixed, the mixture is subjected to a detailed quality assessment. Before hydration, the uniformity of the structure is checked – whether it is free of clumps, impurities and foreign bodies.
It is then subjected to quality testing in accordance with the scope of testing and inspection established for the product type. After hydration, it is subjected to sensory evaluation, during which its submersibility, solubility, odor and taste are verified.
We qualify for the next stage of production only those mixtures that receive a positive control evaluation.
A number of 100% inspection points have been planned for the packaging process, with automatic rejection of products that do not meet the established acceptance criterion (packaged products control, metal detector, presence of induction insert, seal quality, and coding of unit and bulk packaging).
Before leaving the production plant, pallets of finished products are secured and marked with a logistics label. Thus prepared, they go to the Fitness Authority® distribution center in Otomin, from where deliveries are made directly to several hundred customers in more than 80 countries around the world.
Our state-of-the-art production line makes it possible to print information on self-adhesive and heat-shrinkable labels (sleeves) or directly on unit packaging. The use of dedicated color ink allows us to print on black containers as well. Thanks to these solutions, we can be sure that products leaving the packaging line are labeled in an aesthetically pleasing, legible and durable manner, and fully in accordance with the individual preferences of each customer.