Manufacturing

ERC is a leading contract manufacturer that specializes in enzymes and enzyme-based products. Our facilities operate under strict Good Manufacturing Practices (GMP’s)(2009)
and have been inspected and audited by independent third parties. ERC facilities are
also EURO(2005), Kosher (2012) and Organically Certified(2005). From qualifying our suppliers to delivering the finished product every step in our process is carefully monitored and documented with full traceability. Due to the intense amount of testing and documentation that is now required our typical lead times for finished powder or encapsulated products is approximately eight weeks.

ERC’s manufacturing and packaging operations are split between two buildings.
All manufacturing operations happen in the main building which is approximately 10,000 square feet. All packaging, fulfillment and shipping operations happen in the second
building which is over 11,000 square feet.

In addition to our highly organized and immaculate facilities we also maintain an Advisory Board that helps us stay on top of the latest developments in the enzyme industry. The Board includes leading medical doctors, naturopathic doctors, chiropractors, pharmacists and research scientists.

Custom Blends

If you or your client are looking for a specific blend of multiple enzymes ERC offers single batches ranging from five (5) kilos to two hundred and fifty (250) kilos. If additional ingredients are required for a blend we also stock probiotics, herbals as well as specialty raw materials. All finished powdered products are packaged in two 4-mil poly bags with desiccant(s) added and then sealed with zip ties. They are then placed in single walled corrugated kraft cardboard boxes with weights from one (1) kilo to ten (10) kilos. Double walled corrugated kraft cardboard boxes are used with weights from eleven (11) kilos to twenty-five (25) kilos. All boxes will have a red ERC QC seal of approval.

Quality Assurance

Our quality assurance department has the responsibility and authority in the following two areas:

INTERNALLY

    • GMP training is given to all personnel. This means every employee that works in our production areas are trained and qualified. Post GMP tests are given to ensure the effectiveness of the trainings.
    • Quality improvement means that all of our procedures, paperwork and documentation are continually being updated.
    • Internal audits are conducted quarterly to monitor what we are doing vs. what we say we are doing.

EXTERNALLY

    • QA oversees and facilitates all regulatory inspections as well all client audits.
    • QA establishes our approved suppliers list through verifying their ability to consistently deliver high quality materials.
Quality Control

The quality control department performs all testing and inspection pertaining to the approval and release of all incoming raw materials as well as all outgoing finished products. We have a full service on-site lab that is run by our highly trained, experienced and professionally educated staff. Our laboratory equipment and capabilities include the following:

MICROBIAL SCREENINGS (guarantees purity and safety)

    • E. coli
    • Lactic Acid Bacteria
    • Mold
    • Total Aerobic Plate Count
    • Total Coliforms
    • Yeast

IDENTITY CONFIRMATION (guarantees consistency and accuracy)

    • Fourier Transform Infrared (FTIR)
    • Microscopic Image Analysis
    • Organoleptic Testing

 

ADDITIONAL CAPABILITIES

    • ATP Screening
    • Moisture Content
    • pH Determination
    • Powder Particle Size
    • Stability Studies
Encapsulation

ERC utilizes Model 10 Encapsulation Machines manufactured in the U.S.A. by Schaefer Technologies. The auger and table speeds can be fully adjusted in order to meet our requirements for enzyme production. All capsule polishers are also manufactured in the U.S.A. by Schaefer Technologies. We have multiple sets of change parts in a variety of sizes (#3, #2, #1, #0, #00) that are capable of running any type of capsule (gelatin, vegetable, NP, chlorophyll, etc). All encapsulation machines are run in rooms with:

    • Dust collection
    • Filtered Air (.5 microns)
    • Positive ventilation
    • Temperature and humidity controls
Powder Fill

ERC uses powder fillers manufactured in the U.S.A. by All-Fill.  The powder fill line is operated in a room that has:

    • Filtered Air (.5 microns)
    • Positive ventilation
    • Temperature and humidity controls

We can fill containers ranging in size from one (1) ounce to two (2) kilos. The finished product is weighed twice on two separate scales to ensure that it meets label claim for weight. Scoops and desiccants are added before the lid is applied. Labels and outer shrink sleeves are applied before being run through the heat tunnel. Finished products are boxed according to customer specifications. All boxes will have a red ERC QC seal of approval.

Packaging

ERC’s second building ( over 11,000 square feet) is where all of the packaging, fulfillment and shipping of encapsulated products are completed. We maintain three separate packaging lines. The first semi-automated line is for small trial sample orders that do not exceed 250 bottles. The second semi-automated line is designed for orders from 250-5,000 bottles. The third packaging line is fully-automated using machines manufactured in the U.S.A. by Dietz. Any orders over 5,000 bottles are run on this line. We have the capacity to produce over eight (8) million bottled products annually running our machines two shifts per day four days per week.

Shipping

All finished products are either shipped by CDS, Kuehne + Nagel, UPS or USPS.
Both incoming and outgoing vehicles/trailers are visually inspected every time.
We have ongoing agreements with our shippers that ensure the quality and safety of our products during the shipping process. Adequate amounts of insurance are purchased for every shipment.

 

  • Shipments that are a half-pallet and larger are processed and shipped through
    Complete Distribution Services anywhere in the USA. They meet or beat 98%
    of the quotes that we receive from other carriers.
  • Kuehne + Nagel offers a fast and affordable option for shipping larger
    quantities internationally.
  • UPS offer fully trackable and traceable deliveries world-wide with a daily
    scheduled pick up.
  • USPS offers online postage and labeling world-wide with delivery confirmation
    (USA only) and picks up small fulfillment packages from our facility daily.