1 · Where we are
PharmaZen Magnesium Bisglycinate runs in DE / FR / IT / ES. Record week: ~4,200 jars. We buy finished jars from Slovenia at €2.45/jar.
2 · Assumptions — drag, type, challenge Click to expand sliders
Every number carries a confidence tag: verified estimate unverified guess. Click a tag to change it. Changes are saved for everyone.
3 · Cost per jar — us vs Slovenia
We pay BIO PAK €2.45 for a finished jar today. Here is what it costs if we make it ourselves in Poland.
4 · Production line
Fully automated capsule line — fill through checkweigh. D-Top quote Mar 2026
- NJP-1200 capsule filler — powder into empty caps
- Deduster — vacuum clean filled capsules
- 16-channel counter — count caps into jars
- Desiccant inserter
- Capper
- Induction sealer (tunnel) — tamper-evident seal
- Labeler
- Checkweigher — reject out-of-tolerance jars
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Bill of Materials — per jar (FOB China, low bound)
120 HPMC size 00 caps, PET 250cc, silver closure + induction seal, peel-off label. EU packaging sourced locally; actives + capsules from China with inbound freight.
| Component | Qty / jar | Unit | Price | € / jar | Source / note |
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5 · Multi-product factory — use the line for more SKUs
Same capsule line can fill other UK portfolio products — not just EU magnesium. Tick products to see how extra volume spreads fixed costs and speeds payback. Jun 2026 candidate list
6 · Cost per jar by volume
Slovenia price is flat. Own production falls as fixed costs spread over more jars. Dotted line = today's volume.
7 · Open questions
Click a status to cycle: open → in progress → done.
8 · Compliance in Poland — what the law actually requires
Supplements are a food business, not pharma-GMP. That keeps costs down — but several steps must be done by licensed professionals, not in-house.
- Class D GMP cleanroom with full HVAC validation is not required for food-grade supplement production.
- You need hygienic rooms: washable surfaces, clear flows (people / materials / waste), separated zones, hand-washing points.
- Capsule filling can run in a clean, normal production room — not a classified cleanroom.
- Class D only matters if you target pharma certification or specific export markets. Skip it at launch to save money.
These cannot be done by the owner or a general builder and signed off legally on your own.
- Projekt technologiczny (technological layout for Sanepid) Prepared by an authorised food technologist. Floor plans, material & people flows, equipment layout, water/sewage points. Without it you will not pass Sanepid odbiór (final acceptance). Cheap but critical — a few thousand PLN. Order this first, before any build-out or container install.
- Sanepid process management Handling approvals with the sanitary inspectorate. Often bundled with the technologist — e.g. DDD-NOWICKI, SANEFIT. Saves expensive rework.
- Powiadomienie do GIS (product notification to Chief Sanitary Inspector) Must be filed at least 14 days before sales. Can be done yourself, but a consultant is safer — rules tighten from April 2026.
- Electrical install + machine connections Panel, grounding, line hook-up. Requires a certified electrician with SEP qualifications and official protocols. You cannot legally sign off the electrical acceptance yourself.
- Water & sewage connection Plumbing — especially in a container setup — needs professional install and official odbiór (acceptance sign-off).