Zventory’s AI-powered system enabled a GMP-certified nutraceutical manufacturer to ensure complete batch traceability, QC compliance, and faster, audit-ready production approvals.

Achieving Complete Batch Traceability, QC Compliance & Faster Production Approvals Using the Zventory (AI Powered)

Industry: Nutraceuticals, Herbal Supplements, Wellness Powders, Capsules & Tablets

Company Size: 300+ workforce, GMP-certified facility

Modules Used: Inventory, Production, QC/QA, Purchase, Sales, Dispatch, DMS, HR

Key Challenges: Batch tracking, QC compliance, document control, expiry management, audit readiness

Background

A rapidly expanding nutraceutical manufacturing company producing herbal supplements, protein powders, wellness capsules, gummies, and vitamin tablets was struggling to maintain regulatory compliance and operational efficiency.

• GMP (Good Manufacturing Practices) adherence
• Batch traceability
• QC/QA approvals
• Regulated documentation
• Expiry & shelf-life tracking
• Purchase planning for active ingredients

Previous reliance on spreadsheets, manual batch records, and scattered documents caused delays in QC approvals, material mismatches, expiry-related rejections, missed audits, and slow production cycles.

To eliminate inefficiencies and improve compliance, the company implemented the Zventory (AI Powered).

The Challenges

1. Batch Management Issues

Manual tracking of ingredients like herbal extracts, vitamins, capsule shells, and flavoring agents caused:

• Wrong batches used in blending
• No visibility of batch lineage
• Issues during product recall simulations
• QC delays due to missing batch details

2. QC/QA Documentation Problems

QC testing for heavy metals, microbial load, particle size, moisture, nutrient composition, and sensory checks was:

• Paper-based and misfiled
• Difficult to access during audits
• Not linked to production batches
• Absent digital trail

3. Production Planning Delays

Production teams lacked clarity on:

• Raw material availability
• Upcoming orders
• Pending QC approvals
• Machine availability
• Shift-wise workload

4. Expiry & Shelf-Life Issues

Short shelf-life ingredients such as probiotics and herbal powders caused:

• Near-expiry batches not used in time
• Material discards
• Finished goods stock losses

5. Audit Readiness Challenges

Scattered documentation led to:

• Long GMP audit durations
• Difficulty tracing specific batch records
• Outdated or missing SOPs
• Regulatory inconsistencies flagged by inspectors

The Solution Implemented

The Zventory (AI Powered) implemented a fully compliant, traceable, and automated operational ecosystem.

✔ Complete Batch-Wise Tracking

• Batch number, manufacturing date, expiry date, QC status, supplier details, storage zones
• Full backward & forward traceability: Raw Material Batch → Production Batch → Finished Product Batch → Dispatch
• Regulatory alignment and easier audits

✔ Digital QC/QA Module

• Sample registration
• Inward, in-process, and finished goods QC
• Stability tests and approval workflows
• Automatic batch status updates preventing unapproved production

✔ Seamless Production Planning

• BOM-based material consumption
• Machine-wise production scheduling
• Running vs pending job reports
• Workflow tracking: blending, granulation, encapsulation, coating, packing
• Shift-wise workload assignment

✔ Expiry Tracking & FIFO Execution

• Near-expiry raw material alerts
• FIFO execution for batch consumption
• Finished goods nearing shelf-life highlighted

✔ Document Management System (DMS)

• SOPs, BMRs, BPRs, QC reports, stability reports
• GMP certificates and machine calibration logs
• Instant auditor access

✔ Auto Purchase Indent & Forecasting

• Automatic purchase indents based on production load
• Vendor lead time tracking
• AI-driven future requirements forecasting

✔ Dispatch Automation

• Dispatch only after QC approval
• Packaging verification
• Batch documentation checked before delivery
• Complete digital logistics visibility

The Results

1. 100% Accurate Batch Traceability

2. QC Approval Time Reduced by 55%

3. 40% Improvement in Production Efficiency

4. Expiry-Related Wastage Reduced by 65%

5. Fully Audit-Ready Documentation

6. Zero Manual Errors in Dispatch

Conclusion

The Zventory (AI Powered) provided the nutraceutical manufacturer with a robust, compliant, and scalable digital infrastructure. Automated batch tracking, QC integration, DMS, and intelligent production planning enabled higher compliance, lower wastage, faster production, consistent quality, and stronger customer trust—transforming GMP audits and production capacity with confidence.