Osberley’s production facility is located in an industrial zone designated for biotechnology and feed additive manufacturing. The layout follows a linear flow — raw material reception, fermentation, downstream processing, blending, and packaging — to minimize cross-traffic and contamination risk. Visitors are not permitted in production areas without proper gowning and prior notice.

Fermentation Area

The fermentation section houses stainless steel vessels ranging from 5,000 to 30,000 liters. Each vessel is equipped with automated controls for temperature, pH, dissolved oxygen, and agitation speed. Operators monitor parameters from a separate control room. Sampling ports allow aseptic collection without opening the system.

Downstream Processing

After fermentation, the broth moves to separation and concentration units. Centrifuges separate biomass from supernatant. Filtration and spray drying follow. The entire downstream train is enclosed. No manual handling occurs between unit operations.

Blending and Formulation

Dry ingredients are weighed and transferred into ribbon or paddle blenders. Blending times are preset based on product-specific validation runs. The blending area maintains negative air pressure relative to adjacent corridors to contain dust.

Packaging and Labeling

Finished products are packaged under controlled humidity. Lines are cleaned between batches. Labels are verified by scanning before application. Each container receives a batch number and expiration date printed directly on the package. Secondary packaging uses corrugated boxes with internal dividers.

Warehousing

Raw materials and finished goods are stored separately. Temperature and humidity are monitored continuously. First-expiry-first-out (FEFO) rotation is enforced. Quarantine zones hold materials awaiting test results. No product is released without a signed Certificate of Analysis.

Visitor Protocol

Factory tours are available for qualified business partners by appointment. Visitors must wear provided coveralls, hairnets, and shoe covers. Photography inside production areas is restricted. Tours last approximately 45 minutes and cover the main production flow without entering restricted zones.