Create formulations

Formulations represent product recipes with ingredients, quantities, processing instructions, and quality parameters. Each formulation can have multiple versions to support development iterations and regulatory approvals.

To create a new formulation, follow these steps:

1. Select the Search icon , enter Formulations, and then choose the related link.
   The Formulations page opens.

2. On the action bar, select New to create a new formulation or select the required Formulation No. field value to open an existing formulation.
   The Formulation page opens.

3. On the General FastTab, enter the required information in the following fields:

   Field	Description
   Formulation No.	Select the unique identifier for the formulation record. The system assigns this value based on the number series set up on the Formulation Setup page.
   Description	Enter a name or description of the formulation, often the product name or recipe name.
   Version Nos	Select the number series from which the version number is assigned. This controls how version numbers are generated when creating new formulation versions.
   Active Version	Specifies which version of the formulation is currently active (certified). This field is not editable and shows the version number that is currently certified for production use.
   Effective Date	Select the date on which this formulation version becomes effective for production use. If this value is left blank, the formulation can be used immediately upon certification.
   Status	Select the current lifecycle status of this formulation version. The available options are: New, Under Development, Certified, and Closed. This value is set to New by default.
   Notes	Enter general notes or a description of the formulation.

4. On the Product Information FastTab, enter the required information in the following fields:

   Field	Description
   Product Type	Select whether the formulation output is linked to a regular Item or a Catalog Item. The available options are: Item and Catalog Item. This value is blank by default.
   Product No	Select the Item No. or Catalog Item No. option that this formulation is intended to produce. This field is filtered based on the Product Type selection.

5. On the Output FastTab, enter the required information in the following fields:

   Field	Description
   Output Quantity	Enter the standard batch size that the formulation produces, if using batch size. This determines the base quantities for all ingredient calculations.
   Output Unit of Measure	Select the manufacturing batch unit of measure.
   Yield %	Enter the expected overall yield of the formulation batch as a percentage of output versus input. For example, enter 95 if you expect a 5% loss during processing. The value must be between 0 and 100.

6. On the Serving FastTab, enter additional information:

   Field	Description
   Serving Size UOM	Enter the serving size for nutritional calculations in the Output Unit of Measure field, if applicable.
   Serving Size	Enter the serving size for nutritional calculations in the Serving Unit of Measure field, if applicable.
   Serving Unit of Measure	Select the unit of measure for the serving size. This may differ from the Output Unit of Measure field value for consumer packaging purposes.
   Serving Count	Specifies the number of servings produced by this formulation batch based on the Output Quantity and Serving Size UOM field values. This field is not editable.

7. On the Security FastTab, enter additional information:

   Field	Description
   Formulation Visibility	Select the visibility level of this formulation. The available options are: Private (visible only to the creator), Shared (visible to all users with appropriate permissions), Group (visible only to members of a specific R&D Group).
   Owner Code	Select the owner of this formulation. For Private formulations, the system displays the creator’s user ID (read-only). For Group formulations, select the R&D group code that owns the formulation. For Shared formulations, this field remains empty. This field is editable only for Group visibility and when the formulation is not certified.

8. On the Notes FastTab, enter additional information:

   Field	Description
   Notebook ID/Name	Enter a reference to the lab notebook identifier or name.
   Page Number	Enter the page number in the lab notebook where this formulation is documented.
   Experiment Reference	Enter the experiment reference code or identifier in the lab notebook.

9. On the Production Integration FastTab, view the automatically generated production records:

   Field	Description
   Production BOM No.	Specifies the production BOM number generated from this formulation for traceability. This field is automatically populated when the formulation is converted to production structures.
   Production BOM Version	Specifies the production BOM version generated from this formulation for traceability.
   Routing No.	Specifies the routing number generated from this formulation for traceability when operations and phases are included.
   Routing Version Code	Specifies the routing version code generated from this formulation for traceability.
   Production Scenario No.	Specifies the production scenario number generated from this formulation for integration with production planning systems.

To add formulation lines, follow these steps:

After setting up the formulation header, you must add ingredient lines and processing instructions on the Lines FastTab.

1. On the Lines FastTab, select New Line to add ingredients and instructions.
2. For each line, configure the line type and identification.

3. In the Line Type field, select the type of line you are adding. The available options are:

   • Phase/Operation: use for processing steps, mixing instructions, temperature controls, and timing requirements.
   • Item: use for ingredients from inventory that are tracked in the item master.
   • Catalog Item: use for non-inventory ingredients that need to be tracked in formulations.
   • Formulation: use for sub-formulations to create hierarchical formulation structures.
   • Production BOM: use to reference existing production BOMs for ingredients or sub-assemblies.
   • Comment/Instruction: use for text-based instructions, warnings, or notes that do not represent physical ingredients.

4. In the No. field, select the number based on the line type.
   The Description field specifies the description.

5. For ingredient lines (Item, Catalog Item, Formulation, Production BOM), configure the quantity information.

6. In the Active Quantity field, enter the desired active amount of this ingredient. This is the primary editable field for quantity entry. The system uses this value to automatically calculate the net and gross quantities based on the ingredient type and potency settings.

For active ingredients with potency, when the Component Type is set to Active ingredient and the item has a potency attribute configured, the system performs the following calculations:

• Net quantity = active quantity ÷ (potency % ÷ 100) × (1 + overage % ÷ 100)

• Gross quantity = net quantity ÷ (1 − loss % ÷ 100)

• The Overage % field adds extra material to compensate for potency variations.

For non-active ingredients, when the Component Type is not Active ingredient or the item has no potency attribute, the system performs the following calculations:

• Net quantity = active quantity
• Gross quantity = net quantity ÷ (1 − loss % ÷ 100)

The Overage % field has no effect in this scenario since potency calculations are not applied.

The Quantity (Net) field displays the calculated net quantity required for the batch after potency and overage adjustments. This field is automatically calculated and not editable.

The Quantity (Gross) field displays the total quantity required, including loss allowances. This field is automatically calculated and not editable.

1. In the Unit of Measure Code field, select the unit of measure for all quantity fields on this line.
2. In the Loss % field, enter the expected scrap percentage for this ingredient during processing.
3. In the Overage % field, enter any overage added for potency compensation. This field applies only when the Component Type is Active ingredient and the item has a potency attribute.

For advanced ingredient management, configure the component classification.

1. In the Component Type field, select the component classification for this ingredient. The available options are:

   • Active ingredient
   • Dependent ingredient
   • Filler

2. In the Active Ingredient Line No. field, for dependent ingredients, select the line number of the active ingredient that this ingredient is associated with.

3. In the External Cost field, the system allows manual cost input for specialized pricing scenarios. For more information, see cost rollup analysis.

Adding phase/operation lines

When you select Phase/Operation as the Line type, the system enables specialized functionality for managing processing steps, timing, and resource requirements.

For phase/operation lines, enter the required information:

Field	Description
No.	Select the required value.
Description	Specifies the phase/operation description.

When you create a phase/operation line, the system automatically creates a corresponding phase/operation detail record. To configure phase/operation details, follow these steps:

1. Select a formulation line with the Line Type field value is set to Phase/Operation.
2. The phase/operation details group becomes visible and editable on the formulation line.
3. Configure the resource and timing information.