The facility uses an American tablet press. “We extensively modified it,” says Raunegger. First the probiotic bacteria are pre-pressed into a fragile structure less than one millimeter thick. Then comes the mineral layer, followed by the vitamins. At the end of the process, the tablets are transformed into a viscous fluid state under more than two tons of pressure. When the pressure is removed, the tablet solidifies through mechanical interlocking. After powder has been removed by means of brushes, the tablets are sent to a coater that continually sprays them with a protective coating over a period of several hours.

That’s the basic version of the process, at least — but a closer look reveals a series of details that together ensure a consistent level of quality. When the tablet press is in operation, for example, it must be kept free of powder from the ingredients that invariably accumulates on it, to ensure there are no deviations from the formula and no discoloration of the different colored layers. “The amount of the substances entering the system is controlled by tare weighing,” Raunegger explains, adding that the precision of each individual measurement must be very high because of the possibility of cumulative errors.

Process quality is ensured by examining samples from every batch with regard to weight, hardness, thickness, the amount of force needed to break a sample, and the time it takes for the tablets to dissolve in water at a temperature of 37 °Celsius. The latter test simulates the tablets’ passage through the human body: If a tablet dissolves in the water before the specified time, the probiotic bacteria will not reach their destination in the intestine.

In the final step, the Bion®3 product is placed into plastic bottles that hold either 30, 60, or 90 tablets. Staff can do a recount if they want — but the photoelectric device at the end of the production line is infallible. “Each of these tablets,” says Raunegger, rolling a few around in his hand, “is like a tiny work of art.” And the formulation requirements do result in a product that is not only manufactured using sophisticated methods but also very attractive — even in an aesthetic sense. The underlying concept, which has led to the production of several billion such tablets in Spittal to date, also can be used for other tablets in the future. When we ask what kinds of tablet he has in mind, however, Raunegger remains silent for the first and only time during our visit.