Pfizer, Sterile Manufacturing Expansion

About this project

The master plan assessed the opportunities on the existing site for cost effective logical development, including all aspects of a manufacturing facility; supply chain, materials handling, warehousing, dispensing, QC laboratories, utilities, administration and traffic management.

The concept design involved 2 separate sub-projects;

• Multi-product Aseptic Area – standalone independent 3 floor facility with dispensing, formulation, equipment prep., filling and lyophilisation with future expansion opportunities.
• CA2E – Current Aseptic Area Expansion – reduced cost option, leveraging existing aseptic suite facilities for shared services, equipment wash and preparation and formulation.
  The concept study addressed the most space and cost effective design for a new isolated filling line with lyophilisers and assessed a number of manufacturing strategies.

Key project attributes

The concept design involved a significant capacity analysis exercise utilizing Schedule Pro, where numerous manufacturing strategies were assessed to enable the most cost effective, operationally efficient option to be developed. A number of technology assessments were undertaken and white papers generated which were reviewed and risk assessed in order to take considered decisions;

• Formulation Strategy
• Single Use Fluid Path Design
• Lyo Refrigeration
• Lyo Load and Unload
• Isolator vs RABs

The main long lead equipment URS’s were developed and budget quotations solicited from a range of vendors.