Pfizer, Sterile Manufacturing Facility, Site Master Planning, Spain

About this project

DPS were engaged to carry out a Site Master Plan and Feasibility Study for the Pfizer Algete site in Spain for a future sterile manufacturing expansion for a range of product formats; vials, pre-filled syringes, cartridges and dual chamber syringes and sterile bags. The study assessed the opportunities on the existing site for cost effective logical development, including re-purposing of existing buildings and potential expansion opportunities. The study took account of all aspects of a manufacturing facility; including supply chain, materials handling, warehousing, dispensing, QC laboratories, utilities, administration and traffic management.

The feasibility study for the new high speed Pre-Filled Syringe Line assessed a number of manufacturing strategies, potential locations and selected a preferred option based on a benefit analysis of each option considering areas such as; investment costs, operational costs, warehousing, implementation schedule, impact on existing operations etc. The pre-concept design considered lean engineering principles, minimising clean space and maximising grey space. Pre-concept layouts took account of optimum materials and personnel flows with unidirectional flows where appropriate. Indirect black utilities were provided from the existing CUB with clean utilities dedicated to the proposed new sterile facility.

The master plan succeeded in demonstrating logical development and expansion of the site within a cost effective strategy as a centre of excellence for sterile manufacturing.