Top Plant 2012: Pfizer Global Supply

12/17/2012


The savings are significant. Taylor said the annual energy decrease is more than 23,000 MWh. The fluorescent T8 lamps provide higher lumen output and better lumen maintenance, and they provide the opportunity to switch lights on and off based on occupancy, he said.

The Kalamazoo plant’s water conservation projects include process-water control-automation improvements, condensate return line replacements, and HVAC retrocommissioning. The average annual water consumption decrease is more than 2,000,000 cubic meters.

Robots insert formulated product materials into trays in the drug product plant. Robotics play a key role in plant operations. Courtesy: Pfizer Global SupplyThe energy management system installed at the plant in 2009 monitors utilities and provides data to the utility historian. In addition to displaying data in real time on the plant’s Web-based energy dashboard, the facility has more than three years of data archived within the utility historian.

“We created internal Web pages where we can view and trend every utility meter on campus,” Taylor said. “Anyone on-site can look at this tool. Operators can see immediately how their processes affect energy usage.”

As with many facilities, one of the Kalamazoo plant’s major challenges is to continue to identify and act upon energy-saving opportunities with limited resources.

Operations, continuous improvement

Pharmaceutical raw materials are produced in the Kalamazoo facility’s active pharmaceutical ingredient (APl) plant in preparation for formulation in the drug product (DP) plant. API processes include fermentation, isolation, and chemical synthesis. The Capped vials are inspected, labeled and packaged before shipping, as part of the rigorous requirements in the Pfizer plant. Courtesy: Pfizer Global Supplytypes of equipment used in the API plant are similar to those used in a typical chemical plant: pressure vessels, heat exchangers, piping systems, and water filtration devices. Equipment used in the DP plant includes container filling lines, freeze-dry operation, packaging machines cartoners, and palletizers.

Product flow generally begins with materials made in the API plant and ending in the DP plant for formulation. After formulation, vials or bottles are processed through the various filling areas, with some being freeze-dried, and are ultimately capped. The capped vials are inspected, after which they are labeled, packaged, and shipped.

“This plant is diverse,” said Jason Cassiday, senior manager, operational excellence. “The batch processes in our plant are very similar to what you’d find in a chemical plant. We also have typical production lines where we fill bottles and vials.”



The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Women in engineering; Engineering Leaders Under 40; PID benefits and drawbacks; Ladder logic; Cloud computing
Robotic integration and cloud connections; SCADA and cybersecurity; Motor efficiency standards; Open- and closed-loop control; Augmented reality
Controller programming; Safety networks; Enclosure design; Power quality; Safety integrity levels; Increasing process efficiency
This article collection contains several articles on how advancements in vision system designs, computing power, algorithms, optics, and communications are making machine vision more cost effective than ever before.
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Automation Engineer; Wood Group
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me