The company expanded capacity by re-purposing existing manufacturing space and adding new vaccine and bioprocess suites
The US-based International Society for Pharmaceutical Engineers (ISPE) named Pfizer Ireland Pharmaceuticals as the 2014 Facility of the Year Awards (FOYA) Overall Winner at the Society's annual meeting in Las Vegas, NV.
Pfizer Ireland's Network Strategy Implementation (NSI) Capacity Expansion project re-purposed an existing manufacturing space for a new vaccine suite and a new multi-product small-to-medium scale drug substance bioprocess suite at the company's Grange Castle plant in Clondalkin, South County Dublin.
Dublin-based Ardmac provided fit outs for the three new bio-manufacturing suites including ISO 6, 7 and 8 cleanrooms, enabling Pfizer to introduce new processing units and expand production and testing capabilities.
Ardmac was involved in all architectural elements to cGMP requirements, together with performance responsibility for lighting, air distribution, LAFs, clean cold rooms, biosafety cabinets and other equipment.
The fast track programme required innovative ideas to meet the NSI schedule, including the selection of a cleanroom ceiling to facilitate first and second fixed process services installation. This enabled parallel construction activities, resulting in one of Pfizer's fastest-ever project completions.
'The NSI Expansion Capacity project exemplified the mission of FOYA,' said ISPE President and CEO John Bournas. 'Pfizer Ireland's vision of empowerment and operational excellence enabled the company to produce a world-class manufacturing environment and expand the capacity of its biotech operations on an aggressive timeline.'
Throughout the project, Pfizer Ireland adopted a Lean Management Strategy and a 5S programme in the design process to ensure flow and operations. In addition, a Six Sigma toolkit was developed for all project personnel, and all production processes were value stream-mapped. The project team also ensured the new manufacturing suites included the latest technologies (i.e. EBR, PAT and disposable bag).
'The Society was impressed with the NSI Capacity Expansion project and the company's ability to effectively manage the challenges of maintaining supply with the demolition of existing facilities, new construction, and start-up and integration activities,' said James Breen, Chairman of the FOYA Judging Panel.
Celebrating its tenth year, FOYA showcases the pharmaceutical manufacturing industry's accomplishments in facility design, construction and operation, while sharing the development of new applications of technology and cutting-edge approaches.