Pfizer makes a major mark in Ringaskiddy

Pfizer was the first major pharmaceutical company to establish a presence in Ireland. In 1969 it began building a plant at Ringaskiddy in Cork that went into production in 1971 and today is the ADM citric acid facility.

It subsequently increased its capabilities in the area with the construction of four organic synthesis plants, which came on stream in 1972, 1984, 1995 and most recently at the end of 2001.

All these plants are computer-controlled batch operations for the bulk manufacture of active pharmaceutical ingredients. They are designed for optimum flexibility and are multipurpose plants for producing a variety of products. In addition, Pfizer has plants in Loughbeg, Little Island and Dublin, but with a staff of around 580, the Ringaskiddy plant is the largest in terms of employment.

no skills shortage

Ireland is Pfizer's biggest business unit globally, measured in manufacturing capacity. There are two main reasons why the country is a magnet to pharmaceutical companies, according to Jack Allen, director/team leader, Ireland Project Engineering, Pfizer Ireland Pharmaceuticals. The first is the attractive rate of corporation tax, and the second is the availability of a qualified workforce. 'In the early 70s there was a shortage of experienced personnel, but the area is now very well served with a good supply of third level graduates from the local Universities and Institutes of Technology. As time went on the people in the area became very good at operating the plants - in general, they adapted very well even though they had no prior experience.'

The ready availability of skilled people applies also to the construction and maintenance of the plants. Pfizer moved towards using local management of projects with the refurbishment of the OSP1 plant in 1980. Then when the time came to build the three further plants, the design, construction management and commissioning were all managed by staff from the local facility and the entire projects were headed up by Pfizer Ireland teams. 'There is also a lot of construction support and general support locally,' says Allen.

A list of approved suppliers would be drawn up and given to the construction contractor. 'In putting that list together we would be conscious of maintaining a number of Irish suppliers provided that they are up to scratch in terms of materials and costs,' stresses Allen.

For example, the main design contractor for OSP4 was Foster Wheeler, of Reading in the UK, but virtually all the other contractors were Irish. Exceptions were items of equipment, which were obtained from companies with which Pfizer has a long-standing tradition of supply and which are not available from Irish manufacturers, and some of the stainless steel vessels, which Irish fabricators were either unable to handle or too busy to make. On the other hand, the heating and cooling systems and sampling systems came from Irish suppliers. 'They were very professional and offered a highly satisfactory service overall,' comments Allen.

'The other advantage of using local suppliers is that you can just pick up the phone or pop down the road see that everything is OK. We have also found that they come in on time, and once you have agreed on a design, you get what you asked for. They are also good at providing the support documentation. 'And because they have experience in working with the local pharmaceutical industry they have a good understanding of what you are looking for,' he adds.

But the real benefit lies in the after-sales service. 'Among suppliers we look for quality systems, good management structure, ability to respond and deal with an issue, and good value for money. You judge people on the work they do. If circumstances are right, you give them a chance and if they do well, you continue to do business with them.'