Top Plant 2012: Pfizer Global Supply
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.
The 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 types 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.”
Annual Salary Survey
After almost a decade of uncertainty, the confidence of plant floor managers is soaring. Even with a number of challenges and while implementing new technologies, there is a renewed sense of optimism among plant managers about their business and their future.
The respondents to the 2014 Plant Engineering Salary Survey come from throughout the U.S. and serve a variety of industries, but they are uniform in their optimism about manufacturing. This year’s survey found 79% consider manufacturing a secure career. That’s up from 75% in 2013 and significantly higher than the 63% figure when Plant Engineering first started asking that question a decade ago.