KASON AND MARION BOOST BLENDING CAPACITY AT ALMAC PHARMA SERVICES NORTHERN IRELAND

Background and history

Almac Pharma Services, a member of the Almac Group, is a leading global pharmaceutical and biotechnology outsourcing partner, boasting over 50 years of experience. With a workforce of over 1,600 highly skilled individuals spread across four locations in the UK, Europe and the US, Almac Pharma Services provides a comprehensive suite of services. These include early and late-phase pharmaceutical development, clinical and commercial drug product manufacturing, product launches, commercial packaging and global distribution. 

Almac Pharma Services supports client portfolios in over 70 countries, offering fully integrated, end-to-end solutions tailored to the unique needs of clients and their patients.

Partnership

Since 2010, Almac Pharma Services has maintained a strong partnership with Marion and Kason, acquiring numerous pieces of both large and small-scale equipment and supplies. Marion and Kason's collective understanding of the company’s systems, procedures and processes, coupled with their ability to provide designs that can be easily replicated, thereby reducing the engineering work required by the company, makes them the optimal choice for its technological advancements.

The integration of Marion and Kason in 2019 as part of Advanced Materials Processing (AMP), has further solidified their role as a vital partner. Their continued grasp of Almac Pharma Services' operational framework makes them the perfect fit for its ongoing and future technology requirements.

Almac Pharma Services Northern Ireland requirements and challenges

Almac Pharma Services recently completed a significant expansion project at their global headquarters in Northern Ireland. This project involved the construction of a 32,000 sq ft custom-built, high-volume facility designed to enhance their commercial manufacturing and packaging capacity for sachet drug product presentations, serving their global client base.

The new facility includes additional large-scale manufacturing suites, automated primary and secondary sachet packaging technologies, and an expanded QC Laboratory testing capacity. This expansion required the addition of two new blending suites to meet the growing needs of their clients.

The primary challenge being to accommodate the increasing demand for high-quality sachet drug products while maintaining production efficiency and stringent quality control standards.

Marion and Kason’s solution

Almac Pharma Services invested in new blending and sifting equipment to accommodate the increased production demands from their global client base. The systems supplied were upgraded versions of previously installed equipment and included:

• Kason MO-B-V Centrifugal Sifter x 2 - able to screen powders, granular materials, and continuous scalping of dry or moist materials.
  
  
• Marion 400L (14 ft³) V Cone Blender x 2 - provides quick blends with consistent, gentle mixing ideal for delicate materials and abrasive solids. Its characteristic V shape promotes better drainage and discharge and is inherently clean by design, lacking any internal moving parts and eliminating product buildup.
  
  
• Marion 4200L (148 ft³) Double-Cone Blender x 2 - sets the industry standard for batch mixing with minimal maintenance. Tumble blending offers rapid, low-impact mixing for high-precision blends.

The newer systems were designed to meet the latest standards for ATEX, CE and Pharma Good Manufacturing Practice (GMP), ensuring compliance with stringent safety and quality regulations. Additionally, the control systems were extensively redesigned to include audit trail monitoring and data integrity assurance, critical for maintaining rigorous pharmaceutical manufacturing standards. The systems also required integration into the site-wide single log-on (LDAP) system and additional process routes to accommodate potential new products under development. Furthermore, it was recommended that a new powder discharge assist system be included. 

Installation and commissioning process

The installation and commissioning process was well planned and executed, beginning with a thorough site assessment and logistics coordination. Any installation issues were promptly resolved, resulting in the successful commissioning of the equipment within the specified timeframe, ensuring it was fully operational and ready for use.

Equipment performance and business benefits

• Equipment Performance - the newly installed blending equipment has demonstrated exceptional reliability and efficiency in its operation. Key performance aspects include:
   
  • Reliability - the equipment operates consistently without unexpected downtimes, ensuring continuous production cycles. This reliability is crucial for maintaining uninterrupted operations and meeting production schedules.
    
    
  • Effectiveness - the blending equipment effectively fulfils its required functions, including precise mixing of materials to achieve uniform consistency. This ensures high-quality output that meets the stringent standards of Almac Pharma Services and its clients.
    
    
  • Advanced technology - the equipment incorporates advanced blending technology, enhancing operational efficiency. Kason sifters include high-throughput centrifugal screening and continuous scalping, while Marion blenders feature efficient tumble blending and innovative design for gentle, uniform mixing and easy maintenance.
    
    
  • Ease of use - user-friendly interfaces and controls make the equipment easy to operate, reducing the likelihood of human error and increasing overall productivity.
    
    
  • Maintenance - the equipment is designed for easy maintenance, with accessible components and straightforward maintenance procedures, minimising downtime for repairs and servicing.

• Business benefits - the installation of the new blending equipment brings several significant business benefits to Almac Pharma Services:
  
  
• • Increased blending capacity - the primary advantage of the new equipment is its increased capacity, allowing Almac Pharma Services to blend larger volumes of materials in a shorter timeframe. This scalability is vital for meeting the growing demands of its expanding client base.
    
    
  • Enhanced efficiency - the advanced technology and reliability of the equipment enhance overall production efficiency. This means faster turnaround times for client orders and the ability to handle more projects simultaneously.
    
    
  • Quality assurance - the precise and consistent blending capabilities ensure that the final products meet high-quality standards. This quality assurance strengthens Almac Pharma Services’ reputation for delivering reliable and superior solutions to its global customers.
    
    
  • Timely deliveries - with increased capacity and efficiency, Almac Pharma Services can meet tight deadlines more effectively, ensuring timely delivery of products. This reliability in meeting deadlines is a critical factor in maintaining and expanding client relationships.
    
    
  • Cost savings - the reliable performance and ease of maintenance of the new equipment reduce operational costs associated with downtimes and repairs. Additionally, the increased capacity can lead to economies of scale, further lowering production costs.
    
    
  • Competitive advantage - the ability to meet higher demands and deliver quality products promptly gives Almac Pharma Services a competitive edge in the market. This positions the company as a preferred supplier in the industry, capable of handling large-scale and complex projects.

Future Plans

Almac Pharma Services has established a strong working relationship with AMP, largely characterised by regular communication with a designated project manager, responsiveness in addressing maintenance requirements and resolving any issues.

Looking ahead, Almac Pharma Services plans to continue working with AMP for future equipment and supply needs. As Almac Pharma Services continues to expand and meet ongoing client demands, the proven reliability and performance of AMP's equipment make them a preferred partner for future investments.

Summary 

The partnership between Almac Pharma Services and AMP-AHS demonstrates a successful collaboration that both fulfils current needs and anticipates future growth.

Through this case study, it is clear that Almac Pharma Services’ strategic choice of equipment providers and its commitment to quality and efficiency, continue to drive its position as a world-leading outsourcing partner in the pharmaceutical and biotechnology industry.

"Our collaboration with AMP has been valuable. Their understanding of our needs and their ability to deliver high-quality, reliable equipment has enabled us to significantly enhance our manufacturing capabilities. We look forward to continuing this successful partnership as we expand and innovate to meet the growing demands of our global clients." 

Wayne McCarten
Technical Specialist 
Almac Pharma Services

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