INDUSTRIES

Pavilion Pharmaceutical Solution

 

Pharmaceutical Industry Challenges

The pharmaceutical industry is undergoing a period of dramatic change. Pharmaceutical manufacturers today are challenged by increasing global competition, commoditization, new regulations, and higher quality standards. These market dynamics have made it clear that pharmaceutical manufacturers must fundamentally change their production processes to profitably compete in the global market while ensuring patients receive the highest quality products in time to make a difference in their lives.

To explore Pavilion’s approach to value for pharmaceuticals click here: “ValueFirst for Pharmaceuticals: A Four Phase Approach”

The FDA’s Process Analytical Technology (PAT) initiative is at the heart of this inflection point in the industry. While not the initial intent, regulatory requirements have restricted the pharmaceutical industry’s ability to quickly deliver qualified drugs to the market while continuously enhancing overall quality and efficiency. In an attempt to transition the industry from one of procedural requirements to one of continuous improvement, the FDA has sponsored the PAT initiative, which is defined as a:

“System for designing, analyzing, and controlling manufacturing through timely measurements (i.e., during processing) of critical quality and performance attributes of raw and in-process materials and processes with the goal of ensuring final product quality.”

Pavilion's Powerful PAT Portfolio

For more than 14 years Pavilion has helped leading chemical and food manufacturers deploy software solutions to transform large volumes of data into process understanding, and process understanding into real business value. Pavilion is uniquely suited to leverage investments in NIR sensors and other sensor technologies that produce volumes of online process data. Pavilion’s suite of software can mine volumes of data to identify what key process variables are affecting results.

Pavilion’s Suite of PAT Portfolio includes:

  • Multivariate data acquisition and analysis
  • Off-line “what if” analysis and simulation
  • Off-line model predictive control
  • Soft Sensor® online process monitoring and prediction
  • Soft Sensor® online validation and back-up
  • Online model predictive control solutions to achieve continuous improvement
  • Performance management solution to monitor and manage to key performance targets

 

Pavilion’s PAT portfolio leverages the powerful, easy-to-use Pavilion8 technology bolstered by more than 139 patents in the field of data cleansing, modeling, and control. Pavilion8, an integrated software suite, enables pharmaceutical companies to drive operational performance to desired business objectives while maintaining regulatory compliance. Powerful technology for modeling, control, monitoring, analysis, visualization, and integration are combined to provide targeted solutions, delivering faster time-to-value and greater cumulative value than alternative solutions.

Pavilion’s Pharmaceutical Solution

Pavilion’s Pharmaceutical Solution enables companies to visualize and analyze complex process relationships and directly leverage these advanced manufacturing models to enhance product quality and maximize production, while simultaneously reducing operating costs and improving manufacturing efficiency. Pavilion’s solutions can be applied at the pilot phase of drug development or in mature manufacturing environments. In the drug development cycle, Pavilion’s PAT solutions help to identify key variables affecting the production process, reduce process variability, and ensure continuous improvement is built in to the final manufacturing process. In a mature product, Pavilion’s solutions will help identify ways to reduce variability and costs, enhance product consistency, and increase production to meet market demand.

Pavilion is uniquely qualified to ensure your PAT investments deliver value. Pavilion can apply its suite of multivariate data analysis, online monitoring, prediction and control solutions to the following production processes.

To explore Pavilion’s approach to value for pharmaceuticals click here: “ValueFirst for Pharmaceuticals: A Four Phase Approach”

Pavilion’s Pharmaceutical Applications:

  • Granulation
  • Drying
  • Blending
  • Compression
  • Coating
  • Energy / Utility Center
  • Sensor Validation

 

Pavilion’s Biological Applications:

  • Fermentation
  • Sterilization
  • Filtration
  • Drying Liofilization
  • Energy / Utility Center
  • Sensor Validation

Transferability of Success to Pharmaceuticals

Pharmaceutical manufacturers can achieve the same successes with multivariate data analysis, prediction and control that other industries have realized. As an example, Fonterra Co-operative Group Ltd.’s dairy ingredients group, NZMP, began to implement Pavilion’s model predictive control (MPC) solution at its production facilities in 1995 to improve processing efficiency for milk proteins, powders, cheese and casein. The company realized a return on investment of over 60%. This value was derived by applying Pavilion’s model predictive control software to reduce variability of the evaporator, dryer and energy center processes. As a result NZMP was able to increase production rates by 5 to 15%, enhance product quality by 50%, increase energy efficiency by 5 to 12% improve overall product yields. Given this success, Fonterra elected an enterprise-wide agreement to install APC at many of its 23 New Zealand-based operations and majority-controlled overseas joint ventures.

For a detailed look at this Dryer & Evaporator Control case study, Click Here.

Pharmaceutical Solution Benefits

Our solutions are tailored to deliver results that achieve your business operating objectives, which may vary by phase of product development, maturity of product, geography, product type, and market demand. However, our solutions consistently deliver the following performance results for clients in a wide range of industries:

Accelerate Revenue

  • Increase production 1 – 12%
  • Speed time-to-market

Enhance Product Quality

  • Enhance customer satisfaction
  • Consistently achieve quality targets
  • Reduce risk for recalls

Reduce Costs

  • Reduce wasted use of raw materials by reducing process variability 10 – 80%
  • Reduce energy costs per ton by 1 – 10%
  • Enable more reliable, predictable plant operation
  • Reduce waste product

Environmental Compliance

  • Reduce emissions compliance costs by as much as 50%
  • Maximize production rates while not exceeding environmental constraints
  • Reduce emissions by 1 – 20%

 

To contact us for more information on Pavilion’s pharmaceutical solution, Click Here