AB | Case History

AB forPfIZEr

A SIGNIFICANT TECHNOLOGICAL AND APPLICATIVE CASE IN THE FIELD OF COGENERATION TO SERVE

THE PHARMACEUTICAL INDUSTRY

AB for PZIfEr

AB IS A PArTNEr of PfIZEr,

TO WHICH IT SUPPLIES ELECTRICITY

for ITS INTErNAL MANUfACTUrING AND

LINES AND UTILITIES.

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STRATEGIC

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CoGENErATIoN:

Pfizer is one of the leading

international Groups worldwide

in the field of research applied to

the pharmaceutical industry. for

some years now, Pfizer has been

extremely attentive towards the

themes of eco-sustainability and the

quality of the natural and working

environments. This philosophy has

been applied by long-term choices

also involving a growing attention for

energy production and cogeneration

in particular, which is considered the

ideal solution for the optimisation

of performance, at the same time

consolidating a commitment to the

environment from all viewpoints.

The awareness of the advantages of

cogeneration has, in fact, led Pfizer

engineering to request development

of a cogeneration plant able to meet

the growing needs of their production

lines, and those of the service

infrastructures.

A ProCESS WHErE IT IS ESSENTIAL To STrEAMLINE ENErGY CoSTS WHILE MAINTAINING PEAK PErforMANCE IN fULL rESPECT of THE ENVIroNMENT.

STRATEGICfor THE PHArMACEUTICAL INDUSTrY

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THE PFIZER GROUP: rESEArCH, AUTHorITY AND ATTENTIoN To QUALITY IN ALL ASPECTS.

Founded in the United States of America in 1849,

Pfizer is today the pharmaceutical company that

invests most in research and development, with

more than 8 billion dollars invested in 2007. They

have research centres in various different countries,

and particularly in the United States of America

and England. Today, they can rely on around 85

thousand employees worldwide, with products

exported to more than 150 different countries. The

product portfolio includes 7 different pharmaceutical

products, number one in their respective therapeutic

areas, and a turnover that in 2007 exceeded 48 billion

dollars. Over the last ten years, investment in basic

research has tripled production and allowed for

the discovery of new pharmaceutical products. The

Pfizer research laboratories are responsible for the

discovery of some of the most innovative medicines

in recent years.

The research group is involved in various clinical

experiments aimed at producing data useful to the

registration of pharmaceutical products the world

over. Specifically, many of the clinical studies carried

out in Italy today, are multicentre international

studies with phase II, II, III or IIIb.

In 2007, Pfizer Italy’s total expenditure for research

amounted to 8.3 million euros, exceeding the efforts

made in 2006,when approximately 6 million euros

were invested. With 938 centres and 70 researchers

involved (43 employees and 27 on a specific contract),

Pfizer Italy research mainly concentrates on oncology

and other areas of significant interest: infection

diseases, central nervous system, endocrinology,

cardiovascular diseases, diabetes, urogynecology,

pain and inflammatory diseases.

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The Ascoli Piceno plant was set up in 1972 to produce

for Italy, the United States of America and Japan. It

is the only plant in the whole world to produce a new

pharmacological product to treat gastrointestinal

tumours. Although the production plant dates back to

1972, it is one of the most advanced around, from both

a technological and industrial architecture viewpoint.

Over the years, the plants have been significantly

modernised, with the introduction of new technology

and the extension of services. The plant occupies

a total surface area of 164,000 square metres, of

which 24,000 m² covered by plants, warehouses and

other structures, and 140,000 m² land: the sheer size

of this surface area not only leaves plenty of room

for the existing structures, but also allows for the

planning of future extensions according to company

strategies and objectives. The large areas taken

up by production departments and services allow

for complete compliance with good manufacturing

standards and the movement of raw materials and

finished products in accordance with maximum

rationality criteria. The plant has an estimated

production capacity of around 90 million packages a

year, with three production shifts. Apart from a fully-

automated warehouse with 13,000 automatic pallet

places, it also boasts technology that allows for the

highest levels of automation and maximum control of

movement of the active ingredients, which therefore

never once come into contact with the production

workers. The conditioning system provides ample

assurance against cross contamination: the area is

never recycled and is treated with absolute filters,

both in and out. The main pharmaceutical forms

supplied are: granules, simple and coated tablets,

rigid capsules, for a total of 1300 presentations

distributed on more than 100 markets. More than

60% of production goes to foreign markets, meaning

that the procedures and processes are aligned to the

strictest standards imposed by international laws,

and specifically to the United States FDA.

The Ascoli Piceno plant is currently the only one

worldwide to produce a pharmaceutical product,

Sutent (sunitinb malate) for the treatment of

gastrointestinal tumours and metastatic renal

carcinoma.

THE PfIZEr GroUP HAS BEEN A PrESENCE IN ITALY SINCE 1955, WITH TWo ADMINISTrATIVE offICES IN roME AND MILAN, AND ProDUCTIoN PLANTS IN ASCoLI PICENo (MArCHE) AND PISTICCI, ProVINCE of MATErA (BASILICATA).

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A CoLLABorATIoN AND A PLANT To BE ProUD of.

AB and PFIZER

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The system designed and built by AB for the Pfizer Ascoli Piceno plant is a significant technological and applicative

case history in the field of cogeneration to serve the pharmaceutical industry. The reasons for the interest in this

plant go well beyond the simple fact that working for Pfizer, one of the most important international groups

worldwide in the field of applied research into pharmaceuticals, is, without doubt, in itself greatly satisfying.

Meticulous as always, in all development initiatives, Pfizer carefully monitored the cogeneration market,

identifying AB as their ideal partner for the intended solution, but also in terms of overall business reliability that

ranges from the capacity for preliminary consultancy to service and assistance guarantees. After a call for bids,

the order was formalised in September 2007. The perfect integration into the general pre-existing plant complex

and compliance with the strict, demanding supply timing, stand out in particular. This is also why the Pfizer case

history is important, well beyond the technology applied within the plant.

AB and PFIZER

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THE Ecomax®

PFIZER, HAS SPECIFICALLY REqUESTED A PLANT WITH THE FOLLOWING CHARACTERISTICS:ELECTrICAL PoWEr: 2,0 MWTHErMAL VECTorS: STEAM 1,040 KW AT 9 BArG / HoT WATErMAINTENANCE SErVICE: 10 YEArS

PLANT

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≤ THE ASCOLI PICENO PFIZER PLANTAND THE rEQUEST for A NEW CoGENErATIoN PLANT.

THE Ecomax®

An awareness of the advantages of cogeneration

led Pfizer engineering to evaluate the possibility

of a new plant for Ascoli Piceno, technology for

energy production that would be able to meet

the growing needs of their production lines

and service infrastructures. The order was

formalised in a call for bids held in September

2007, specifically setting out the following basic

characteristics: an electrical power of 2.0 MW,

thermal vectors for hot water and steam at 1,040

KW (9 barg), functioning 24 hours a day. Maximum

attention also to the elimination of polluting

substances and emissions into the atmosphere

in accordance with the commitment to eco-

sustainability pursued by Pfizer as a company

value that is an integral part of their market

image, towards public opinion (local and general)

and the masters of the company themselves.

After a strict and meticulous evaluation of the

proposals presented, Pfizer chose AB as their

ideal partner for the design, realisation and

maintenance of the plant, on the basis of the

plant’s technical-functional characteristics,

hypothesised performance and assistance

guarantee. Specifically, AB carried out a detailed

study on the needs and feasibility, advising Pfizer

engineering to opt for the container solution

ECOMAX® 18 NGS with electrical power of 1,824

KW rather than the 2000 initially hypothesised

by the company. The excellent prerogatives of

the AB plant, the result of unique experience in

the sector and tested references in the field of

chemical-pharmaceuticals and, in particular, on

plants of this range of power, showed, in fact,

that optimal performance could be obtained

with the ECOMAX® 18 NGS plant, appropriately

implemented for this specific application.

PLANT

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Perhaps one of the determining prerogatives in

Pfizer engineering’s decision to prefer the proposal

drawn up by AB was the certainty of having a point

of reference at top design levels available. The AB

design department enjoys professional resources

and know-how that are able to develop solutions

able to integrate perfectly with the plant scenario

and specific needs of each customer, providing

ad hoc solutions precisely suited to even the most

articulated and complex demand. The design

department starts with a careful study of the

specific needs and feasibility, following through

to the implementation of the ideal system,

from every point of view: technical-functional

characteristics, performance, reliability. In the

case of the Ascoli Piceno Pfizer plant, this skill

was seen particularly in the implementation of

technological solutions able to interface with the

pressure values of the plants that were already

operative, and with the application of devices built

to guarantee the best possible heat recovery, with

the production of steam and hot water in excess

of the nominal values, and fume temperatures

less than 120°C.

Ecomax® 18 NGS

Fuel consumption Nm3/h 445

Power introduced kW 4,318

Electrical power (cos.phi=1,0) kW 1,824

Electrical yield % 42.2

Steam kg/h kWbarg

1,200 7829

Hot water kW°C

1,007 88

Thermal yield % 41.4

Total yield % 83.6

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ELECTrICAL ENErGY 1,824 kW

NATUrAL GAS 455 Nm3/h4,318 kW

STEAM 1,200 kg/H - 782 kW

HoT WATEr 1,007 kW- 88 °C

GREENENERGY PFIZER

Ecomax®18 NGS

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The drasTic eliminaTion of harmful

subsTances released inTo The

environmenT.

Upon specific request by Pfizer, an industrial

company that has always been extremely

attentive to eco-environmental problems and the

quality of life in the territories where its plants

are located, the new cogeneration plant had to

comply with strict parameters in terms of release

of harmful substances into the environment. The

choice for cogeneration in itself was a long-term,

significant decision in this direction, further

optimised by the characteristics of the plant

ECOMAX® 18 NGS designed and built by AB. The

technological choices have, in fact, allowed for

high performance in all operative parameters, at

the same time reducing release of CO2 into the

environment.

The results have been so great that the

plant management decided to present the

positive scenario in detail during the plant

opening ceremony, also attended by the local

authorities, and involve the whole team in this

eco-environmental threshold. A threshold that

falls well in line with the commitment by Pfizer,

marked by their own trademark: Greenenergy.

In the environments given over to the staff

canteen, a display has been put up showing

the main data relating to the function of the

cogeneration plant designed and built by AB

in real time, highlighting the benefits for the

environment, work and the eco-system overall.

e l’ecosistema nel suo complesso.

In the elements making up the order, one important

factor was identifying the timescale and methods

by which the supply was to be implemented.

In practice, Pfizer wanted to have the plant up and

running by the end of September 2008, with terms

for the executive development and start-up of just

three months.

As such, AB developed a meticulously detailed

work diagram, able to rely on a carefully planned

and tested organisation of our departments.

The strict delivery times were thus not only

respected, but start-up was even brought forward.

The site within the Ascoli Piceno Pfizer plant

lasted just two months: as the module arrived in

early August, the engine was started up in late

September.

*values refer to the date of plant opening

ELECTRICAL POWER

THERMAL ENERGY

ELECTRIC POWER

THERMAL POWER

CO2 NOT EMITTED

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THE METICULOUS RESPECT OF THE STRICT, DEMANDING SUPPLY TIMING.

TIMELINE WORK 2008

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Planning

Realization works buildingsAssemblysRealization connectionsStartersContinuous operation

January February March April May June July August September MonthWeek 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Prefabrication in workshop

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PLANT PErforMANCE IN THE WorDS OF THOSEUSING IT.

Interview with the engineer Gianluca fioravanti (Maintenance Manager)

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What led you to decide on a new cogeneration plant for your Ascoli Piceno plant?

Essentially, it was the need to optimise our energy potential by using technology that could guarantee high performance, and which at the same time was in line with the Pfizer philosophy of paying great attention to the environment. These principles are an integral part of the approach to eco-sustainable energy that marks our group on an international level. In the particular case of the Ascoli plant, the development of production lines was accompanied by the need to integrate the new cogeneration plant in an overall evolution of the industrial energy plan. We wanted to obtain more, reducing costs. A real challenge that was well met by cogeneration.

How was the decision to entrust AB with plant development, reached?

We evaluated the market of reference very carefully, and saw that AB was simply the most valid option from all viewpoints.We were positively struck by the fact that today, on the Italian market, only AB is able to monitor the design, construction, installation and maintenance of this type of plant, directly and fully. Pfizer considers, in fact, collaborations and all types of entrepreneurial dialogue, well beyond that of the traditional relationship between customer and supplier, however competent and well-prepared they may be. We look for a real partner, rather than a supplier. first and foremost, this means consultancy, advice, instructions, and making the most of know-how at top levels, together with a willingness to open up to useful dialogue.The case of the cogeneration plant developed by AB is an example of just how important the AB – case history really is: our original supply plans requested a plant with 2000 kW electrical power. By dialoguing with the AB specialists, we were able to understand that even better performance levels could be obtained with a 1800 kW plant built with certain characteristics advised to us by the Brescia-based company staff. There is then the ‘timing’ aspect: we had to remain within strictly defined timescales, avoiding any lengthy suspension of production during the integration of the plant into our energy system. AB was well able to meet both these requirements, supplying us with a perfectly functional plant in record time, and limiting the stop of operation to the time at which the cogeneration plant was linked in synergy to our system. And on this, we should also remember that the AB technicians were able to deliver us a plant that had been practically made-to-measure, integrating optimally with the existing plant.

Now that you are using it, are you happy with the plant performance and yields you manage to obtain?

our judgement is all positive. The plant has been working non-stop and at full capacity for some months now, and has shown the validity of the design choices and the quality of what has been installed. We are entirely satisfied with its reliability too, which allows us to relax, and not have to set aside particular resources for checks, maintenance and controls. Again from this point of view, we can also relax in terms of the assistance service entrusted to AB Service, a company belonging to the AB Group, which we consider the logical and beneficial continuation of what engineering has managed to achieve.

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AB

HO

LDIN

G S

PA

AB Ambiente Srl

AB SETS THE

CoGENErATIoN STANDArDS

GLoBALLYAB INDUSTRIAL GROUP HAS

BEEN OPERATING FOR OVER

30 YEARS IN THE SECTOR

OF COGENERATION AND

PROMOTION OF ENERGY

FROM RENEWABLE

SOURCES.

AB Energy SpAITA LYSALES

AB Impianti Srl AB Power SrlPRODUCTION

AB Service SrlSERVICE

AB fin-solution SpAFINANCING

RENEWABLEENERGY

AB Energy International GmbH

KWE Technika Energetyczna Sp. z.o.o.

AB Energyromania Srl

AB EnergyEspaña S.L.

AB EnergyHrvatska d.o.o.

Green House Power Netherlands BV

EPS AB Energy Canada Ltd.

AB EnergySrbija d.o.o.

AB Energy Ceská s.r.o.

AB Energy do Brasil Ltda

FOREIGNBRANCHES

AB Energy (UK) Ltd.

AB EnergyDeutschland GmbH

AB Energy USA LCC

AB Energyrussia

AB EnergyIsrael Ltd.

AB Energy france

AB Energy Turkey

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AB is currently made up of 24 companies and over 500 employees and is a single entity able to manage the entire manufacturing cycle of a cogeneration plant: consultancy, design, production, installation and start-up with a comprehensive service. This has enabled AB to acquire unparalleled know-how, to become acquainted with every product detail and to provide a top-quality and highly-effective after-sales service. The success of AB - which has already designed and built more than 900 plants - stems from ongoing investments in cutting-edge technologies, from the constant training and professional specialisation of all operators and from the development of an absolutely unique engineering

department: a team of over 110 engineers engaged in developing the industry towards the production of increasingly more reliable and higher performance plants. AB cogeneration plants are distinguished by modularity, compactness and ease of transport and cater to the energy requirements of a number of different companies. outright leader in Italy, AB is also expanding globally: in Spain (2007), in romania (2009), in Poland (2010), and again with the opening of subsidiaries in Croatia and Serbia (2011). from 2012 AB is in Czech republic, from 2013 also in the Netherlands, Austria, Brazil, francia and Canada. from 2014 AB in UK, Germany, USA and Israel and from 2015 in russia and Turkey too.

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Cogeneration has proven to be a winning choice, also in other industrial and non-industrial fields, such as food chemical, pharmaceutical, textile, plastic, paper, brick, etc.

700 customers, some of them are:Amadori, Benetton, BNL, Buitoni, Cartiere Saci, Coca - Cola, Cotonificio Albini, Eridania, Esselunga, fatro, ferrero, felli Color, Galbani, Garda Plast, Granarolo, Gruppo Cremonini, Gruppo Mapei, kraft, Lafarge, Lilly, Martini & rossi, Nestlè, orogel, Pastificio Garofalo, Pastificio rummo, Peroni, Pfizer, Polynt, Spumador, Wienerberger, etc.

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com

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www.biogaschannel.com

www.cogenerationchannel.com

AB Energy SpAVia Caduti del Lavoro, 13 25034 orzinuovi BS - ItalyT. +39 030 94 00 100www.gruppoab.com

DIAGrAM of ECoMAX® 18 PLANT ASSEMBLY

fUNCTIoNAL DIAGrAM of ECoMAX® 18 PLANT

MoNITorING SYSTEM