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
1
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
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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.
wel
com
eadv
.it
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