Bayer’s new wa­ter fa­cil­ity

DEMM Engineering & Manufacturing - - FRONT PAGE -

Bayer is con­tin­u­ing

its in­vest­ment in pro­duc­ing high- qual­ity an­i­mal health medicines in New Zealand with the com­mis­sion­ing of a new $3 mil­lion wa­ter treat­ment sta­tion at its Manukau pro­duc­tion site.

The Bayer An­i­mal Health (NZ) state- of-the-art fa­cil­ity in­cludes full au­toma­tion and con­trol with lo­ca­tion and remote process vi­su­al­i­sa­tion. It in­cor­po­rates on­line qual­ity mon­i­tor­ing of con­duc­tiv­ity, tem­per­a­ture and to­tal or­ganic car­bon.

The new wa­ter pu­rifi­ca­tion plant is used to pro­duce pu­ri­fied wa­ter (PW), wa­ter for in­jec­tion ( WFI), and pure steam for the use in the man­u­fac­ture of ve­teri­nary drug prod­ucts. It meets the de­mand­ing re­quires of the Euro­pean Phar­ma­copeia, pro­duces wa­ter suit­able for hu­man ther­a­pies and is the most ad­vanced fa­cil­ity of its kind in New Zealand, says Bayer. The plant takes or­di­nary tap wa­ter and, through a sys­tem of fil­ter­ing, deion­iz­ing and soft­en­ing, con­verts it into Pure Wa­ter (PW). Pu­ri­fied wa­ter is pro­duced con­tin­u­ously from mu­nic­i­pal drink­ing wa­ter at 2000L/hr us­ing pre-fil­tra­tion, ion ex­change, re­verse os­mo­sis, and elec­tro- deion­i­sa­tion. It is cir­cu­lated through the liq­uids and paste and ster­ile man­u­fac­tur­ing plants from a 5000L elec­tropol­ished stain­less steel stor­age tank.

PW is fur­ther re­fined and dis­tilled to cre­ate Wa­ter For In­jec­tion ( WFI) by three-stage dis­til­la­tion at 700L/hr us­ing pu­ri­fied wa­ter feed and cir­cu­lated to the ster­ile man­u­fac­tur­ing suites from a 4000L stor­age tank. The dis­til­la­tion unit also pro­duces high pu­rity phar­ma­ceu­ti­cal grade steam for process ster­il­i­sa­tion.

Both types of wa­ter are used in man­u­fac­tur­ing a wide range of an­i­mal medicines and prod­ucts rang­ing from metabol­ics for dairy cows to drenches and sup­ple­ments for farm live­stock and horses.

As well as treat­ing wa­ter, the new plant also dis­trib­utes it through­out the Manukau pro­duc­tion site 24/ 7 and has two large stor­age tanks.

Bayer New Zealand managing di­rec­tor Derek Bartlett says the new wa­ter treat­ment plant is a ma­jor leap for the pro­duc­tion site.

“Pre­vi­ously it would take about six hours to pro­duce 2000 litres of Wa­ter For In­jec­tion. Now we can pro­duce 2000 litres in one hour. We can now get high qual­ity wa­ter whenever we want with­out any re­stric­tions, which will im­pact pos­i­tively on our pro­duc­tion times.”

An­other im­por­tant fea­ture of the wa­ter treat­ment plant is its abil­ity to self- mon­i­tor.

“Ba­si­cally, it self- checks it­self to en­sure the wa­ter being pro­duced does not get con­tam­i­nated or go out of spec,” says Bartlett.

Fol­low­ing the com­mis­sion­ing of the plant, there will be a two-month test­ing and val­i­da­tion process be­fore full man­u­fac­tur­ing be­gins in Jan­uary.

The new wa­ter treat­ment plant is part of a se­ries of multi- mil­lion up­grades to the Manukau plant. Other im­prove­ments will be made to its Liq­uids and Pastes pro­duc­tion fa­cil­ity start­ing next year.

“Bayer firmly be­lieves in sup­port­ing our lo­cal farm­ing in­dus­try here in New Zealand,” says Bartlett.

“To do that, it is cru­cial that we in­vest in our man­u­fac­tur­ing plant, which not only pro­duces an­i­mal medicines for lo­cal use, but also ex­ports to more than 70 coun­tries around the world.”

The plant was de­signed and con­structed by AB Man­dal Pty Ltd, Phar­ma­ceu­ti­cal process en­gi­neers based in Syd­ney and in­cor­po­rates key com­po­nents from the United States, the UK, and Italy.

The equip­ment and pip­ing and was in­stalled by Umech Pty Ltd, a high pu­rity pip­ing con­trac­tor also based in Syd­ney. They used the lat­est Au­to­matic or­bital weld­ing equip­ment to in­stall over one kilo­me­tre of elec­tropol­ished stain­less steel tub­ing. The com­pre­hen­sive qual­ity in­spec­tion pro­gram for the pip­ing in­cluded in­ter­nal video borescop­ing of tube welds.

The pro­ject was com­pleted on time in just over 10 months and was a huge lo­gis­ti­cal ef­fort with com­po­nents and sys­tems shipped from around the world. Bayer CEO, Chris Dorthe But­tkus, com­mented at the open­ing of the fa­cil­ity in early November that “it was the best run pro­ject she had ever been in­volved with”.


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