Bring integrated pharmaceutical lines into production faster and more safely

Production start-up of integrated pharmaceutical lines faster and safer

At its German headquarters, OPTIMA invests in a state-of-the-art facility with over 4,000 square meters of space for assembly

As part of the celebration of its 100th anniversary on May 5, 2022, the Optima Group inaugurated the CSPE II Center. Thus, the Optima Pharma division is expanding its production area for the assembly, commissioning and qualification of pharmaceutical filling lines by more than 4,000 square meters. Additional new office space has also been created. Minister-President Winfried Kretschmann visited the site especially for the inauguration. The first lines were installed just seven months after the start of construction. Optima Pharma thus responds to customer demands and further extends the successful CSPE process for a quick and safe start of production of integrated filling lines with isolators and freeze dryers. Optima is investing a double digit sum of one million in the new building.

“Celebrating the company’s 100th anniversary provides the perfect backdrop for the inauguration of Center CSPE II,” said Hans Buehler, Managing Director/CEO of Optima Group. The inauguration of the new building took place during the event which was attended by many guests from business and politics. The Minister-President of Baden-Württemberg, Winfried Kretschmann, made a special visit to the inauguration and extended his congratulations on the occasion of Optima’s 100th anniversary. “This investment reaffirms our commitment to the Schwaebisch Hall site and creates the conditions for continued growth with confidence,” says Hans Buehler. Despite the COVID-19 pandemic and a shortage of materials in the construction industry, the new building was completed in a record time of just twelve months. “We would like to express our thanks and gratitude to our architect Rolf Blank, as well as to all the companies and authorities involved, for this masterful achievement”, emphasizes Buehler. The installation, commissioning and qualification of the equipment was possible after a record time of only seven months, starting in December 2021.

CSPE 2.0: At the best time to start production

“CSPE 2.0 enables an even higher level of integration. Work that usually took place at the customer’s site will be even more carried out in one of our CSPE centers,” said Gerhard Breu, President of the Optima Pharma Division. Scientific Comprehensive Process Engineering (CSPE) accelerates processes, from system design to production launch. A key aspect is full process simulations, as well as integrated factory acceptance testing for complete systems. In addition to filling and closing systems and isolators, freeze drying systems can now also be configured and tested under realistic conditions, as a fully functional overall unit. As a supplier of complete systems, Optima Pharma now manages further qualification measures in-house, including important parts of cycle development. This dramatically reduces the time from installation to the start of production at the customer site, as well as a reduction in the time from product development to market launch.

Bigger, more efficient and more convenient

The new building offers short distances, pooling of forces and efficient operating processes for Optima. The experience gained in the operation of the CSPE I center was integrated into the design and led to further rationalization. The new building is 25% larger and offers even more space for large turnkey lines. Optima Pharma’s production area will expand by more than 4,000 square meters. Including the adjacent three-story office building, the new structure covers 7,000 square meters.

Flooded with light, transparent and energy efficient

Employee working conditions meet the highest standards. The bright building with transparent glass facades offers pleasant temperatures all year round, both in the production area and in the office wing. An energy-efficient concrete core activation system heats and cools the production area, while a high-performance heating and cooling ceiling regulates the temperature in the office building. Spacious meeting rooms provide ample space for project meetings and customer conversations. Soundproof rooms for phone calls and video conferencing are scattered throughout the building to facilitate focused work. There are offices that can accommodate up to 150 employees. As part of Optima’s sustainability strategy, the energy-efficient building was built to Energy Efficiency Level 55 and, like the majority of the company’s buildings at Schwaebisch Hall, is connected to the heating network urban of Schwaebisch Hall. This provides Optima with regenerative generated remote heating. Photovoltaic systems are installed on the roof and supply the public electricity network. The car parks will be equipped with electric charging stations.

Expansion in the pharmaceutical sector

Optima Pharma inaugurated the first CSPE center in June 2019 at its headquarters in Schwaebisch Hall. Since then, the CSPE I Center has been running at full speed. At Optima Pharma’s site in Gladenbach-Mornshausen near Marburg (Hesse), the current area for assembly, commissioning and qualification of multi-stage freeze-drying systems has increased by more than 50% over the past past year. An extension building with offices and assembly space is planned at the Optima Metall+Plastic branch in Radolfzell on Lake Constance. Metall+Plastic’s isolators and cleanroom technology are essential for the aseptic processing of pharmaceutical products. This means that Optima Pharma is able to provide integrated global solutions from a single source. Provided that this strong growth continues, another CSPE Center could be added to the south of the CSPE II Center.

In the new CSPE Center II, an Optima Pharma employee carries out safety and qualification tests on a pharmaceutical line. (Source: Optima)

Optima Pharma is now able to carry out even more comprehensive qualification measures in-house as part of the reinforced CSPE process. This further reduces the time between installation and the start of production at the customer’s site. (Source: Optima)

Press contacts:

OPTIMA packaging group GmbH

John Deininger

Group Communications Manager

+49 (0)791 / 506-1472

[email protected]

www.optima-packaging.com

About OPTIMA

Optima supports companies around the world with flexible, customer-specific filling and packaging machines for the pharmaceutical, consumer goods, paper hygiene and medical device markets. As a solution and system provider, Optima accompanies these companies from product idea to successful production and throughout the entire machine lifecycle. More than 2,800 experts from around the world contribute to the success of Optima. 20 locations in Germany and abroad ensure worldwide service availability. In 2022, Optima celebrates the 100th anniversary of the company.