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Kek-Gardner help Almac meet increased demand


Pharmaceutical manufacturers are constantly striving to meet the increased demands of today's rapidly changing healthcare environment and meet customer requirements at the same time. Almac Pharma Services are no exception. Established in 2001, Almac, is a Contract Development and Manufacturing service provider to the Pharmaceutical and Biotechnology industries with over 30 years expertise in the development and manufacture of solid, oral dose products. Innovation, quality and customer service are at the forefront of the company’s philosophy. With market expansion throughout Europe for one of their client’s key lead sachet products, Geoff Sloan, VP Manufacturing Operations at Almac Pharma Services needed a solution to meet the five fold demand increase  "We simply could not meet demand. The only option was to expand our commercial facilities". Almac Pharma Services, with their client partner, invested £2 million adding a new dedicated 5,500ft2 facility. With an aggressive timeline, the facility was built, equipment sourced and fully validated within nine months. The new facility incorporates dispensing and blending suites to accommodate 2.5 tonne batches along with sachet filling and packaging lines for processing up to 120 million sachets per annum. With a User Requirement Specification (URS) to detail critical requirements coupled with a strong Almac Pharma Services' existing relationship with both the Kek-Gardner team and their Irish Distributor meant that Geoff Sloan had no hesitation in approaching the company when he had an engineering requirement for the new Blending Suite. Almac Pharma Services already have Kek Sifters, Kek Cone Mills and a Gardner Blending System at the Craigavon site and were pleased with the equipments’ performance.  As Geoff Sloan commented “We are committed to meeting our customer’s requirements and Kek-Gardner were happy to discuss the process. Together we developed the right solution to meet the specifications and the project deadline”.  Almac Pharma Services concluded that the process would be more efficient and cost effective if a large blender was used to meet the increased production capacity whilst ensuring the accuracy of the finished drug product. Trials at Kek-Gardner’s technology centre confirmed that the equipment would meet the stringent cGMP standards as detailed in the URS both in terms of throughput and product quality. As a result a blending suite comprising a Gardner 4200 litre working capacity Double Cone Blender, a Gardner 700 litre working capacity Y Cone Blender and a Kek K650CV inline Vacuum Centrifugal Sifter, tied together by lean phase pneumatic conveying was installed at Almac Pharma Services. The process begins with a premix of salts and the active pharmaceutical bulk material, which is initially sifted in the K650CV Sifter and transferred to the 700 litre working capacity Y Cone Blender for preliminary blending. The pre mixed material is then conveyed to the 4200 litre Double cone Blender where it is blended along with the rest of the active pharmaceutical bulk material. The material is then discharged into a Matcon bin and transferred to the Mediseal LA 500 / P1600 packing line for processing into finished sachets.   GARDNER Blenders are part of a comprehensive range of mixing equipment supplied by Kek-Gardner, which also includes Plough and Ribbon Mixers. In addition, Kek-Gardner also supplies the full range of Size Reduction Mills, Air Classifier Mills and Centrifugal Sifters. Kek-Gardner’s intimate knowledge of the pharmaceutical industry enables them to produce bespoke equipment to meet the demands of the major pharmaceutical companies and their regulatory authorities and are prepared to work with each customer to offer a process solution to any application requirement. The full scope of Kek-Gardner’s products can be seen on their web site at www.kekgardner.com. Alternatively, to discuss a specific application, contact them on +44 (0) 1625 665999. Almac Pharma Services is an FDA approved global outsourcing partner with over 30 years' experience in the development and manufacture of solid oral dose products. Their capabilities include: formulation and analytical development, clinical and commercial-scale drug manufacture, primary and secondary packaging and labelling, EU import testing, QP release and global supply chain management to end-users.

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