Vaccine production against Covid-19 is also a very special task for the manufacturers of filling and packaging systems. Even before authorisation was granted, pharmaceutical companies had already started to expand their production capacities, and there is currently no end in sight. But plants that produce other important medicines must not lose sight of this either.
Naturally, the southern German Mechanical engineering company Bausch+Ströbel, when one of the company's own plants is shown on the news: Because when it comes to the production of vaccines against Covid-19, the filling and packaging systems from Ilshofen can be seen in action from time to time.
„We are naturally pleased and proud that we can make our contribution to the fight against the pandemic - but this also means a great responsibility for us,“ says Managing Director Dr Hagen Gehringer. The tasks currently facing all machine manufacturers who produce specialised machines for the pharmaceutical industry are quite general Major challenges.
In demand: effective lead time
Pharmaceutical companies prepared for the production of their vaccines at an early stage: They started expanding their production capacities at a time when it was not yet clear whether the developed vaccine would even be authorised. „Without these preliminary measures, a rapid supply of the vaccine would not currently be possible,“ Managing Director Dr Hagen Gehringer is certain. This led very early on to increased Enquiries from specialist machine manufacturers, who are active in this area.
Demanded: Expansion of vaccine production capacities
The first enquiries arrived in Ilshofen as early as March 2020: For example, a labelling machine was ordered explicitly for processing a future vaccine, which was delivered a few months later.
However, a fully automated filling and packaging line usually requires significantly more lead time. As pharmaceutical companies are faced with the challenge of having enough processing lines available for the production of these special medicines in the shortest possible time, the aim in this first phase is to already have quickly put ordered systems into operation and, in parallel, existing systems for this special application to convert. This is the only way to quickly ramp up production in order to supply the markets in the shortest possible time.
For the rapid changeover, new format sets must be created in the shortest possible time or filling tests must be carried out to ensure that the vaccine is also optimally processed on the systems is carried out. As a rule, system manufacturers offer this in their own test rooms. Which dosing method is the best? Which environmental parameters achieve the best results? These are questions that are clarified in this phase.
„All of this is also a major task for us, as there is still great demand worldwide for other medicines, for which facilities must also be made available. The capacities of plant manufacturers cannot be expanded in such a short space of time that numerous additional orders can be accepted. The recruitment of specialised personnel and the expansion of production areas are not possible indefinitely and also require time.“ Dr Hagen Gehringer, Managing Director at Bausch+Ströbel
Guaranteed: Focus on prioritisation
Plants that produce other important medicines must not be neglected either. There are still other diseases for which therapies must also be made available. For the expert, there is currently only one way forward: „fair prioritisation“.
In addition, pharmaceutical companies are planning ahead and are already investing in new facilities. This is because it is now becoming apparent that Covid-19 requires vaccination to be refreshed at certain intervals. This goes beyond the initial supply and consequently also affects plant manufacturers. Vaccines mainly filled in vials. In the future, however, they will certainly become like other common medicines, in disposable syringes which requires different filling and packaging systems.
„The current situation will continue the trend in speciality mechanical engineering, systems that are as flexible as possible The demand for packaging that can be converted to other packaging materials and other medicines with little effort and in a short space of time will certainly increase,“ Dr Hagen Gehringer is certain.
Secured: Organisation of service assignments
Much can be prepared in the offices, production and assembly halls of machine manufacturers. However, much of the work has to be carried out by technicians or programmers. on site be realised. „We were able to compensate for some tasks here by making greater use of digital tools, such as our RemoteService,“ explains Dr Hagen Gehringer. Fortunately, we were already well advanced in introducing these technologies before the pandemic. But not everything can be solved remotely.
The plants of pharmaceutical companies are located all over the world. After all, it is an advantage, to produce the vaccine where it is needed. Every assignment must be in line with the safety of employees and therefore requires intensive preparation and support. And, of course, employees need to be prepared to travel, even during a pandemic. „Fortunately, we are very willing to do this,“ emphasises Dr Hagen Gehringer.
