Zydus Pharmaceuticals Recognized as FOYA 2024 Honorable Mention Award Winner

Zydus Pharmaceuticals Ltd., a subsidiary of Zydus Lifesciences Ltd. (formerly Cadila Healthcare Ltd.), has a legacy dating back to 1952. Today, it stands as one of India’s leading pharmaceutical companies. Their new greenfield facility is dedicated to the 100 percent US export of OSD products, exemplifying cutting-edge design and operational excellence.

A Facility Designed for Agility and Economies of Scale

The Zydus Greenfield OSD manufacturing facility is built on two fundamental principles: agility and economies of scale. This dual concept is embodied in its two distinct production blocks:

1. Small Volume Block (Cheetah):
   • Designed for flexibility and adaptability
   • Supports a wide variety of manufacturing capabilities, including wet and dry granulation, top and bottom spray, capsule and sachet filling, imprinting, blister packaging, and bottle packaging
   • Tailored to accommodate products requiring diverse manufacturing processes and therapeutic categories
2. Large Volume Block (Elephant):
   • Innovatively designed for high-volume production, catering to larger batch sizes
   • Features a four-floor unidirectional vertical material flow design to streamline operations
   • Targets the goal of becoming the world’s lowest-cost producer, ensuring patient affordability

The facility’s focus on these complementary principles ensures that Zydus remains competitive in producing both specialized and mass-market pharmaceutical products.

Technological Prowess and Automation Excellence

Zydus’s large volume block demonstrates an exceptional level of technological innovation. With a production capacity of six billion units per year, the facility leverages automation and process optimization to achieve unparalleled efficiency. Key features include:

• Integrated Closed System Trains: Two fully automated trains manage material flow from charging to final packaging without human intervention
• Massive Equipment Capacity:
  • A 1.8 KL IGL granulation line
  • A colossal 18 KL Glatt Bin blender, one of the largest in the industry
  • Fette Compression Machines with segmented turrets (110 stations) and a Continuous Ohara Coater capable of 1,200 kg throughput per hour
  • A fully automated Sensum tablet inspection machine ensuring 360° quality control
• High-Speed Packaging: The central packaging area features three CVC Technologies bottle packaging lines with speeds of 200 bottles per minute
• Dense Phase Transfer System: A first for the pharmaceutical industry, this system can transfer 600 kg of material in just 15 minutes, accommodating batch sizes up to 6 metric tons

Innovation in Material Handling and Process Efficiency

Zydus’s facility employs advanced material handling technologies to reduce waste, improve efficiency, and maintain quality standards. Key highlights include:

• Matcon Cone Valves and Gentle Transfer Chute (GTC) Technology: These innovations minimize material loss and ensure gentle handling of products
• Process Analytical Technology (PAT): Enables real-time monitoring of blend homogeneity
• Automated Wash-In-Place (WIP) Systems: Ensure thorough cleaning, reduce water consumption, and prevent cross-contamination

The facility’s material handling advancements significantly contribute to its ability to deliver a swift turnaround time of just five days from dispensing to packaging.

Sustainability and Smart Warehousing

Sustainability and efficient resource utilization are at the core of the Zydus greenfield facility. The warehouse features an integrated warehouse management system and a fully automated storage and retrieval system (ASRS). This system can store up to 12,870 pallets and transport materials to heights of up to 32 meters, directly delivering to the fourth floor. Additionally, the inclusion of AI-enabled robots for material transfer and floor cleaning reduces reliance on manual labor and enhances operational safety.

Driving Innovation for Patient Affordability

One of Zydus’s standout achievements with this facility is its unwavering focus on affordability. By leveraging high-volume production and cutting-edge technology, the facility aims to lower production costs and enhance access to essential medications for patients globally. This initiative aligns with the company’s mission to improve healthcare outcomes while maintaining stringent quality standards.

Recognition Well-Deserved

The FOYA Honorable Mention award underscores Zydus’s excellence in facility design, process innovation, and operational efficiency. Their greenfield OSD manufacturing facility exemplifies the principles of agility, scalability, and sustainability.

Zydus’s achievements in streamlining production processes, integrating advanced automation, and prioritizing patient affordability set a benchmark for the global pharmaceutical industry. As the industry evolves, facilities like Zydus’s will undoubtedly play a pivotal role in shaping its future. Congratulations to Zydus Pharmaceuticals for their well-deserved recognition in the 2024 FOYA awards!

About the ISPE FOYA Program

Established in 2005, the Facility of the Year Awards (FOYA) recognize state-of-the-art projects utilizing new, innovative technologies to improve the quality of products, reduce the cost of producing high-quality medicines, and demonstrate advances in project delivery. The FOYA program provides a platform for the pharmaceutical science and manufacturing industry to showcase its accomplishments in facility design, construction, and operation, while sharing the development of new applications of technology and cutting-edge approaches. 

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