Pharmaceuticals manufacturer in final phase of R80m plant upgrade

11th October 2013

By: Samantha Herbst

Creamer Media Deputy Editor

  

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South African pharmaceuticals contract manufacturer Wrapsa has embarked on the final stage of an R80-million refur- bishment project, initiated in July 2007, which has focused on increasing the capacity and upgrading the facilities of the company’s 13 000m² packaging and manufacturing plant in Centurion, Gauteng.

Having completed six of the seven phases of the refurbishment project, Wrapsa CEO and founder Nardus Alberts reports that the final phase of the project – which will result in the upgrade and refurbishment of the oral solid dosage plant – is due for completion in July 2014.

He tells Engineering News that the primary focus of refurbishment was to improve the quality of air within the manufacturing facilities to adhere to international standards.

“In July 2007, South Africa become the second developing country to join the Pharmaceutical Inspection Convention and the Pharmaceutical Inspection Cooperation Scheme – jointly referred to as Pic/s,” explains Alberts, adding that Pic/s, which currently comprises 43 members, aims to ensure that all participating countries operate according to the same international level of standards.

“These standards include training and inspec- tion formats, among many other stringent guidelines, which are vital for compliance with the international field of good manufacturing practice (GMP).”

Alberts believes that the initiation of South Africa as a Pic/s member means that the infra- structure of the country’s pharmaceuticals manu- facturing industry has to be examined, which is why Wrapsa decided to refurbish its facilities and to focus on improving the quality of air within the plant.

“Years ago, strict air-flow control and handling were only applied for the manufacturing of highly sterile products. Pic/s, however, has implemented a standard which states that, in any pharmaceuticals manufacturing scenario, it is required to minimise cross-contamination of the air within a facility.”

Alberts further explains that each type of product needs to be separated and isolated individually, within an air-controlled environment. As a result, Wrapsa is installing a new heating, ventilation and air conditioning system for its facilities and implementing the correct procedures for its operation.

This has also impacted on the health and safety of Wrapsa’s employees, as it provides clean and cool air, significantly improving the work environment.

Another important and ongoing aspect of the refurbishment costs includes the running and maintenance of the new facilities and operational systems. Alberts explains that the upgraded processes require a significant increase in electricity demand to power the technical elements within the plant, as well as in-depth training.

He adds that, once the facility upgrades were initiated, Wrapsa incorporated all the necessary skills elements into the existing training regime, which is considered a daily exercise and “taken very seriously” by Wrapsa’s entire staff complement of more than 500 employees, most of whom are already highly skilled.
“The reaction to the various changes and newly laid out standards has been enthusiastic and it is great for us to move forward and advance our organisation. Training also creates highly valuable learning opportunities to increase skills levels and understanding,” Alberts says.

He tells Engineering News that the refurbishment project included the task of getting Wrapsa’s employees to understand and accept the overall concept of improving the company’s operating standards.

“We needed to create awareness that Wrapsa is moving into a new era but I think that, by now, most of our employees support the company’s vision,” he says.

Alberts adds that the R80-million upgrade has significantly increased the value and equity of the company, as well as its foothold in the market, turning Wrapsa into a “world-class contract manufacturer”.

Having recently reached its 30-year milestone, Wrapsa has registered significant growth since its infancy, with local and international customers eagerly awaiting the company’s compliance with Pic/s standards.

“Being the largest of a handful of companies that will be able to meet these stringent standards, we will achieve a superior positioning as the South African supplier of choice to many major international pharmaceutical brands and organisations. For consumers, this will provide the priceless benefit of . . . relying on the safety of pharmaceutical and toiletry products,” says Alberts.

Since the start of the Pic/s programme in South Africa, Wrapsa has been actively involved in the process, with the company being fully aware of the importance and implications of manufacturing standards in the pharmaceuticals industry.

“It is important to achieve the same standard of manufacturing throughout the industry, as it levels the playing field in the local market and ensures that all medicines are manufactured to some level of quality and GMP.

“This type of activity is a dynamic, ongoing process that requires sustained investment. It is certainly not a one-off exercise. That is why we decided to invest in these upgrades – we believe that our compliance will be worth the cost . . . for our business and our customers,” concludes Alberts.

Edited by Martin Zhuwakinyu
Creamer Media Senior Deputy Editor

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