Biopharmaceutical shipping

Page 1

Biopharmaceutical Shipping - Bio-pharmaceutical products shipped frozen from UK to destinations throughout Europe

Description:

Bio-pharmaceutical products shipped frozen by common carrier (courier and airfreight) from UK to destinations throughout Europe. Materials are ship-ped Mon-Thursday on a two-shift basis.

Equipment:

2x Triventek PE80 Pelletizer (8mm extrusion plates) 2x Triventek RE80 Recovery Units 2x Bitzer LH104/4TCS8.2Y Condensers*

Installation date:

October 2008

Dry Ice consumption bought-in:

300,000 kg/year

Key cost data:

Bought-in dry ice: Estimated excess wastage bought-in over on-site: Triventek Equipment: Liquid CO2: Vessel rental: Installation**: Cash Payback: Dry Ice cost after payback: Ongoing cost reduction:

Key cost data:

Dry Ice cost after payback: Ongoing cost reduction:

£0.40/kg 25% £96,000 £100/tonne £850/month £20,000 22 months £0.20/kg 63% £0.20/kg 63%

Aquila Triventek A/S · Industrivej 9 · DK-5580 Nørre Aaby · Tel. +45 70 22 12 92 · aquila@triventek.com · www.aquila-triventek.com


Biopharmaceutical Shipping - Bio-pharmaceutical products shipped frozen from UK to destinations throughout Europe

Key financial data:

Installation:

Internal rate of return:

25.3%

Operating profit before depreciatio:

630,401

Years payback:

2.04 years

Approximately 6m x 2m space was found within 10m of the packing stations, and next to the liquid nitrogen bay for the installation of the PE80 and RE80 equipment Recovery Units during installation The vessel was located immediately outside with approx 10m of insulated pipework running from the front of the horizontally-arranged tank. A hard-standing was made for the external Bitzer condensers and approx 3m refrigerant runs to the RE80’s were installed: 1. Vent of approx 850*850 mm was installed in the external wall. 2. Powered extract vents were installed at low-level and linked to a CO2 monitor/alarm A comprehensive risk assessment, including Pres-sure Equipment Directive (PED) assessment was carried out by Facilities Engineering. CO2 gas concentration was measured within 1m of the operating production equipment and showed no increase on background levels (influenced by the packing stations).

Aquila Triventek A/S · Industrivej 9 · DK-5580 Nørre Aaby · Tel. +45 70 22 12 92 · aquila@triventek.com · www.aquila-triventek.com


Biopharmaceutical Shipping - Bio-pharmaceutical products shipped frozen from UK to destinations throughout Europe Operation:

Packaging Department management and opera-tives expressed their satisfaction on the following points: • Cost reduction • Waste reduction: it was estimated by packaging staff that previously approx 25% of bought-in dry ice had to be thrown away, having been over-ordered to cover fluctuations in demand. It was estimated that 5% of on-site produced dry ice needed to be ‘over-produced’ to cover unexpected eventualities. This is calculated as 20% excess waste for bought-in compared to on-site. • Approximately 5% per day losses can be expected from within an insulated box (accelerating for older ice). Bought-in dry ice was delivered on a 2-day cycle and would be between 1 and 3 days old; on-site is produced on a 1-day cycle. It was calculated that bought-in dry ice would have in this instance a 5% excess waste over on-site produced. • Packaging Department operatives and management soon took on the rhythm of starting production at a time to suit the production volumes needed for the following shift, and gauging when to shut down according to latest shipping order volumes. • Fresh, site-produced dry ice nuggets were noted to last longer in the box than bought-in Nuggets. • Previous concern about possible noise nuisance turned out to be unfounded

Aquila Triventek A/S · Industrivej 9 · DK-5580 Nørre Aaby · Tel. +45 70 22 12 92 · aquila@triventek.com · www.aquila-triventek.com


Biopharmaceutical Shipping - Bio-pharmaceutical products shipped frozen from UK to destinations throughout Europe Operation:

• Labour time to start-up the equipment and to replace filled boxes was thought to be negligible, and similar to time unloading bought-in boxes, ordering etc. • One unexpected fault occurred within two weeks of commissioning when a high pressure cooling alarm was triggered. This was dealt with by opera-tives with phone support from the factory. • Simple non-powered wall ventilation proved adequate and no instances of excess gas concentra-tion, or triggering of the exhaust system, occurred.

Comments:

*This installation was the last of the RE80 series using outboard condensers requiring site installati-on and commissioning. Subsequent RE80-C model has condensers built in at the Triventek factory **1) Approximately £7,000 was spent on a ducted ventilation system, which turned out not to be needed and has never run. It retains an emergency evacuation function, however this might more eco-nomically be achieved with simple wall fans. 2) In this event poor ground conditions, and horizontal arrangement of the CO2 vessel meant that the civil engineering works to build a plinth/pad for the tank were unusually costly. Protective guard installed We believe that this installation was particularly successful because the Packaging Department management and staff embraced the opportunity for both cost saving and logistical improvement, which this new way of working offered.

Aquila Triventek A/S · Industrivej 9 · DK-5580 Nørre Aaby · Tel. +45 70 22 12 92 · aquila@triventek.com · www.aquila-triventek.com


Turn static files into dynamic content formats.

Create a flipbook
Issuu converts static files into: digital portfolios, online yearbooks, online catalogs, digital photo albums and more. Sign up and create your flipbook.