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Telstar Completes Two cGMP Plants for Square Pharma

Telstar recently completed two new pharmaceutical manufacturing plants for Bangladesh-based Square Pharmaceuticals, a CMO with plans to process liquid and solid dose forms in the new facilities.

 Telstar announced it has finished constructing two pharmaceutical plants for Square Pharmaceuticals, a Bengali company and the largest manufacturer of pharmaceutical products in Bangladesh. According to Telstar, it is the largest project developed by the company in Asia. Telstar, providing project management and administration, engineered and constructed both plants including pharmaceutical architecture, process equipment integration and all critical installations.

Square Pharmaceuticals
Square Pharmaceuticals Limited is the largest manufacturer of pharmaceutical products in Bangladesh. The most prominent company of the Square Group since its founding in 1958, it has experienced solid growth leading to its current leadership position in its country and in the Asian continent. Since 2003, Telstar says it’s collaborated with Square on a number of highly complex projects. Examples include cephalosporin plant built in 2005, a sterile filling and bottling line using blow-fill-seal (BFS) technology in 2007, a new insulin production plant in 2010 (with the ability to produce up to 13 million vials of insulin per year). Other projects include an SVPO plant inaugurated in 2008 to produce small-volume parenterals and ophthalmology products.

The first project, a plant intended to manufacture oral solid dose formulations, encompasses a four-story, 100,000 sq. ft building housing seven fluidized bed granulation lines, 11 tablet lines, four capsule lines, 16 primary and secondary packaging lines, plus a second 3,000 sq. ft service building. The second project, says Telstar consists of a four-story 65,000 sq. ft building that will process liquid medicines, parenterals in small and large volume formats. To cover most parenteral applications, Square Pharmaceuticals will be ready to meet market needs with two blow-fill-seal (BFS) lines equipped with two, 20,000-litre reactors, a glass bottle filling line, another for bags, two for vials, two for prefilled syringes, one for lyophilized vials with two freeze-dryers and one topical aerosol production line.

To get the job done Telstar says relied on the support of the local Bangladeshi workforce and attributed the success of this highly complex project through its sole and direct control of all phases of the project. According to Telstar, the two plants were design to meet the strictest international regulations and comply with GMP guidelines throughout.

Advanced simulation technologies support A&E
To develop the new facilities, and control of the entire life cycle of the building and its installations, Telstar applied Revit building information software and its BIM (Building Information Modelling) capabilities. These advanced simulation technologies says Telstar provide a high-degree of control over a project’s life cycle. For this project Telstar reinforced the BIM system with new technologies like modelling software and documentation package and a software package to manage the entire life cycle of the project. Finally, in the design phase Telstar also incorporated SchedulePro, a programming tool for resource allocation and management, which, through simulation technology, is used to optimize the process depending on the specific needs and to detect key routes so as to “decongest” processes, as well as planning, programming and capacity analysis functions. The system, says Telstar, has advanced conflict resolution, reprogramming and production monitoring functions.

Telstar claims the implementation of Revit BIM and Schedule Pro technologies in the engineering phase saves an average of 20 percent in time and costs by pre-empting hitherto unforeseen issues in the construction process of the plant.