API Synthesis Line Integration

Seamlessly connected new API lines into existing operations for streamlined output.

Client

Active Manufacturer

Service

Production Line Integration

Industry

Pharmaceutical

Compliance

ICH, GMP

Project Overview

The client, an international pharmaceutical company, was launching a new manufacturing site for sterile drug production. Within the project scope, it was necessary to provide comprehensive support during the commissioning phase — from verifying the performance of engineering systems to preparing documentation in compliance with international GMP and FDA standards.

The main challenge was the tight timeline to transition from the construction phase to production, while meeting stringent quality and safety requirements.

Approach

Our team developed a step-by-step commissioning strategy that included:

  • preliminary audit of technical documentation and design solutions;
  • testing of critical systems (HVAC, purified water, sterile environments);
  • preparation of a complete package of IQ/OQ documentation and procedures;
  • integration of the process with the client’s internal standards and upcoming audits.

Special attention was given to communication between equipment suppliers, the client’s technical department, and regulatory consultants. This ensured that delays were avoided and identified deviations were resolved quickly.

Outcome

As a result, commissioning was successfully completed, and the manufacturing site was fully prepared for validation and subsequent production. The transition time from the construction stage to the first production cycle was reduced by 20% compared to the initial schedule.

All engineering systems passed verification without critical deviations, and the documentation was approved by the client’s internal quality department. Thanks to a structured approach and close collaboration with all stakeholders, the client gained full confidence in the site’s readiness for GMP and FDA audits.

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