Novartis Environment Awards 2012

12
Marcelo Costa, Process Engineering Coordinator December 2012 Blister optimization initiative reduces materials and cost

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Transcript of Novartis Environment Awards 2012

Page 1: Novartis Environment Awards 2012

Marcelo Costa, Process Engineering Coordinator December 2012

Blister optimization initiative reduces materials and cost

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Welcome to Cambé

Cambé (PR) – Såo Paulo (SP) 550km

Capital: Brasilia (DF)

Area: 8.5 million m2

Population: 190 million (2010)

Population growth: 1.17% (2000 – 2010)

Local market

Regional packaging center

Global plant for Hormones & other (eg. Diclofenac, Atenolol)

Oral Solids capacity: 2.0 Bi SDU | 75 million packs

| 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

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Basic principles of the project

| 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

Blister Optimization Initiative

Launch: 2007

Goal: Reduce consumption of primary packaging material (blister)

Low volume occupancy per dose/tab opportunity

Optimized operations

Higher output

Reduced cycle time

10tablets

per blister

3blisters

per carton

Before

15tablets

per blister

2blisters

per carton

After

Trilax12 Tab

0.5 tons of aluminum | 2.5 tons of PVC foilsWaste reduction

9% on product weightPackaging weight reduction

USD 17 300material savings

Results

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Challenges

Marketing

QualityOperations

Internal

PackagingMachineSupplier

Benchmarking New

Technologies

External

Stakeholders

• Develop a viable, sustainable packaging design

• Ensure a collaborative dialogue between product design, marketing, operational teams and suppliers

• Challenge existing packaging machines

• Identify opportunities

• Test potential new ways to find the best possible packaging solution

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Achievements

Summary of annual savings

The 27 SKUs blister improvement

initiatives completed to date

represent a significant

improvement in sustainable

packaging versus the packaging

solutions that existed in 2007

Cost savings USD 201 200

Material reduction3.3 tons aluminum (lidding material)

7.7 tons PVC | 12.9 tons PVdC (forming material)

Packaging weight reduction

SKUs specific: -9% for Trilax c/12 (3.6 tons/year);-5% for Doxuran 30 FCT (1 ton/year)

GHG emissions from transport

1.0 ton CO2e (from natural material only)

Other savings Waste reduction, improved packaging leadtime

Energy savings*

Electricity Pack. Machine

Chilled Water

Compressed Air

Total

kWh

110.309

96.521

161.522

368.352

GJ

397

347

581

1.326

tCO2

8

7

12

27

* Yearly figures based on 2011 volumes

Besides blister / carton optimization, other enhancements contributed for speed increase (e.g. Line 3 new secondary

packaging machine, Line 4 primary packaging machine retrofit)

| 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

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Cambé's "environmental heros"!

Energy Team

2012 WinnerSustainablePackaging

2011 TechOpsTeam ExcellenceAward

| 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

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Back up

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2-day visit Photos

| 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

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Ceremony Photos

| 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

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Ceremony Photos

| 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

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Ceremony Photos

| 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

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Ceremony Photos

| 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only