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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
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