Confidential
AbbVie: A Leading Global Biopharmaceutical Company
TRADITIONAL PHARMA
BIOTECH
The expertise, financial stability and resources to effectively commercialize products
The focus, culture and innovative spirit to achieve breakthrough science
FOCUSED
PASSIONATE
REMARKABLE IMPACT
ABBVIE
A GLOBAL BIOPHARMACEUTICAL
COMPANY
BIOTECH TRADITIONAL PHARMA
AbbVie established independently from Abbott Laboratories in January 2013 A publically traded company (NYSE ticker ABBV)
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AbbVie: Corporate Overview
Sales: $19.96B (YE 2014)
Experience: Biopharmaceutical organization with leading scientific experience People: 28,000+ employees Global understanding: 30 commercial products in 170+ countries
>120+ years of pharmaceutical development and manufacturing
Offer both specialized and standard type manufacturing
Plants: 12 State-of the-art global manufacturing facilities
North America & Europe (Singapore under construction)
Reliability: Exceptional Quality, Regulatory and Delivery track record
Long term Vision: Investing in success
Therapeutic Areas of Focus: Immunology, Kidney Disease, Liver Disease, Neuroscience and Oncology
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AbbVie: Toll Manufacturing
Embedded business unit built on a strong foundation and broad manufacturing capabilities.
Objective: Commercial manufacturing
Commitment: o Sales > $500 Million/year o More than 25 years of tolling
experience o Global Operation
Markets served: o Agrochemicals o Pharmaceuticals o Nutriceuticals/Dietary Supplements o Food Ingredients o Industrial Applications
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AbbVie: Manufacturing Locations
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Ludwigshaven, Germany
Sligo, Ireland
Cork, Ireland
Campoverde, Italy
Lake County, Illinois, USA
North Chicago, Illinois, USA
Worchester, Mass., USA
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Wyandotte, Michigan, USA
Barcelonetta, Puerto Rico
Jayuya, Puerto Rico 10
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AbbVie: North Chicago at a Glance
History: Started as Abbott manufacturing site in 1920’s and started fermentation in 1940’s.
Size: ~ 0.75 km2 (180 acres)
Purpose: - HQ for AbbVie Operations and Tolling - Fermentation Operations - Primary QA release site for region - Pharmaceutical R&D People: ~1,500 employees at the Site ~400 Employees Supporting Fermentation Products: Majority are for tolling customers ~40 Different Types of Products in Powder or Liquid Forms Customers: ~100 different customers served
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Raw Materials • Close proximity to natural raw material
sources • Rail spur for receipt of raw materials • On-site procurement and raw materials
testing on-site Solvents • On site bulk solvent tank farms with
storage of >2,000,000 Liters • On-site solvent recovery • Able to handle HAP solvents
Utilities • Access to Lake Michigan for cooling
water with back-up chillers • Double-ended grid supplied electricity • Natural gas supply • Steam generation
AbbVie | Company Confidential © 2015
Capabilities. Performance. Commitment. Site Infrastructure
Waste Treatment • Anaerobic and aerobic basins for
treatment prior to sending to public treatment
• On-Site Hazardous Waste Management • Odor control
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Capabilities. Performance. Commitment. Cell Banks & Inoculum
Experience with many different types of organisms including: • Actinomycetes • E. coli • Fungi • Bacillus spp.
Currently manufacturing using genetically modified organisms:
• Institutional Biosafety Committee review per NIH guidelines • Organisms would need to meet GLSP criteria
Preparation of master and working cell banks:
• Compliant with ICH Q7 for API manufacturing • Cell Bank maintenance with backup and redundant equipment/controls
Inoculum process development:
• Streamlined, robust processes for consistent inoculum performance.
Strain improvement programs via:
• Classical techniques • Recombinant techniques
Fermentors
38 total fermentors
Sizes ranging from 19 – 135 m3
Total capacity > 3000 m3
Primary size is 135 m3
Additional Tankage
Seed tanks (1 to 12 m3)
Feed tanks
Formulation tanks •
Sterilizers
Media sterilizers (continuous)
Seed media sterilizer
Oil sterilizer
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Capabilities. Performance. Commitment. Fermentation
Monitoring/Controls OSI-PI software for web based access Temp, agitation, pH, DO, off gas.
Broth Separation
Scroll Decanters
Microfiltration
Disk Stack Centrifuges
Belt Filter
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Capabilities. Performance. Commitment. Downstream Processing
Extraction
Whole Broth Extraction
Podbielniak Liquid-Liquid Extractors
Westfalia Liquid-Liquid Extractors
Concentration
Reverse Osmosis
Thin Film Evaporation
Flash Evaporators
Mechanical Vapor Recompression (MVR)
Reactors
Large, agitated and jacketed
reactors with sizes ranging
from (1-10 m3)
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Capabilities. Performance. Commitment. Downstream Processing
Purification
Chromatography
Ion Exchange (Adsorption)
Ultrafiltration
Decolorization
Sweco Sifters
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Capabilities. Performance. Commitment. Downstream Processing
Drying/Bulk Packaging
Blender Dryers
Fluid Bed Dryers
Tray Dryer
Filter Dryer
Milling
Dry Blending
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Capabilities. Performance. Commitment. Downstream Processing
Filtration & Isolation
Cartridge and Depth Filtration
Crystallization
Filter Press
Basket Centrifugation
Filter Pot
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AbbVie offers the full spectrum of fermentation development capabilities including:
Robust & Efficient
Manufacturing Process and
Product
Strain Development and
Improvement
Method Development
Recovery Process Development
Fermentation Process
Development and Characterization
• Strain improvement via classical and recombinant techniques
• Process development and characterization at lab and pilot scales from 10 L – 750 L
• Customizable recovery process development for extraction, crystallization, blending, drying, and milling.
• Method development and validation for analytical, microbiological and cleaning methods
60+ years developing and optimizing fermentation manufacturing processes
AbbVie | Company Confidential © 2015
Capabilities. Performance. Commitment. Technical Transfer and Development
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Capabilities 88 pilot scale (55 L) fermenters Permanent staff dedicated to pilot plant operations Identical software as commercial production (OSI PI):
• Temperature, agitation, pH, DO and off-gas.
• Frequently scale directly from 55 L to 100,000 L commercial scale
Expertise Personnel are expert in process development and scale-up, running hundreds of pilot batches every year Average experience at the pilot plant is 20+ years
AbbVie | Company Confidential © 2015
Capabilities. Performance. Commitment. Pilot Plant
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HPLC (reverse/normal phase and ion exchange, with UV/Vis, RI, fluorescence, ECD and ELS detection)
GC (direct injection and headspace analysis with FID and TCD detection)
Ion Chromatography
GC-MS and LC-MS
Spectroscopy (FT-IR, UV/Vis and AA)
ICP-OES and ICP-MS
Powder X-Ray Diffraction, TGA and DSC
Optical and Electron Microscopy
Surface Area and Particle Size Analysis
ICH and Development Stability Chambers
Cleaning Methods (LC and TOC)
Microbiology Lab for product testing and facility environmental testing.
Highly experienced staff provide method development, validation and transfer services, as well as submission, audit and manufacturing support
AbbVie | Company Confidential © 2015
Capabilities. Performance. Commitment. Analytical and Microbiological Testing
Environmental Health & Safety
• OSHA Recordable
• Lost Time Injuries
• Near Misses
• Spills
• Loss of Primary Containment
• EPA Notice of Violations
Quality
• Right the First Time
• Lot Non-Conformances
• Number of Exceptions
• Exceptions Closed On-Time
• Number of Complaints
• Complaint Closure Rate
Scheduling
• On-Time Delivery to Approved Stock
• On-Time Purchase and Receipt of Materials
• On-Time Start
• On-Time Finish
• On-Time Release
Capabilities. Performance. Commitment. Measuring Excellence
Productivity
• Titer by Product
• Recovery Yield by Product
• Foreign Growth
• Equipment Utilization
• Labor Utilization
Equipment Maintenance
• % Repair Related Downtime
• % PM Scheduling
• PM Completion On-Time
• Spare Parts Availability
GOAL: On-Time, Consistent Supply to Our Customers
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Capabilities. Performance. Commitment. EH&S
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2013 2014 2015 YTD
Nu
mb
er
of
Occ
urr
en
ces
OSHA Recordable
Lost Time Injuries
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• November 2013 - IEPA Air Inspection , 1 day – no findings
• June 2013 - IEPA Storm Water Inspection, 1 day – no findings
• March 2013 - IEPA Air Inspection, 1 day – no findings
• November 2012 - IEPA Air Inspection, 1 day – no findings
• August 2012 - IEPA Air Inspection, 1 day – no findings
• July 2012 - IEPA Storm Water Inspection, 1 day – no findings
• May 2012 - IEPA Air Inspection of Emissions Reduction Market System (ERMS), 1 day – no findings
• June 2011 - IEPA Storm Water Inspection, 1 day – no findings
• December 2010 - IEPA Air Inspection, 1 day – no findings
• November 2010 - IEPA Air Inspection of Emissions Reduction Market System (ERMS) , 1 day – no findings
• August 2009 - IEPA Air Inspection of Pharmaceutical MACT, 1 day – no findings
• July 2009 - IEPA Storm Water Inspection, 1 day – no findings
• July 2009 - IEPA Resource Conservation and Recovery Act (RCRA) Inspection, 1 day – no findings
• June 2009 - IEPA Storm Water Inspection, 1 day – no findings
Capabilities. Performance. Commitment. Environment
Capabilities. Performance. Commitment. Quality
• Greater than 1000 fermentation runs per year • Excludes fermentation runs lost due to foreign growth
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2013 2014 2015 YTD
Number of Non-Conforming Lots
98.0%
98.5%
99.0%
99.5%
100.0%
2013 2014 2015 YTD
% Right the First Time
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Capabilities. Performance. Commitment. Productivity
• Greater than 1000 fermentation runs per year
0.0%
1.0%
2.0%
3.0%
4.0%
5.0%
2013 2014 2015 YTD
% Foreign Growth
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Capabilities. Performance. Commitment. Scheduling
• Greater than 1000 fermentation runs per year
85.0%
88.0%
91.0%
94.0%
97.0%
100.0%
2013 2014 2015 YTD
% On-Time Delivery to Approved Finished Goods
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Capabilities. Performance. Commitment. Business Excellence
Class A Certification (2007/2011/2014) Based on Oliver Wight manufacturing philosophy
KPIs to ensure performance
Master production schedule conformance
Supply plan achievement
Data accuracy
New product introduction milestone achievement
Perfect index
Right the first time
EHS index
Customer service
Days on hand
Business Processes established
New product introduction
Master production scheduling
Material ordering and inventory management
Supply and operations planning meetings
Monthly management reporting system
Continuous Improvement Tools Utilized Kaizen Root Cause Problem Solving 5S Six Sigma
Dedicated Internal Business Excellence Organization AbbVie | Company Confidential © 2015
Physical
24/7 On-site Security
Gated Site
Video Surveillance
Badge Access For Each Building
Cell Banks Are Under Lock and Key with Restricted Access
Manufacturing Documents in Controlled File Area
Personnel
Policies and routine training on handling of confidential information
Employees required to sign a confidential agreement upon hiring.
Capabilities. Performance. Commitment. Security
AbbVie has many layers to ensure your proprietary information is safe:
Cyber
All computers are virus protected
All shared sites password protected with restricted access
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Proposal Stage:
Initial evaluation for site fit
• EH&S
• Organism
• Scale
• Commercial
Process Evaluation for equipment fit
• Commercial pricing estimate
• Capex estimates
Tech Transfer Proposal
• Tailored to customers needs; can include detailed activities with sub-stages
• Timelines
• Defined success criteria
Letter of Intent/Supply Agreement
• LOI enables immediate transfer
• Project governance
Program execution:
Manage the successful implementation of products into manufacturing
• Develop project plan and schedule
• Form project team
• Kick-off meeting
• Facilitate team meetings
• Track progress against milestones
• Report to Governance Committee
Communication • Routine meetings
• Face to face visits/telecon/webex
• Sharepoint site development
• Elevation strategy
• Engaged senior leadership
Capabilities. Performance. Commitment. Customer Experience
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• Stable and committed partner with 25+ years tolling experience
• 65+ years of classical fermentation expertise and know-how
• Established site infrastructure to ensure reliable supply
• Proven ability to consistently meet delivery commitments
• Robust compliance and business processes
• Excellent environmental, health and safety record
• Strong culture of continuous improvement
• Trusted partner to maintain confidentiality
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Capabilities. Performance. Commitment. AbbVie Fermentation – Your Preferred Partner