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Pharmaceutical IndustrySandoz& Bayer
Erenşah KAYAHande KARTALZüleyha ATLAYMerve MAÇİN
Sandoz
- is one of the largest manufacturer of generic pharmaceutical product in the world.
- İs a member of Novartis Group
- Sandoz is the champhion of exportation for last year
Manufacturing;
-more than 200 products
- More than 500 package sizes
Bayer is also the most famous manufacturer
Subgroups of Bayer
BAYER HEALTHCARE
BAYER CROPSCIENCE
BAYER MATERIAL SCIENCE
BAYER TOPKAPI
Establishment date: 1955
Personel number: 429
Closed Area: 22.000 m²
Residental Area:
16800m²
Certificates
Major Groups of Pharmaceutical Manufacturing:
-the production of active drug
(Primary processing)
-The conversion of the active drugs into products suitable for administration (Secondary Processing)
Secondary Processing Steps:
Granulation DryingTablet
pressing
Printing & Coating
Filling & Packaging
PRODUCTS
For Bayer
- Tablet form- Liquid form- Pomade form
For Sandoz
-Pellet form- Tablet form
Industrial Pollution
According to manufacturing steps, air emissions, liquid effluents ( wastewater) and solid wastes may be generated.
To reduce the wastes, They reuse and recycle. Remaning wastes is treated according to characteristic.
Acts& Standards
Treated wastewater should be discharged; According to The Control of Water Pollution Management ( 04.09.1998)
Discharge Standards For Pharmaceutical
Acts& Standards
Hazardous wastes are removed accoding to
Control of the Hazardous Wastes
-APPENDIX 11-A
- APPENDIX- 6
Weighing and mixing:
raw materials from the warehouse to weighing part.
The weighing is made by the Automotic Container Weighing System.
mixed at the mixer for desired revolution and time.
The aim homogeneous mixing.
Granulation:
The aim homogeneous granules Weighing is again The solution is prepared ,added raw
materials. The demineralized water can be added if it is
required. The prepared granule is sifted (sieving). Dried to reach a certain moisture value.
Tabletting:
The mix that is dust , is collected to press machine.
The pressing is applied. Some portion of the sample is taken and sent
In Process Control (IPC)
after approval the ICP it is continued to tabletting.
Film Covering:
The tablets, are taken to the film covering boiler.
A solution is prepared homogeneously and sprayed to the tablets.
After that the tablets are dried at a certaion temperature in the same boiler.
Packing:
This part is seperated to 2 parts: Primer and Seconder Parts. In the primer part the blisteration process is
made. In the seconder part the boxing and packing
is made.
Warehousing :
The boxes ,
that will be sent to pharmacies , are packed with
polyethylene as groups of 5 or 10.
At final they are packaged and warehoused.
Potential Environmental Issues
Air emissions Wastewater Solid and hazardous wastes
Air emissions
Volatile organic compounds(VOCs)
Acid gases
Particulates
Greenhouse gas emissions (Combustion Source Emissions)
Volatile Organic Compounds
significant emissions of VOCs come from
In secondary pharmaceutical manufacturing;
mixing, compounding, granulation, and formulation
operations involving the use of solvents (e.g. granulation)
alcoholic solutions (e.g. tablet coating)
How can control the VOCs emissions? Also odor problem.
wet scrubbers
Wet Scrubbers
At total 5 wet scrubbers
Retention time = 4.6 to 6.5 sec Velocity = 1.2 to 1.7 m/sec
Particulate Matter
The most common sources of particulate include milling mixing compounding formulation tableting packaging
Air emissions
Particulates
Solution ; hepa filters
HOW CAN CONTROL PARTICULATE EMISSIONS?
CYCLONE
Combustion Source Emissions
FROM DISTRIBUTION SERVICES
TRUCKS
CARS
SOLUTION ; DIESEL MOTORS
Solid Wastes
In both plant solid wastes include as
Spoiled packing material Waste papers Waste glass Waste plastics Household wastes Electronic wastes
Treatment of solid wastes
These wastes are collected and sent to the
agredite organization that concern about these
wastes .
HAZARDOUS WASTES
Used scrubbers solutions Cyclone wastes Used hepa-filters Container residues Laboratory wastes
İZAYDAŞ
Process and Effluent Treatment Sludges
NO SLUDGE PROBLEM
SENT TO İZAYDAŞ
(10 tons in 2008.)
Wastewater Management at SANDOZ
Wastewater
Process wastewater
wet granulation preparation
wet granulation sizing
tablet plating
Sources
Municipal wastewater
toilets
refectory
Separate systems
process wastewater
wastewater treatment plant of facility
organized industry locale WWTP
municipal wastewater
organized industry locale WWTP
SANDOZ Wastewater Treatment Plant
Coarse screen
EqualizationTank
HClNaOH
Neutralization Tank
Aeration Tanks (4)
SludgeCollectionTank
Polymer
Filter Press Main sewer line
effluent
sludge
coarse screens : big particles captured
equalization tank : control fluctuations in ww characteristic
neutralization tank : adding HCl or NaOH
aeration tanks : biological treatment and sedimentation
sludge collection tank : sludge is pumped from aeration tanks to the collection tank
filter press : dewatering
Standards
Local organized industry discharge limits
COD : 4000 mg/L
TSS : 200 mg/L
pH : 6-9
SANDOZ wastewater treatment plant effluent
COD : 600-650 mg/L
TSS : 48
pH : 7.2
Wastewater Management at BAYER
Combined System
process municipal
wastewater wastewater
wastewater treatment plant
sea
Main Sewer
line
The first washing process wastewater with antibiotics is collected in a tank and sent to the İZAYDAŞ.
30-35 ton / year
BAYER Wastewater Treatment Plant
Oil & grease separator
Equalization Tank
Neutralization Tank
Aeration Tanks (2)
Sedimentation Tanks
(2)
sludge Gravity
Belt thickener
RAS
main sewerline
effluent
Sludge cake
HClNaOH
aeration tanks : air supplied from blowers, biological treatment
sedimentation tanks : solid settling, sludge production, recycle of sludge to the aeration tanks
Oil & grease seperator : removes oil&grease from the water
equalization tank: control fluctuation in ww
neutralization tank : pH adjustment
Gravity belt thickener: thickening of sludge
High TOC in dewatered sludge, sent to the İZAYDAŞ.
BAYER influent parameters
pH : 6.8
COD : 800 mg/L
TSS : 208 mg/L Oil&grease : 50 mg/L
Total N : 18.6 mg/L Total P : 2.4 mg/L
Acts & Standards
İSKİ deep sea discharge after pre-treatment
pH : 6-10
TSS : 350 mg/L
oil & grease : 50 mg/L
COD : 600 mg/L
total N : 40 mg/L total P : 10 mg/L
BAYER wastewater treatment plant effluent
pH : 7.4
TSS : 53 mg/L
Oil & grease : 4.7 mg/L
COD : 175 mg/L
total N : 8.5 mg/L total P : 1.4 mg/L
References
http://www.us.sandoz.com/site/en/company/profile/history/content.shtml
http://www.cygm.gov.tr/yonetmelik.htm http://www.bayer.com.tr/ebbsc/cms/tr/
BayerTurk/Locations.html “Bayer ilaç fabrikaları A.Ş. ‘de endüstriyel
atık yönetimi”, “Asiye BACIOGLU, Özlem DAGLI”, “Mayıs 2000”
http://www.iski.gov.tr/Web/UserFiles/File/mevzuat/pdf/Y_atiksularin_kanalizasyona_desarj_yonetmeligi.pdf