The requirements for quality assurance systems in the life science industry (pharmaceuticals, cosmetics, medical devices and food) are constantly increasing. Current incidents are leading to corresponding tightening and adjustments by legislators and the relevant authorities. Efficiency and effectiveness are to be further improved with increasingly complex workflows and supply chains. Companies often lack the experience and human resources to implement all these requirements.
With experience from many successful compliance projects, Chemgineering supports you in maintaining an overview of the conflicting regulatory and corporate requirements and in producing efficiently and compliantly in the long term.
Risk assessment and risk management
Risk assessments and risk management are our tools for solution-oriented GMP compliance consulting. We focus on the aspects that are really relevant to quality and systematically check all areas. With the experience of our specialists, the end result of your compliance project is not a mountain of paper and frustrated employees, but GMP-compliant systems and processes that withstand audits at the first attempt.
Chemgineering supports you in the introduction of a compliant quality management system tailored to your company according to your specific requirements, for example:
ISO (22000, 13485, 17025, 22716)
European Guidelines (2009/94/EC, Eudralex Volume 4, 1223/2009)
FDA (21 CFR Parts, 111, 210&211,225 & 226, 820)
AMG (Germany)
revHMG (Switzerland)
AMG (Austria)
Norms (ASTM)
As part of your team, we work with you to develop a system tailored to your company and your needs and accompany you through the entire life cycle. From development to implementation and monitoring in day-to-day work.
Inspections and audits: prepare, manage, pass
The authorities have announced their visit? An important customer wants to carry out an audit to check the agreed measures? Do you have many suppliers but too few resources to carry out the necessary audits? With experienced auditors and a professional organization, we support you in the preparation and organization of inspections and audits. With the help of mock audits, we put your systems and processes through their paces, draw up a report and help you implement improvement measures. Following the actual audit by the authorities, we support you in the evaluation of action plans and responses to the authorities.
Validation: conception, planning, implementation
The validation of procedures, methods and processes is standard practice. You think. Designing, planning and carrying out validation requires more than just knowledge of the relevant rules and regulations. What sounds simple is difficult to implement in practice if there is a lack of experience. With the know-how from many successfully completed validation projects, we support you in the validation of processes and analytical methods. The validation concepts we have developed have already been tested several times by authorities and assessed as compliant. We always focus on your needs and the requirements of the product or process. This gives you a sustainable concept that is easy to implement. We accompany you through the entire validation process, from development to implementation on site. The training of your employees goes without saying.
Unsere Leistungen im Bereich Pharma Compliance Beratung
Life cycle management for processes and plants
Concept development
Quality management: optimization and implementation
Risk management
Quality oversight & KPIs
Training on all quality-related topics
ICH Q3D implementation
Technology and method transfer
QC system optimization
Analytical method validation
Supplier qualification and 3rd party audits worldwide
Inspection preparation and follow-up
Mock audits & GAP analyses
Secure track & trace concepts
Person-in-plant and interim management
Relevant Projects
Expansion of Production by Two Glass-lined Reactors
New Facility HD15
60m³ Fermentation System
New Solids Launch Facility (NSLF)
Filling line for pre-filled syringes
First plasma fractionation plant in Turkey
New glycoenzyme production
Concept Design Cell Therapy Laboratory
F/3000 DSP Cystine León
Recombinant Ebola Vaccine Production
Pharma Compliance I
Pharma Compliance II
Validation of COVID-19 Vaccine
Production Expansion for HA Filler
Inhouse Training – Customer Specific
HVAC Qualification
Expansion of Production by Two Glass-lined Reactors
Planning of two glass-lined reactors, including all connections for steam, air, cooling water, exhaust air, vacuum, nitrogen.
Customer
Biosynth AG
Location
Staad, Switzerland
Budget
1.7 Mio CHF
Year
1 Year
Mandate
Planning
Services
Process Design: Detail Design
Plant Design: 3D Laser Scanning, Layout Equipment, 3D Piping
Qualification: DQ, IQ, OQ
Commissioning: Control of Mechanical Completion
New Facility HD15
Planning and execution of a new plant (4 floors) for the production of natural products under high pressure conditions (supercritical CO2 up to 1,000 bar).
Customer
Hopfenveredelung St. Johann GmbH
Location
Wolznach, Germany
Budget
6 Mio. EUR (excl. Engineering Fees)
Year
3 Years
Mandate
General Planner
Services
Basic & detail engineering, support of the procurement process (tendering procedure, contract negotiations), construction management, support of commissioning
Chemical engineering departments: project management, HVAC incl. automation, process planning (building services, packaging unit, piping, 3-D model)
Special features: Process automation of the customer, relocation of existing process equipment (e.g. extraction system)
60m³ Fermentation System
Conceptual design for the implementation of an upstream and downstream process in an existing building. The project included a 90m² clean room, 270 m² fermentation area (60 ³ capacity), a tank farm and utilities.
Customer
Phyton Biotech
Location
Ahrensburg, Germany
Budget
30 Mio. EUR
Year
4 Months (Planning), 2 Years (Implementation)
Mandate
General Planner
Services
Project coordination and scheduling
Process: Mass and energy balance, blow flow diagram, process flow diagram, concept for waste water treatment
Layout planning / 3D modelling: Personnel and material flow, conceptual planning of utilities, HVAC and building
Supplier coordination for key equiment
Cost estimates
Automation concept
New Solids Launch Facility (NSLF)
New building for the production and packaging of solid dosage forms and inhalation products.
Customer
Novartis Pharma AG
Location
Stein, Switzerland
Budget
500+ Mio. CHF
Year
5 Years
Mandate
General Planner Process
Services
Project management
Concept study, basic and detailed design
3D planning pure media supply
Construction management
Qualification
Procurement support
Expediting
Document management
Filling line for pre-filled syringes
Planning of a filling line for pre-filled syringes in Switzerland, including planning of all process systems and building infrastructure through to commissioning.
Customer
International Pharmaceutical Manufacturer
Location
Switzerland
Budget
35 Mio. CHF
Year
3 Years
Mandate
General Planner
Services
Project management
Planning for all process systems and entire building infrastructure in existing production building (ventilation, clean room, connection to energy and media supply, incl. EMSR and building automation)
Conceptual design, basic design, detail design
Procurement support, expediting
Support for installation management (conversion during ongoing operations)
Planning of a plasma fractionation with 650,000 l / 1 million l (expansion) per year; basic fractionation, purification, fill & finish, products: IVIG, albumin, FVIII, each in different concentrations. Planning as a "sandwich concept", production-centered arrangement with the supply below and HVAC above.
Customer
Maxicells
Location
Isanbul, Turkey
Budget
Confidential
Mandate
General Planner
Services
Concept & basic design (completely 3D)
Tender design (all trades), tender procedures
Investment cost estimation, value analysis
URSs
Preparation of schedules
Procurement support
New glycoenzyme production
Planning of a production plant for endoglycosiadases (and in future also mRNA). Microbiological plant (yeasts and bacteria) with 30l / 300l (after expansion) fermentation volume. Planning as a classic upstream-downstream plant with single-use technology for fermentation and purification.
Customer
Daiichi-Sankyo
Location
Pfaffenhofen, Germany
Budget
Confidential
Mandate
General Planner & General Contractor
Services
Concept design, basic design, detail design
All trades
Investment cost estimation, value analysis
URSs
Preparation of schedules
Concept Design Cell Therapy Laboratory
Cell therapy laboratory with various clean room zones incl. storage/logistics and technical areas. Development of the user requirements and the optimum room concept in close cooperation with six different user groups (different processes / laboratory requirements). Total area of 1,000m².
Customer
University Hospital
Location
Switzerland
Budget
Confidential
Year
2 Years
Mandate
Concept Design Planning
Services
Concept design for production area (cleanrooms incl. unclassified technical areas)
Elaboration of the qualification concept
Elaboration of user requirements and future needs
Elaboration of the optimal layout
GMP consulting
F/3000 DSP Cystine León
Downstream process for the production of cystine powder.
Customer
Wacker
Location
León, Spain
Budget
10 Mio. EUR
Year
2 Years
Mandate
Engineering, Procurement and Construction Management (EPCM)
Services
Basic and detail engineering
3D planning
Purchasing
Construction management
Support during commissioning
Recombinant Ebola Vaccine Production
Conversion of a production facility, USP and DSP, for cell culture-based vaccine production, including adaptation of media, clean rooms, HVAC and chemical wastewater inactivation.
Customer
Janssen Vaccines AG (J&J, ex. Crucell)
Location
Bern, Switzerland
Budget
8. Mio EUR
Year
2 Years
Mandate
General Planner
Services
Concept design, process layout, basic design, incl. HSE and GMP reviews, detail design
Disposable equipment installation
Conversion of ventilation & media supply
Construction management and commissioning
Planning and implementation of chemical wastewater inactivation
Pharma Compliance I
Implementation and support of internal audits at the company's locations (worldwide) in a team with the customer.
Customer
International Pharmaceutical Company
Location
Switzerland
Budget
600.000 CHF
Year
1 Year
Mandate
Consulting
Services
Preparing the audits in the team
Conducting the audits on site, mostly as lead auditors
Preparing the audit reports
Checking the proposed corrective measures of the audit committee
Pharma Compliance II
Creation of a system to assess the appropriate GMP level of excipient suppliers.
Customer
Medium-sized Pharmaceutical Company
Location
Switzerland
Budget
11.000 CHF
Year
2 Months
Mandate
Consulting
Services
Preparation and implementation of a workshop on the evaluation of excipients
Creation of a concept for the evaluation of the appropriate GMP level of excipients based on the customer's existing system
Creation of the necessary SOP and documentation
Training of employees
Validation of COVID-19 Vaccine
Transport validation of the world's first approved COVID-19 vaccine from BioNTech. Transportation at -70°C ±10°C and seamless compliance with the cold chain were essential for the rapid and safe delivery of this important vaccine.
Customer
BioNTech SE
Location
Mainz, Germany / Worldwide
Budget
Confidential
Year
Since October 2020 (ongoing)
Mandate
Consulting
Services
Transport validation of the COVID-19 vaccine (master plan, test planning and evaluation, final report)
Supply network from raw materials to finished product
Temperature mapping (-80°C to room temperature)
Production Expansion for HA Filler
Planning, execution and commissioning of GMP production rooms and laboratories including process media.
Customer
Merz Anteis SA
Location
Lonay, Switzerland
Budget
Confidential
Year
1 Year
Mandate
General Planner
Services
Development of layout variants
Planning, tendering and construction site management:
TGA
Cleanrooms
Cleanroom and airlock furniture
Electrical and sanitary installations
Process media and distribution (gases, vacuum and WFI)
Construction activities
WFI production and storage
2 GMP washing machines
Qualification support
Inhouse Training – Customer Specific
Planning and execution of customer-specific in-house training courses, topics as required, e.g: CSV, GMP basics, data integrity.
Customer
Several Customers, Classroom Seminar or Online Training
Budget
variable
Year
ongoing
Mandate
Consulting
Services
Depending on subject areas and duration from approx. CHF 2,300
Duration from half a day. Typically 1-2 days
Determining the training requirements
Drawing up a training schedule, coordinating the content and duration
Preparing the content and training documents
Conducting the training, possibly in combination with a topic-specific workshop
Issuing training certificates
HVAC Qualification
Design review and qualification of the HVAC systems in the new building for oral solid and liquid dosage forms (production and packaging).
Customer
Ilko Ilac
Location
Konya, Turkey
Budget
5 Mio. EUR
Year
1 Year
Mandate
Design Review and Qualification
Services
Technical and GMP design review of HVAC systems
Qualification of HVAC systems
Preparation of all qualification documents for QMP, RA, DQ, IQ, OQ and PQ
Coordination and monitoring of qualification activities
If you have any questions about pharmaceutical compliance, please contact us
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