Pfizer Ringaskiddy Organic Synthesis and Viagra Plant, Republic of Ireland

Pfizer's newest synthesis facility at Ringaskiddy started production in mid 2001. The process of construction began in 1998 in a response to the anticipated global demand for Sildenafil citrate, the active pharmaceutical ingredient of Viagra (used to treat erectile dysfunction disorders).

Pfizer entered Ireland with a citric acid plant at Ringaskiddy in 1969. The company constructed its first synthesis plant there in 1972 (OSP1) and commissioned its second plant OSP2 in 1984. The third synthesis plant, OSP3, required an investment of $130 million and was completed in 1995, doubling production capacity at that time. The latest plant expansion saw an investment of $302 million by the Irish-based company. Pfizer now has seven sites in Ireland employing over 1,400 people. The Ringaskiddy complex is the largest Pfizer production facility outside the US. The OSP4 plant produces active pharmaceutical ingredients for Viagra, Norvasc, Zoloft and Zithromax.

CONTRACTORS AND SUBCONTRACTORS

The construction contract was awarded to Foster Wheeler UK and Project Management Ltd of Cork. The building contract for OSP4 was awarded to Sisk building contractors. Sisk worked on the foundations, superstructure and cladding of OSP4. They also installed external services and underground services to the building. The Sisk contract was estimated to be worth £30 million.

The architectural glass (curtain walling of stairwells and thermally broken windows) were provided by Classic Building Solutions. Douglas Control and Automation provided control, automation and data management systems for the OSP4 plant along with being involved in validation.

Solartron Mobrey installed short fork level switch squing as an intrinsically safe sensor system to detect chemical levels as part of the solids containment system. The Squing, constructed from hastelloy for corrosion resistance, was installed in head tanks, filters and crystallisation vessels. Squing was used because of the absence of secondary electronics and its reliability. Heinzer Eco-management carried out a pre-assessment of the OSP4 environmental management systems in 2000 as part of a pre-validation check.

VIAGRA MANUFACTURING

Pfizer manufactures the active pharmaceutical ingredients for Viagra at Ringaskiddy, which accounts for 15% of its total output. The company also produces some 17 other products, the main one being Norvasc, which is used in the treatment of hypertension and angina, and is one of Ireland's largest sources of investment. The entire facility at Ringaskiddy, County Cork, covers 200 acres, has four production units and employs 500 people. The OSP4 plant starting production in 2001 allowed the plant to increase production by 40%.

The company contributes close to $151 million to the Irish economy and its current investment of $302 million in the OSP4 plant brings its investment spending over a five year period to more than $453 million. With net profit of $2 billion in 1998, Pfizer has invested more than $362 million in Ireland since 1994. This investment includes the construction of new offices and warehouses which have been opened in Dublin to provide a distribution network for Pfizer products in Ireland.

ORGANIC SYNTHESIS PLANT

Foster Wheeler and Project Management were responsible for the construction of the new organic synthesis plant (OSP4) as well as a finished goods building (FGB) and all supporting services.

The project started in March 1998 and manufacturing at the plant started in March 2001. The relationship between Foster Wheeler and Project Management allowed for Foster Wheeler to be in overall control and thus responsible for work carried out by Project Management.

The design of the plant utilised Foster Wheeler's project management system and was closely modelled on the OSP3 plant at Ringaskiddy. The OSP4 facility is capable of producing primary bulk, batch pharmaceutical products at a nominal reactor capacity of 150,000 litres and six lines of these at full production scale. In 2003, Pfizer was seeking planning permission to build a third liquid waste incinerator at Ringaskiddy to service OSP4.

The products manufactured at the plant are bulk active ingredients or drug substances. The bulk materials are shipped to other Pfizer sites where they are incorporated into their finished formulations and packaged.