Designing and building an insulin plant is not a breeze: the plant has to follow cutting-edge technologies and be managed with sophisticated automation systems to implement process phases and to obtain a product to be classified as sterile. 

The partnership with one of the largest Pharma Company, specialized in diabetes care, has been written in stone thanks to almost 10 insulin plants developed in 15 years.

The insulin market is constantly growing and so it does manufacturers’ need of production. These plants indeed are one of the most required: more than 450 million adults (20-79 years) lives with diabetes; prediction says by 2045 this number will rise to 700 million (International Diabetes Federation). 

The Insulin Plant is fully compliant with PED, CEI, cGMP, cGEP, FDA, GAMP regulations and produces a five-digit number batch of 3 ml insulin cartridge each hour.

The plant is composed of four formulation tanks and related formulation stations, four filtration lines, two sterile and fixed receivers, two intermediate portable tanks, nine Temperature Control Modules and two C.I.P. skids for cleaning and sterilization of the whole plant.

Solution 1, Solution 2 and Solution 3 respectively held in 100 L portable tanks on floor scale pass through peristaltic pumps to the three 500 L portable tanks. The three solutions obtained are transferred by the formulation transfer panel. The solution is prefiltered by the prefilters and the sterile filters, then transferred by the sterile transfer panel to 2500L fixed sterile receiver. The optical density sensor tests samples of the solutions before moving towards filling lines.