The Role of Pharma Engineering in Addressing the Vaccine Imbalance

Vaccinations stand as the most effective means of preventing infectious diseases. Beyond their role as simple injections, they play a pivotal role in generating life-saving antibodies within our bodies, effectively eradicating numerous infections and strengthening our immune systems.

Despite the remarkable strides made by medical professionals in vaccine research and development, the global community struggles to achieve equitable access to vaccines for a vast and diverse population. 

For instance, developed nations could secure a significant portion of getting free COVID-19 vaccines from supermarkets, clinics, and pharmacies. However, many countries in middle Africa continued to struggle to obtain the same level of access. 

Moreover, even within regions where vaccines are available, people face additional hurdles in reaching vaccination centers, with some traveling extensive distances of 15-20 hours to get vaccinated.

This graph illustrates the distribution of vaccine doses between rich and poor nations from 2020 to 2024. The noticeable gap highlights the urgent need for a quicker pursuit of vaccine equity and a faster and fairer recovery from potential pandemics in the future.

This stark contrast in vaccine availability has led to disproportionately low vaccination rates worldwide, highlighting an urgent need to expedite vaccine distribution in underserved nations. 

However, the challenge extends beyond supply alone, as various factors influence the efficient production of vaccines.

As a global pharmaceutical engineering firm, Fabtech approaches these challenges from a unique perspective. 

Over the years, we have developed capabilities to address the complexities surrounding vaccine manufacturing and distribution. Through our initiatives and projects, we strive to play a pivotal role in enhancing global vaccination efforts and fostering community well-being.

Our diverse portfolio of engineering solutions has significantly contributed to several pharmaceutical manufacturing plants involved in vaccine production. 

Here’s a glimpse of our offerings:

1. Prefilled Syringe Machine

Fabtech’s FilPac pre-filled syringe machine is designed for filling and closing disposable, nested syringes. 

It features a time pressure filling system with peristaltic pumps and a modular design capable of outputting up to 6000 L/hr or 8500L/hr with five pumps at maximum capacity. With its compact and superior construction, along with the highest dosing accuracy, the machine ensures sterility throughout the entire process.

2. Vial Filling Isolators 

Aseptic filling isolators are utilized to enclose filling lines during batch production of vials, pre-filled syringes (PFS), and cartridges. The isolators play a critical role in creating a bio-burden-free aseptic environment, guaranteeing the sterility, integrity, and safety of the pharmaceutical products.

3. Vial Filling and Capping Machine 

Fabtech’s vial filling and capping machines can be installed as a stand-alone unit or integrated with upstream and downstream equipment. Their slim and compact modular design and construction provide space-saving advantages. 

These machines feature a maximum output of 5 pumps and are compatible with various filing systems, offering output capabilities ranging from 1,500 L/h (2 pumps) to 6,500 L/h (5 pumps).

4. Water for Injectables (WFI) and Distribution System 

WFI, as the name implies, is sterile and ensures the utmost chemical purity of water. The preparation of injection solutions involves distillation, i.e. changing from a liquid state to vapor. 

The distilled water then undergoes further purification through a Multi Column Distillation Plant (MCDP), operating on the principle of heat exchange. The WFI generation system involves the water passing through a series of columns, undergoing repeated heating and cooling cycles of distillation. 

This water is 100% pyrogen-free and is stored in a continuously circulating system at 80– 85ºC to preserve its properties. This purification process eliminates ionic materials, particulates, colloids, non-volatile organic compounds, and bacterial endotoxins, making it the most preferred method for purified water systems in injectable applications. 

5. Sterilizing and Depyrogenation Tunnels 

Sterilizing and depyrogenation tunnels are vital equipment utilized in the pharmaceutical and biotechnology industries to ensure the sterility of injections and vaccines. 

They remove pyrogens from vials, ampoules, or other products before filling them with sterile substances. Thus, pyrogens, known to cause fever and adverse reactions, are meticulously eliminated beforehand. These tunnels are critical for maintaining the quality and safety of injectable medications, vaccines, and other sterile products, thereby enhancing overall product safety.

Our equipment conforms to good manufacturing practices guidelines for pharmaceuticals, meeting the most stringent quality requirements of the pharmaceutical industry. It has earned a significant presence in numerous prestigious pharma and biopharma projects across many nations. 

Here are some of our noteworthy vaccination projects.

1. National Veterinary Institute, NVI, Ethiopia 

With the timely installation of a 70 billion Birr start-to-finish veterinary project in Bishoftu (Debre Zeit), Ethiopia, this project under the National Veterinary Institute is built over 100 million Birr. 

Boasting a vaccine production capacity of 365.34 million, the facility operates to produce animal antibiotics and anti-parasite drugs in 12 different tablet types.  These medications serve to prevent and control various viral and bacterial diseases affecting the country’s livestock.

2. Egypt’s First Covid Vaccine Facility 

Fabtech built the region’s first COVID-19 vaccine facility as a proactive step to strengthen its healthcare system and capabilities.  We undertook the complete turnkey scope including cleanroom panels, cleanroom equipment, HVAC system, and process equipment. 

This $25 million project produced 400 million doses of the Avian Flu (bird flu vaccine) in the first year and over 800 million doses from the second year onwards.

3. Mechnikov, S. A. 

Spanning an area of 9000 sqm, this state-of-the-art production facility ranks among the most advanced and sophisticated pharmaceutical manufacturing facilities in the LATAM region and worldwide. 

Fabtech deployed the project planning, execution, and management team and commissioned the entire project scope. The facility manufactures immunologicals, particularly vaccines to prevent influenza for the LATAM region and other important vaccines, producing up to 30 million doses annually.

4. Wyzon Biotics, Madhya Pradesh, India 

Supporting this pharma facility was one of our instrumental ways of fulfilling the high-priority healthcare needs of people and making optimal medication accessible. We equipped the facility with efficient cleanroom equipment to establish the optimum environment necessary for manufacturing critical injectables such as Insulin and Remdesivir. 

5. National Anti-venom and Vaccine Production Centres 

Our Fill and Finish solutions play a crucial role in anti-venom processing centers, where vials and ampoules are essential for enabling effective injectables for victims of envenomation. 

Our vial filling and capping machines support drug protection against external reactants, contaminants, environmental dust, and other microorganisms, thereby ensuring sterility.

Conclusion:

The ongoing demand-supply gap in vaccines poses long-term consequences, prolonged pandemic recovery, increasing mortality rates in underserved regions, and continuing economic instability. 

This has been largely evident in the recent COVID-19 and previously the Ebola and Zika outbreaks which demonstrated the fast spread of infectious diseases, underlining the imperative need for having rapid response vaccines.

Recognizing this challenge, our turnkey pharmaceutical engineering projects strive to enhance vaccine manufacturing efficiency, thereby promoting equitable distribution and global health resilience.

Achieving vaccination equity is paramount not only for ending diseases and pandemics but also for fostering a more just and resilient global society. Together, let us make a meaningful impact in ending diseases and fostering a more just and resilient global society! Visit our website or contact us today.