About Our Plant Facilities : Plant Tour : Taiyo Pharmaceutical Industry Co., Ltd.

General Antibiotics Building

Prior to the revised Pharmaceutical Affairs Law, we constructed a special General Antibiotics Building. By doing so, we completely segregated the manufacturing facilities of injectables and solid formulations, which must be manufactured in an isolated environment, as well as our quality control, canteen and storage functions. At our special J-GMP and international GMP standard-compliant manufacturing facility for producing non-penicillin type beta-lactam antibiotics, we became the first contract drug manufacturer in Japan to separate the zones for cephem and penem (carbapenem) antibiotics.

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Distribution Center

We are proud of our distribution center, which has a storage capacity of 9800 pallets (equivalent to approximately 7 billion, 100 mg tablets) and attached, perfectly controlled air-conditioned rack warehouse. We even have a large medical refrigerator. In May 2007, we doubled our shipment space, which has even allowed us to take product storage and delivery orders.

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NAS Batteries

Power outages seriously impact the manufacturing of drugs. In particular, air-conditioning shutdowns caused by power outages during the manufacturing process of sterile formulations such as injectables cause product lots to be rejected. We have introduced and installed NAS batteries so that a stable supply of electrical power may be provided to key manufacturing facilities in the event that the power goes down even for a mere fraction of a second. An NAS battery is a storage cell composed of metallic sodium and sulfur that makes an important contribution to manufacturing risk management.

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North Plant (a special plant for manufacturing solid oral dosage formulations)

Photo: North Plant (a special plant for manufacturing solid oral dosage formulation)

Operations at the North Plant, a special plant for manufacturing solid oral dosage formulations, commenced in April, 2007. The plant is a new, special building that has an annual maximum production capacity of 6 billion tablets and is also FDA (US Food & Drug Administration) -compliant. Operations at this plant will increase Taiyo's production of solid oral dosage formulations four-fold, to 8 billion tablets.

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Unit-type Plant

The Unit-type plant is a plant that enables us to separate different sections in accordance with the size and properties of the formulations being manufactured. The area of one section (unit) ranges from 76 m² to approximately 400 m². It is a special manufacturing plant that is able to handle contract orders, which we anticipate will become even more diversified and specialized in the future. The areas required for manufacturing products on a contract basis have a free layout, and, when necessary, these areas can be air-conditioned separately from one another. We guarantee an optimal manufacturing environment that is suited to the drugs being manufactured and we are the first outsourcing business in the industry to provide technology and manufacturing space to the companies we work with on a contract basis.

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Special Production Lines

Not only does Taiyo possess drug manufacturing facilities of a sophisticated level of specialization required for manufacturing formulations such as pre-filled syringes and ODT, also our plant is equipped with the best possible environments (in terms of layout, air-conditioning etc). required to manufacture each individual drug. And, in 2006, we introduced a special production line that utilizes isolator systems in the manufacturing of formulations such as antibiotics and anti-cancer agents, which must be manufactured in isolation from general formulations.

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Utilities

Inside our plants we use AGV (automatic guided vehicles) to reduce the number of people involved in the distribution of formulations. In addition, our plants are equipped to control appropriately the surrounding environment needed for manufacturing drugs in their various dosage forms. Air purity, temperature, water and energy systems are controlled by central monitoring systems. We have even introduced a telephone conference system as a means of sharing information with our contractees and in the area of insect pest control, we thoroughly control bugs by regularly (on a monthly basis) installing traps for catching insects.

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About Our Plant Facilities

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Main Content: About Our Plant Facilities

Introducing our Manufacturing Plant Facilities

General Antibiotics Building

Distribution Center

NAS Batteries

North Plant (a special plant for manufacturing solid oral dosage formulations)

Unit-type Plant

Special Production Lines

Utilities

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