Stand-Alone Simulation: Optimizing Fill & Finish Facility Design

A well-known pharma company was preparing to invest in a new Fill & Finish facility for plasma derived products. The assumption driving this decision was that the existing setup would not meet future production demands. ZETA was brought in to simulate the greenfield facility and validate whether the planned capacity and equipment could fulfill the production targets. Analysis with INOSIM Insight confirmed the production targets could be met with the proposed equipment, helping avoid the cost of a new filling line (approximately EUR 5 million).

In addition, ZETA developed an automatic production scheduling algorithm. With a strong focus on production optimization, the scheduler provided two additional free weeks at the end of the year.

The customer faced a critical decision: proceed with a costly expansion or optimize the current design. They needed clarity on whether the existing equipment could meet annual production goals, how efficiently it would be utilized, and whether storage and production capacities were sufficient.

ZETA developed a comprehensive simulation model of the Fill & Finish process, incorporating real-world variables such as material flow, shift patterns, and maintenance shutdowns. INOSIM Insight utilizes advanced discrete event simulation algorithms to model production workflows, optimize resource allocation, and predict bottlenecks.  Compared to traditional scheduling and simulation tools, such as finite capacity schedulers, INOSIM’s algorithmic approach accelerates scenario analysis and enables faster decision-making. The simulation tested both the customer’s initial plan and ZETA’s optimized scenarios. The entire project was completed in 8 weeks at a cost to the customer of approximately €45,000.

The model is designed to be very intuitive and easy to use. All necessary parameters and controls can be managed using MS Excel sheets. This ensures that the model remains useful throughout the entire engineering lifecycle of the facility.

The simulation demonstrated that the filler and packaging lines operated at an optimal 83% utilization rate, with sufficient storage capacity throughout the year. By avoiding unnecessary investment in a new filling line, the customer realized approximately €5 million in cost savings.  In addition to cost savings, several operational challenges were addressed using INOSIM Insight.