Pharma Manufacturing

The Challenge
A fast-paced pharmaceutical manufacturing site was experiencing consistent product loss at the end of each batch.
Valuable product remained in transfer lines and was discarded.
Traditional recovery methods weren’t compliant with GMP hygiene regulations
Quality and safety teams had previously blocked recovery attempts due to risk
The Work
Identified an opportunity to recover this product without compromising regulatory compliance
Designed and implemented a validated hygienic pigging system tailored to GMP requirements.
Collaborated with cross-functional teams (Quality, Operations, Safety) to resolve objections and build trust in the solution
Developed standard operating procedures to make the process repeatable and auditable

The Results
Thousands of dollars saved per day across multiple production lines
Fully GMP-compliant recovery system, approved by site quality leadership
Improved batch yields with no compromise on safety or product integrity
Why It Matters
In regulated pharma environments, cost savings are often sacrificed to maintain compliance. This solution achieved both — turning end-of-batch loss into recovered profit, without a single deviation.