The general facility of Pharmasia incorporates modern technological advancements with automated material handling systems and multilevel designs to enable gravity feed between processing stages. The building design has also allowed maximum engineering maintenance access without entering into the production areas. Pharmasia provides larger capacity and a stronger platform to manufacture value added generics in different dosage forms for highly competitive market in Bangladesh, and also offering other companies as an attractive platform for being a contract manufacturing partner.
With a focus to prevent cross contamination Pharmasia has the most modern three-layer building concept is adopted in this building. These three layers are segmented as Level–1: A 10 feet height Manufacturing Area dedicated for production operations. Level–2: A 6 feet height Service void namely Service Deck dedicated for service lines and ducting. Level–3: A 12 feet height Energy Deck dedicated for service and utility machinery The whole production facilities of Pharmasia are classified in to three different zones: clean area, optical clean area & grey zone. Dispensing, granulation, blending, tablet compression, film coating, encapsulation, oral liquid manufacturing, cream, ointment & gel manufacturing, PFS manufacturing, external liquid manufacturing, oral liquid primary packaging, cream, ointment & gel primary packaging, blister packaging, powder filling, tablet filling, adjacent corridor and the change rooms adjacent to manufacturing area are clean areas (class E). In class E region maximum permitted number of particle/m3 =0.5-micron 283000 (At Rest) and =5-micron 1750 (At Rest).
Secondary packaging, adjacent corridor and change rooms adjacent to secondary packaging area are designed as an optical clean area (Class F). Primary change rooms, training room, prayer room, adjacent corridor etc are considered as grey zone. In order to avoid cross contamination class E corridor has over pressure against the interconnecting rooms. This measure keeps the dust in the rooms, more over dust is extracted by central wet-de dusters from the source. The production building of Pharmasia is connected to the warehouse by means of corridor/airlock at the back side of the warehouse building. The material is transferred to the production area from warehouse and vice versa through two separate hatches/pass boxes. One is used for primary packaging material and raw material transfer and the other one is used for secondary packaging material transfer. The hatches/ pass boxes are separated from both production and warehouse buildings by air locks. The production facility are designed to perform dry mixing, Wet granulation, blending, tablet compression, film coating, encapsulation, dry syrup process, oral liquid manufacturing, external liquid manufacturing, cream, ointment & gel manufacturing, primary & secondary packaging of all mentioned dosage forms.