Grange Castle is Pfizer's largest single investment in Ireland, a €1.8 billion biotechnology facility located on a 90-acre site in South County Dublin, with buildings and facilities extending to more than one million square feet. The development is one of the largest integrated biotechnology plants in the world and is part of the Pfizer Specialty Biotech manufacturing network. Construction of the facility commenced in 2000, and the site was licensed and officially opened in 2005. Principal manufacturing technologies include large-scale mammalian cell culture, protein purification, vaccines conjugation, and aseptic syringe filling.

The site manufactures biological active ingredients, which are used in parenteral products for the treatment of rheumatoid arthritis, psoriasis and ankylosing spondylitis, and in vaccines for the prevention of pneumococcal disease. The site also manufactures the finished vaccine drug product in pre-filled syringes. As well as commercial operations, Grange Castle is licensed for, and has manufactured investigational medicinal products for use in clinical trials.

Manufacturing at Grange Castle is supported by extensive Quality Control laboratory facilities, which also provide support to other global Pfizer manufacturing sites. Site central utilities support manufacturing through the provision of essential services such as water purification, heating, ventilation and air conditioning, management of plant infrastructure, and calibration and maintenance. Expansive on-site warehousing provides both ambient and cold storage for raw materials, intermediates, and finished products, as well as facilities for the weigh and dispense of materials for use in manufacturing. Administrative support comes from other departments such as human resources, business technology, organisational learning, regulatory affairs, occupational health, and finance.

Grange Castle has significant development operations, and benefitted from a major expansion of its development facility in 2007. This facility houses state-of-the-art pilot-plant, laboratories and equipment for the development of processes for production of many different types of biological drugs, including proteins and vaccines. In addition, Grange Castle is also home to scientists from Pfizer's biotherapeutics research organisation working on a number of drug discovery and optimisation projects in collaboration with other Pfizer research and development sites and various partners.

All of Grange Castle's manufacturing processes are subject to rigorous control to assure the quality of processes and products. This includes a comprehensive Quality Assurance system coupled with a series of stringent Quality Control tests to ensure that each batch meets its requirements for safe and effective patient use. In addition, the highest standards of environmental performance and a deep commitment to safety and corporate responsibility are part of the culture at Grange Castle. In 2011, Grange Castle joined with the other Pfizer Ireland Pharmaceuticals sites to win the prestigious Green Manufacturer Award in Ireland, and in 2012 Grange Castle won The Chemical & Pharmaceutical Manufacturer Award for its submission to the National Irish Safety Organisation safety awards scheme.

Pfizer at Ringaskiddy exports bulk pharmaceuticals, the active ingredients in Pfizer's medication for both humans and animals.

Pfizer was one of the first US pharmaceutical businesses to locate in Ireland and set up its first production facility in Ringaskiddy in 1969 to produce food chemicals, including citric acid and gluconate products. In 1972 the first production plant, Organic Synthesis Plant 1 (OSP1), was constructed to produce bulk pharmaceutical products. The site has grown considerably over the years to meet growing production demands and increase production capacity. The site currently has 3 organic synthesis plants, OSP1, OSP3 and OSP4. In 1990, Pfizer sold its worldwide citric acid business to Archer Daniels Midland.

The site also scales up new products in cooperation with Pfizer Global Research & Development to ensure timely approval and launch of these new products.

In 2007 the Pfizer global Process Development Centre opened a Kilo Technology Laboratory (KTL) on the Ringaskiddy site. The KTL scales up 2nd generation processes coming from the global Process Development Centre laboratories. The KTL specialises in the development and scale-up of novel chemical routes and in the use of new manufacturing technologies.

Our bulk products are shipped from Ringaskiddy to Pfizer plants across the world for finishing and packaging. Each Organic Synthesis Plant is a multi-purpose manufacturing facility capable of producing a wide range of products. Solid and liquid raw materials are added to steel or glass-lined steel-enclosed vessels called reactors. Subjected to temperatures ranging from -50°C to 160°C, pressure or vacuum, and with controlled additions of other raw materials, these mixtures react to form pharmaceutical product. Waste is removed from this product using separation equipment such as filters. Following drying, specially designed mills may be used to grind the material to the correct size. OSP4, the newest facility on-site, contains all standard processing equipment as well as some new technology including extensive use of solids containment equipment, a comprehensive material tracking system and a state-of-the-art control system.

Quality is considered at all stages of processing; all production staff are trained in Good Manufacturing Practices and the Quality Control, Quality Assurance and In-Process Control groups monitor product quality. All raw materials are tested before use and testing during the manufacturing process, as well as final quality control, ensure that all products meet the highest quality requirements before supply to our customers.

Environmental, Health and Safety standards are a major focus area on the site and we actively encourage colleagues' input and suggestions. Waste treatment, waste minimisation, solvent recovery and air emission treatment protect the well-being of colleagues and the environment. The EHS Department continually assesses the way we work and seeks out improvements in all areas of health and safety.

As part of the supply chain and global value streams we have a strong focus on our customers with the goal of being responsive, efficient and cost competitive. Six Sigma and Lean Tools are used extensively across all functions to identify areas of waste and poor flow thus to drive continuous improvement across the site be it in improvements to systems or processes in the areas of robustness or efficiency.