Crate-to-cradle assistance to set up a new Pharma, Nutra, Nutritional, or expansion of an existing set-up. Assistance on reducing the cost of operation

Coporate profile

Energy & Environmental Management. Cost reduction thru Energy audit of any industrial set-up besides Pharma


Syed Musharraf Ali – CEO & Founder of GMS, Inc.

45 years of Global experience in the field of pharmaceutical & energy cost reduction in any type of process Industry.
Permanently relocated to Pakistan from Chicago, USA to serve local industries & provide one stop shop for the pharmaceutical
operation. New Pharma/Nutra/Nutritional set-up/expansion and Energy/Environmental Management for any Industrial set-up

PHARMACEUTICAL PLANTS EXPERIENCES
  • Uganda Master Plan & Execution. Currently appointed as Principal Consultant for a $200 Million Pharma complex funded by Ugandan & Kenyan Govt. The complex will have separate buildings for OSD/ Liquid/ Ointments/ Sterile/ LYO/ Oncology/ CEPH/ Penicillin/ Automated WH & mRNA vaccine. All civil construction started on conceptual layout. Preliminary & Detailed Process & MEP under design phase.
  • As Plant Head of a local company, recently completed setup of a new Nutra unit, expanded pharma unit on BOT (Build, Operate & Transfer) with a total investment of approx. Rs. 4 billion to make operation efficient, environmentally friendly & improved yield without compromising cGMP.
  • MNC experience – Experience is second to none for Pakistan Market. Green field projects in China, Indonesia, Egypt, India, Pakistan, and office buildings set-up at Abbott Park Chicago. LYO Expansions in Russia, OSD/Liquid/Sterile areas expansions of all Asian plants of Abbott. Last assignment was out of Abbott Dubai as Asia Regional Engineering Head & Global Director Energy Management.
  • Merger & Acquisition at Abbott: Has been involved in acquisition of Knoll & Solvay pharmaceutical in EU, Veraphorm in Russia, Baddi in India and CFR in Latin America. Learned lessons in reducing cost of operation by Plant Rationalization.
ENERGY AND ENVIRONMENTAL SME (Subject Matter Expert)
  • Recently completed 6 facilities Energy Audits in Europe & USA as Energy/Environmental Consultant at Curia Pharmaceutical. Hired by Their President who was ex-VP Operation for the MNC I worked for 37 years.
  • Appointed as spokesman on behalf of the American Business Council of Pakistan for rationalization of Countries NEQS during the nineties at the time when wastewater standards were in the development stage. Guided GOP to finalize based on developing countries' standards.
  • Project Director for 12 Co-generations units installed by Abbott Corporation worldwide (Germany, Italy, Mexico, North Chicago, and Pakistan) and many small & big Solar projects besides conventional Energy Conservation.
  • Reduction of CO2e footprint at the worldwide location of Abbott by 32% besides a production increase of 50% at 27 Pharma facilities.

LESSON LEARNED TO HELP PHARMACEUTICAL INDUSTRIES

  • Layout development for current plant expansions or new plant set-up for Pharma, food & Nutraceutical From inception to completion – One window solution.
  • Help in certifications as per client requirement.
    (Local, WHO, PIC/s and for CIS) including regulatory approvals.
  • Reduce operation, maintenance & Energy cost through innovative ideas.
  • Plant rationalization thru BMR (Balancing, Modernization & Replacement) best practices

FOCUS ENERGY CONSERVATION IDEAS FOR ABATEMENT OF CO2E EMISSIONS – HELP ALL INDUSTRIES

  • Energy cost reduction thru Conventional Energy conservation – 10% reduction promised without investment thru Energy audits.
  • Higher return if client is capable of small-scale investment.
  • Highest return in case client is interested in Co-generation & renewable energy investment.
  • Help export industries on Carbon Trading Scheme & local on CO2e emission computation for any Energy project.

Joining hands with

Haffez Uddin Ghouri

Founder & Sole Proprietor
Pecxone International

Deals in industrial process instruments, machineries and,
HVAC equipments with specializations in pharmaceuticals
and food industries across GCC, East Africa and Pakistan

Samir Dossal

President, Canada - Pakistan Business Council
Founder & Sole Proprietor - Linkks Canada, Inc

Over 20 years of experience in business services across
North America and Canada, providing identification of
business, project management, equipment selection and,
concept development


PHARMACEUTICAL OPERATION AND CAPITAL PROJECT
MANAGEMENT WITHOUT COMPROMISING cGMP


  • Maintenance Excellence Plan: MEP should be upon running hours & not on time bound. Pharma Engineers make mistakes by making it quarterly. We have expertise to make MEP based upon usage.

  • POBOS: Pharma Operation Benchmarking for Oral Solid – Where one can reduce the Pharma operation cost drastically. Can help on Pharma machine’s selection based upon Life Cycle concept. Justification of investments based upon Waste Management technologies.

  • OEE (Overall Equipment’s Efficiency) or Operation Excellence whatever you want to call.

  • Maintenance Excellence Plan: MEP on running hours & not on time bound. Pharma Engineers make mistakes by making it quarterly. We have expertise to make MEP based upon usage.

  • CAPEX plan for BMR (balancing, modernization & replacement)

  • Efficient warehouse spacing (Pallet per sqft)

  • Plant Rationalization

  • Operation & Maintenance contract: Expertise available for operation and maintenance contracts to run entire pharmaceutical operations with breakdowns as low as 5%. Utilities & Pharma machines.

  • Lyophilization: Provide us the stoichiometric solution & we will hand over the vials in minimum cost & cycle. Current Lyophilization Cycle optimization expertise are 2nd to none. Complete validation of the cycle included.

  • EHS&E. SME of Environmental Health Safety & Energy. Worldwide speaker on CO2e Management – EHS Manual for any operation

  • SME on RCE’s: (Request for CAPEX) – Computation of DCF/ROI of any project has been my expertise during tenure at Abbott which lasted 37 years.

  • Solvent recovery

  • Yield improvement

  • Help on sustained released technology - Gradumet


Quality. Pharmacovigilance, Medical Affairs & Regulatory


  • Quality Audit Preparation: Worldwide data available & statistically analyzed for common observations in a Plant cGMP audits.
  • Validation Master Plan: Assist plants to prepare quality VMP for DRAP, PIC/s and CIS export market.
  • Science behind Wet & Dry Sterilization: Autoclave validation using F-Subzero concept to ensure proper sterility. Assistance available on DHS to reduce cycle time (Avoid overkill & safe time).
  • 21 CFR Part 11 compliance: Gap analysis expertise available to convert manual data to electronic record keeping – lesson learned during tenure with MNC.
  • Serialization: Though stay order has been taken on full implementation of serialization but assistance available to understand full track & trace cloud concept.
  • UQAP (Utilities Quality Assurance Program). We carry out vendor qualification before API material contracts. Inhouse supply of steam, water, HVAC, process gases etc. effects the quality more. International standards available & plants should be audited for their right quality to help CAPA’s.
  • Future Additions in GMS Inc.
    • Pharmacovigilance assistance will be provided after staff addition.
    • Dossier Development for submission by hiring required staff and prepare dossiers for different products going to be generic in next few years.
    • Will partner with a doctor to establish a Medical Affairs department within GMS Inc.

Training & Development on Pharmaceutical Operations and Energy Conversation

GMS International offers in-house training & seminars specifically based upon operations. GMS will do a survey & canned presentation specifically for your operation based upon lagging exist


Energy & Water Management

Designed & BOT of 12 co-generation, and 15 renewable energy projects during Abbott tenure of 37 years

The cost of Energy is a major portion of the industry overall variable expenses. GMS Inc. provide innovative ideas & solutions to reduce Energy cost in any type of Industry

Co-Generation

Success Stories briefly

  • Asset Management: Masterminded the used assets acquisitions from closed facilities from worldwide location & bring them to Pakistan. They were made complained thru local PLC developed in-house.
  • Acquired a used Lyophilizer back in 1984 from France & installed first unit in the country. Now that MNC has three & many local companies followed. Now a SME on cycle time reduction in any LYO cycle without compromising product quality.
  • First NG fired Munters Dehumidifier designed in their Sweden facility for a project in Pakistan. Steam D/H is a nuisance for Pharma and electric operated is very costly. Research paper written in Eighties for continuous maintenance of required RH for Tablet manufacturing. Presented a paper on difference between HVAC of other Industry versus pharma. Reynold number concept.
  • First Co-generation in Pakistan on small scale for Pharma. Reduction in Energy cost by 40% helped survived that MNC till today.
  • Pioneered sustain released technology transfer from UK to Pakistan – still no other pharma company has that process for tablets.
  • First HW shower autoclave cycle developed for the MNC in Pakistan resulting in launch of Electrolyte solution in plastic bottles – Pedialyte launch in other Asian plants as well.
  • Built start to end green field Pharma in China and Indonesia while based in Pakistan. Handed over the plant in less than 18 months which paved the way for relocation to MNC HQ in Chicago.
  • Served as member of the committees responsible for developing Corporate Standards for Water, HVAC, Compressed air, Electrical and Building finishes.
  • Solar PV panel in the entire parking lot of a huge complex at Puerto Rice, USA – this didn’t only save the energy but provided shades for car - Area temp remains in 30’s and 40’s deg C.
  • Upgraded many Fluid Bed Dryers (FBD’s) to reduce safety risk as well as made the cycle efficient by reducing cycle time & Powder waste.
  • Reduced coating solution cost by comparing cycle time of different plants of same list number tablet resulting in Millions of $’s savings.
  • Headed the Engineering of Nutritional division of the MNC’s. Worked on Capacity expansions of plants in Netherlands, Spain & Ireland. Also helped that MNC to build a plant in Singapore – Total drying capacity increased from 100 million lbs. to 200 million during 2000 to 2004.
  • As head of the green initiative at MNC, Installed Solar panels in Germany, Italy, Argentina, Indonesia, China & Pakistan. In Pharma, this MNC has biggest size installation among Pharma.
  • After relocation to Pakistan 4 years back, installed wastewater treatment plant to meet NEQS as well as reduced the water cost. Other projects completed as Plant Head were Cogeneration, efficient Warehousing, new Nutra plant (PIC/s certified design), a new Admin block, new QA/QC PD department & increased yield of all Pharma operation. Also prepared Site Master Plan for next three years expansions to balance the operation.
One Stop shop
From the stage of project inception either expansion or new plant. From the perspective of structure, electrical, HVAC, all utilities services including machine’s selection for OSD (Oral Solid Dosage),
Liquid, Sterile areas. SME (Subject Matter Expert) on Lyophilization.

+92 303 231 9361 | +1 847 271 0792 | +92 21 3432 2220

info@gmsinc.com.pk

Suite: 401, Mehdi Tower, SMCHS, Karachi, Pakistan