A pharmaceutical company in Philipsburg, New Jersey was utilizing manual labor to clean their tanks.
The company manufactures a wide range of Active Pharmaceutical Ingredients. They were experiencing significant revenue loss to their tank cleaning procedure and they were under significant pressure to provide a more validatable clean and eliminate confined space entry. The company has three process vessels, with center agitators, each costing them $9000 in revenue for every hour out of operation. Their cleaning process included five hours of manual cleaning every three days. In addition to the regular cleaning, a 20-hour manual cleaning was performed every quarter. At such a high cost per hour, any cleaning time saved would have a significant impact on production and revenue. In addition, a repeatable and reliable pattern would satisfy the sanitarian and so would the elimination of confined space entry.