Pharma Industry Storage Requirements Are Unique, But Similar to Cold Storage

Note this is part 2 of a series. Read part 1: Material Handling Solutions and Pallet Storage Systems, Supporting Pharmaceutical Sector Evolution

When planning storage systems for the pharmaceutical sector, engineers must meet strict design requirements that help ensure product safety and integrity – similar to those required for cold storage pallet racking that serves the food industry.

Whether the pharmaceutical storage solution  involves large-scale pallet racking where material handling is done via a combination of automation and manual forklift movement of pallet loads, or via a per-piece picking process, the storage systems must be designed and maintained in a unique manner, notes Mac Aughey, National Account Manager for Steel King Industries.

“A lot of the regulation for the storage and handling of pharmaceuticals is related to temperature,” Aughey says. “But the need to provide antiseptic environments for production – or close to antiseptic – is also a factor in designing and operating the storage and distribution areas or facilities in the industry.”

As noted in a previous post, the evolving pharmaceutical industry is requiring expanded material handling facilities which are designed, built out and operated to meet stringent requirements to safeguard products and to ensure supply chain resilience.

6 Pharmaceutical Storage Requirements for Racking Systems

It starts with developing a facility unique to the materials being handled, then building storage structures such as pallet racking that stands up to cold temperatures and that maintains sanitary conditions, then operating the facility to ensure product security, safety, and traceability.

Aughey cites six areas that contribute to operational conditions which the pharma sector requires:

1. Solid Storage Capacity

Solid storage capacity with equipment designed to hold and move the intended products and to meet seismic codes and other building and equipment regulations. Because seismic zones are defined very specifically, engineers need to know a facility’s exact address to ensure code compliance.

2. Climate Conditions

Climate Conditions that call for racking and other equipment to maintain performance amid cold or freezing temperatures and specific humidity levels. Cold environments also call for storage systems that are dense but that also promote air circulation. Because of the cold environments, Automated Storage and Retrieval Systems (AS/RS) are often used to minimize employee exposure and to help maintain temperature consistency by reducing open/close door cycles.

3. Good Manufacturing Practices (GMP)

Good Manufacturing Practices (GMP) in the design and construction of storage systems such as racking, work platforms, and other storage and handling equipment. GMP guidelines could require non-porous surfaces, no unnecessary holes in racking crossbeams, welded cap holes, and paint coating that is durable so as to prevent rusting. Storage systems must be properly anchored to flooring, and sometimes with stainless steel hardware connections.

4. Inventory Management

Inventory Management that tracks lot numbers, serial numbers, expiration dates and other critical data. This would involve use of a Warehouse Management System that ensures product traceability. It also often calls for the use of pallet flow racking that allows First In, First Out product flow in light of batch expiration dates, and more commonly today – robotics and automation for tracking and product movement. Product that is damaged or expired needs to be moved to a separate, secure area, per FDA requirements.

5. Access Control and Monitoring

Access Control and Monitoring to protect high-value products through the use of security locked cages and gates, and video equipment.

6. Plastic Pallets and Totes

Plastic Pallets and Totes designed to support hygienic conditions, having non-porous surfaces that are easy to clean and sanitize.

Requirements Similar to Those for Cold Storage

Based on experience with food industry cold storage, Steel King has racking and work platform solutions that meet the needs of the pharmaceutical product material handling, including the new SK ADAVNTX Structural Bolted Racking. Components of the company’s racking and mezzanines are powder-paint coated to perform well in climate-controlled environments, and accessories are available to protect systems from impacts caused by forklifts and other vehicles. Different paint colors can be used in a facility to designate product types or handling processes. As an alternative, components can be galvanized.

While components for most storage systems commonly have openings such as bolt holes, beam or column ends, and with some companies’ open-back pieces, Aughey notes that Steel King designs systems that greatly minimize the chances of foreign objects or products getting stuck in a part. That is accomplished through its use of closed-tube components, welded cap holes, and by only drilling bolt holes where bolts will actually be used at crossbeams.

Working with experienced rack manufacturers and system designers ensures that the racking system is properly aligned with your facility’s operational needs. If you’re looking for a partner to tackle your warehouse rack design, request a quote from Steel King today.

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