Nishihongo Plant
TOA Pharmaceuticals in the 21st century is based on the integration of cutting-edge technologies and facilities and has a state-of-the-art production plant that conforms to GMP standards.
Nishihongo Plant Pharmaceutical Buildings
First Pharmaceutical Building (DPI Formulation Building)
This is the first dedicated DPI* factory in Japan.
DPI formulations are manufactured using specific techniques and are micronized powdered pharmaceutical products inhaled through the lungs and nasal mucosa that facilitate the absorption of the product locally or into the body.
Currently, these products are mainly used for respiratory diseases. However, it is anticipated that the application will expand to products that are degraded in the stomach upon oral administration, products that are difficult to dissolve in water, and products that have a low absorption rate using conventional administration methods.
*DPI/Dry Powder Inhaler: abbreviation for powdered inhaled formulations
Compatible with steroid preparations
The manufacture of steroid and general preparations requires the air conditioning of manufacturing rooms to be independent and for air flow to be controlled to prevent cross-contamination.
In particular, steroids are weighed and mixed in a safety booth; the waste from the manufacturing room is collected using HEPA filters, and the waste water is collected in a dedicated ground tank to prevent contamination of the pharmaceutical products.
Second Pharmaceutical Building (Solid Formulation Building)
This plant for solid oral formulations (tablets, granules, and capsules) is the core of the next generation of manufacturing systems.
This plant is mainly involved with the mass production of prescription pharmaceutical products.
Pursuit of Reliability and Safety
- We strictly follow GMP procedures for all the hardware and software employed.
- To prevent contamination and cross-contamination, intermediate products are placed into the same sealed container and transferred to other places for the subsequent procedure, such as granulating, mixing, tableting, and coating. The container uses hoisting equipment and an automatic washer concomitantly to improve operational efficiency.
- Using the same pallets in the respective zones to completely divide each zone prevents contamination and provides insect control.
- MES (Manufacturing Execution System) and BCR (Barcode Reader) are adopted to prevent human errors.
- The temperature and humidity in the working chamber and the warehouse are strictly controlled.
Improved Functionality and Economy
- The layout of the plant enables our staff and materials to move smoothly through the processes of acceptance and storage of raw materials to final product manufacturing.
- This plant uses the most advanced pharmaceutical equipment, tablet inspection machine, tablet printer, and PTP filling and packaging line and is designed for 24-h continuous operation to manufacture high-quality products and improve efficiency.
- The packaging line uses the most advanced PTP packaging machines, with a maximum capability of 6,000 units/min.
- We respond to various demands such as 100% camera inspection before and after PTP filling, PTP sheet mark alignment and laser marking, supply of aluminum pillow desiccant, and GS1 fluctuation information marking on individual cases.
Future Extendibility
- Further expansion of this plant is possible. We have already procured adjoining land considering this possibility.
Introduction of Our Plant
Toyama Plant
The Toyama plant handles solid oral formulations (tablets, granules, and powders), oral solutions (syrups), topical solutions, salves, and other products. We produce a wide range of pharmaceutical products, including prescription drugs, OTC drugs, and household medications.
Nishihongo Plant
This is a state-of-the-art production plant with a DPI-specific plant and a state-of-the-art plant for solid dosage formulations.
We manage the mass production of prescription and OTC pharmaceutical products.