The Blister Optimization Initiative launched in 2007 with the goal of reducing primary packaging material consumption. Through optimizing blister configurations and operations, the initiative achieved a 0.5 ton reduction in aluminum and 2.5 ton reduction in PVC and PVdC foils used annually, along with packaging weight reductions of up to 9%. This generated an estimated annual savings of $201,200 in costs and 1.0 ton reduction in CO2 emissions from transport.

1. Blister optimization initiative reduces materials and cost
Marcelo Costa, Process Engineering Coordinator
December 2012

2. Welcome to Cambé
Cambé (PR) – Såo Paulo (SP) 550km
Capital: Brasilia (DF) Local market
Area: 8.5 million m2 Regional packaging center
Population: 190 million (2010) Global plant for Hormones & other (eg. Diclofenac, Atenolol)
Population growth: 1.17% (2000 – 2010) Oral Solids capacity: 2.0 Bi SDU | 75 million packs
2 | 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

3. Basic principles of the project
Blister Optimization Initiative Before After
Launch: 2007
Goal: Reduce consumption of
primary packaging material
(blister)
10 3 15 2
tablets blisters tablets blisters
per blister per carton per blister per carton
Low volume occupancy per dose/tab
opportunity
Optimized operations
Higher output
Reduced cycle time
Results
Waste reduction 0.5 tons of aluminum | 2.5 tons of PVC foils
Trilax USD 17 300
12 Tab material savings
Packaging weight reduction 9% on product weight
3 | 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

4. Challenges
Packaging
• Develop a viable, sustainable Machine
Supplier
packaging design
• Ensure a collaborative dialogue
between product design, marketing,
operational teams and suppliers Benchmarking
New Marketing
Technologies
• Challenge existing packaging
machines
• Identify opportunities
• Test potential new ways to find the
best possible packaging solution
Operations Quality
Stakeholders
External Internal
4

5. Achievements
Summary of annual savings
Cost savings USD 201 200
The 27 SKUs blister improvement
initiatives completed to date 3.3 tons aluminum (lidding material)
Material reduction
7.7 tons PVC | 12.9 tons PVdC (forming material)
represent a significant
Packaging weight SKUs specific: -9% for Trilax c/12 (3.6 tons/year);
improvement in sustainable reduction -5% for Doxuran 30 FCT (1 ton/year)
packaging versus the packaging
GHG emissions
solutions that existed in 2007 from transport
1.0 ton CO2e (from natural material only)
Other savings Waste reduction, improved packaging leadtime
Energy savings* kWh GJ tCO2
Electricity Pack. Machine 110.309 397 8
* Yearly figures based on 2011 volumes
Chilled Water 96.521 347 7
Besides blister / carton optimization, other enhancements
contributed for speed increase (e.g. Line 3 new secondary Compressed Air 161.522 581 12
packaging machine, Line 4 primary packaging machine retrofit)
Total 368.352 1.326 27
5 | 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

6. Cambé's "environmental heros"!
2012
2011 TechOps Winner
Sustainable
Team Excellence
Packaging
Award
Energy Team
6 | 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

7. Back up

8. 2-day visit Photos
8 | 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

9. Ceremony Photos
9 | 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

10. Ceremony Photos
10 | 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

11. Ceremony Photos
11 | 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only

12. Ceremony Photos
12 | 2012 EEA | Sandoz Cambé, Brazil | Marcelo Costa | December 2012 | Business Use Only