New purified water and water for injection system for Bayer

The Client


Auckland, New Zealand – Bayer Animal Health is one of the world’s leading producers and suppliers of animal health products.
In New Zealand, Bayer Animal Health supplies a wide range of products for both livestock animals and companion animals.

The Client's Needs

In the effort to continuously produce high-quality animal health medicines in New Zealand, Bayer commissioned a new water treatment plant at its Manukau production site., which was going through a series of upgrades.
 The plant was designed and constructed by AB Mandal Pty Ltd, Pharmaceutical process engineers. Veolia Water Technologies was contracted to provide the equipment to produce purified water (PW), water for injection (WFI), and pure steam for the use in the manufacture of veterinary drug products. It meets the demanding requirements of the European Pharmacopeia, produces water suitable for human therapies and is the most advanced facility of its kind in New Zealand.

Veolia's Solution

Purified water is produced by the Orion® 2000 system. The Orion® 2000 is a single skid mounted system, including softeners, 5 micron filter, multi purpose tank, single pass 

Reverse Osmosis , and Continuous Electro Deionisation (CEDI).The RO and CEDI are hot water sanitised..

The resulting treated water is further refined and distilled to create Water For Injection (WFI) by the POLARIS multiple effect still (MED)®. The Polaris MED® produces quantity and quality of WFI, according to EP and USP 36, using the latest GMP falling film technology, that reduces energy costs and start up times, ultimately giving the lowest cost per litre for WFI production. The POLARIS MED® also produces pyrogen free clean steam, with condensate compliant to EP and USP 36 and steam quality.
Veolia Water Technologies supplied a “Comby” unit, which can produce WFI and CS simultaneously.

Process Description

Purified water is produced continuously from municipal drinking water at 2 m³/h using pre-filtration. Pre-treatment for the Orion® 2000 consists of an activated carbon filter for removal of the high chlorine present in the Auckland mains water, 10 / 5 micron filter to protect the RO Membranes and CEDI producing the purified water. It is circulated through the liquids and paste and sterile manufacturing plants from a 5000L electropolished stainless steel storage tank.
 Purified Water is further refined and distilled to create Water For Injection (WFI) by three-stage distillation at 0.5 m³/h using purified water feed and circulated to the sterile manufacturing suites from a 4000L storage tank. The distillation unit also produces high purity pharmaceutical grade steam for process sterilisation.


Veolia’s overall solution approach provided a well-designed and robust water treatment system that will ensure the treated water specification is met at all times.

Bayer New Zealand managing director Derek Bartlett says the new water treatment plant is a major leap for the production site. “Previously it would take about six hours to produce 2000 litres of Water For Injection. Now we can produce 2000 litres in one hour. We can now get high quality water whenever we want without any restrictions, which will impact positively on our production times.”

The packaged plant will also allow Bayer to reduce capital and ongoing operational costs and eliminate interface risks for both the Purified Water Generation and WFI generation plants.