In 2018, we renovated our chemical repackaging facilities, which allow us to take large containers of chemicals from manufacturers and repackage them in smaller containers for compounding pharmacies. We inspect every one of those large containers when we receive them, and we test the chemicals inside them to ensure they meet the high bar we set for the products we offer pharmacies. We even retest all active pharmaceutical ingredient chemical lots again after they are repackaged. It’s not enough to make sure that the chemical is of high quality when we receive it; we also need to confirm that it’s properly labeled and packaged in the appropriate container, as well as conduct secondary identification testing after we have repackaged it. These processes all go into The PCCA Standard™, our commitment to going above and beyond what is required to ensure that we provide the best products possible every single time. A big part of this is our Quality Control (QC) department, and at its heart is the QC lab, where all of that crucial testing takes place.

Since PCCA moved into our current location in 1996, we have had a QC lab that allowed us to consistently and accurately test the chemicals we receive from manufacturers, but as a company, we are always looking to progress. Two of our core values — Innovate Everywhere and Deliver Quality without Compromise — drive us to find ways to improve what we create, what we provide, what we do and where we do it. For these reasons, we renovated our QC lab in the summer of 2019.

The project planning began over two years ago, and by early 2019, we had completed the design for the new lab that took into account not just regulations and guidelines, but also optimized efficiency to ensure that our QC lab works for our employees and, ultimately, for compounding pharmacies’ needs. “The lab is designed in a way that provides everyone ample space to work and allows QC analysts and analytical chemists to carry out their work efficiently, helping to ensure the fulfillment of customer orders in an orderly and timely manner,” said Star Boxie, PCCA Director of QC/QA and Regulatory Affairs.

The whole renovation process included several PCCA departments from QC itself to Information Technology and Facilities as well as several outside vendors. Demolition and the subsequent build-out lasted from May to July 2019. In the end, we had expanded our QC lab by 280 ft² to accommodate new equipment, such as three powder containment hoods ranging from 4 ft to 6 ft, an 8 ft fume hood, an instrument for measuring water activity, pH meters, a Fourier transform infrared spectrometer, labware and personal protective equipment, and additional equipment for working with hazardous chemicals.

“With the additional space and new lab instruments, the QC lab is able to perform more tests to ensure the identification and quality of every product is verified,” said Brooke Lyons, PCCA QA/QC Manager. Blanca Stuhr, PCCA Quality Control Supervisor, added, “The redesign of work space and stations has had a positive impact on safety and productivity due to the improved workflow of the lab.” The new QC lab even takes advantage of the 5S workplace organization system, which helps to decrease the amount of waste while maintaining an efficient, safe and clean work environment.

The results speak for themselves. After more than a year and a half of planning, design and execution, our QC lab is an advanced testing facility that stands as an integral part of The PCCA Standard. This allows us to continue to meet the needs of compounding pharmacies into the foreseeable future.

A version of this article previously appeared in PCCA’s members-only magazine, the Apothagram.