Session II: Inherently Safer Processes

Wednesday, June 6, 2012, 11:45am-1:15pm EDT

Session Chair

Kathy Kas, The Dow Chemical Co.


Presentation Speaker
Introduction to Inherently Safer Design Dennis Hendershot
The Design of Safe, Efficient and Green Processes for API’s Throughout Product Lifecycle John Dillon

Introduction to Inherently Safer Design

Dennis Hendershot, CCPS

Inherently Safer Design (ISD) is one approach to managing process hazards and risks. ISD focus on eliminating hazards where feasible, and minimizing hazards which cannot be eliminated. It applies throughout the process life cycle, from early research through development, manufacturing, and product use. This presentation will provide overview of ISD philosophy, its strategies of substitute, minimize, moderate, and simplify, and the role of ISD in process safety management.

The Design of Safe, Efficient and Green Processes for API’s Throughout Product Lifecycle

John Dillon, Pfizer

Manufacturing performance is a key component of Pfizer’s effort in producing a “green product.” The design of green processes for manufacturing Active Pharmaceutical Ingredients (API’s) offers the greatest opportunity maximizing efficiency and reducing waste. In recent years a number of process tools, equipment and technologies have proven to be essential in augmenting our effort toward developing efficient, safe and green processes.

Of particular importance at Pfizer is the use of Best Process Chemistry, BRITEST, Design of Experiments, High Throughput Reaction Screening, specialized facilities and the application of flow processes and bio-transformations, the latter of which are conducted in aqueous media. A case study demonstrating our approach to process design and optimization for maximizing API manufacturing performance throughout the lifecycle of a marketed product will be presented.


Dr. John Dillon

John is Vice President of API (Active Pharmaceutical Ingredients) Technology Operations, Pfizer Global Supply. He began his career at Bristol-Myers Squibb as a Research Scientist in 1983 and progressed through positions of increasing responsibility culminating in his appointment as Director of Chemical Development Labs.

He joined Honeywell in 2000 as Global Head of Technology for the Pharmaceutical Fine Chemical Business. In 2001 he joined Schering-Plough where he was responsible for Technology Transfer of API (Small-molecule and Biotech) from Research to Manufacturing as well as...Read more

Dennis C. Hendershot

Dennis C. Hendershot is a chemical engineer with 40 years of experience in process research and development, plant design and startup, and process safety. From 1970 until his retirement in 2005 as a Senior Technical Fellow, he worked at Rohm and Haas Company. He then joined Chilworth Technology Inc. as a Principal Process Safety Specialist (retiring again in 2009), and the Center for Chemical Process Safety (CCPS) of the American Institute of Chemical Engineers as a Staff Consultant. With CCPS, he has worked with the Inherently Safer Design Subcommittee, the Risk Tolerance Criteria...Read more