The company operates multiple manufacturing facilities equipped with industrial-scale refrigeration systems that maintain stringently controlled environments for both bulk drug substances and finished products. Their sophisticated cold chain infrastructure encompasses validated temperature-controlled warehouses, specialized shipping containers, and continuous monitoring systems. Given that a single batch of their biologic products can be valued at millions of dollars, any temperature deviation could result in catastrophic losses. To mitigate these risks, the company maintains comprehensive redundant cooling systems, backup power generation, and around-the-clock environmental monitoring.
Research conducted by third party, Zebrafi
Service and Support Excellence
Proactive Problem Resolution and Accountability
One of the most recognized strengths of Zero Zone is its exceptional service, quality, and support, embodied by professionals whose dedication has been repeatedly acknowledged.
“Their engineering people are fantastic. It doesn’t mean they don’t make mistakes. The difference is they own the issues, and they fix them. I honestly believe their people are why we went with another Zero Zone unit.”
This unwavering commitment ensures that technical issues are resolved promptly, minimizing operational disruptions. The Senior Principal Mechanical Engineer emphasized “We are early adopters and Zero Zone was one of the few willing to engage with us. What sustained the relationship through early R&D hiccups was their commitment to figuring it out and getting it right.”
Building Trust Through Client Education and Support
Despite initial challenges with a 300-ton unit, Zero Zone accountability stood out. “They were immediately upfront about any issues and provided schematics and circuit breaker updates,” the client noted. Those proactive measures buillt trust and strengthened the long-term partnership. “I’ve never encountered anyone saying Zero Zone is not picking up the phone.”
Zero Zone efforts to educate clients on troubleshooting fosters self-reliance while maintaining compliance and accessibility for complex issues. Zero Zone Field Service Techs’ ability to train and empower others ensures operational continuity, even if key personnel change roles.
Tailored Solutions for Pharma
Precision Engineering in Industrial Refrigeration Systems
Pharmaceutical companies scrutinize the engineering and technical capabilities of the refrigeration solutions because of their own capabilities and demands. “Zero Zone was able to present the technical details of transcritical operations with enthusiasm, in a way i was looking for, and could trust.” – Senior Principal Mechanical Engineer Pharmaceutical facilities demand precision and adherence to regulatory standards like GMP (Good Manufacturing Practice). Zero Zone bespoke solutions cater specifically to these needs. “We’re not a retail customer like these companies are typically used to. We must know why something went wrong. Zero Zone systems allow us to export inputs and outputs into our SCADA systems for analysis and compliance.”
“We’re not a retail customer like these companies are typically used to. We must know why something went wrong. Zero Zone systems allow us to export inputs and outputs into our SCADA systems for analysis
and compliance.”
Ensuring Compliance and Traceability
The Zero Zone team’s understanding of pharma’s unique needs extends to its use of Allen Bradley PLCs, which align seamlessly with this clients’ SCADA systems. (SCADA is the acronym for Supervisory Control and Data Acquisition – they are systems that monitor, automate, visualize and log data for real time corrective action.) This compatibility ensures traceability and supports audits by entities like the FDA. As the client emphasized,
“We can’t just have someone fix a problem, we as a pharma company have to know what caused a problem. The FDA demands that of us. That is why Zero Zone engineers and people are so special, they do that better than anyone.”
Moreover, Zero Zone flexibility in factory acceptance testing allows clients to ensure system readiness. For example, one facility visited the Zero Zone manufacturing site to verify the setup of a 400-ton chiller, ensuring it met their exact specifications before delivery.
Reliability and System Redundancy
Ensuring Uninterrupted Operations with Redundant Industrial Refrigeration Systems
In pharmaceutical operations, equipment reliability is non-negotiable. Zero Zone chillers play a critical role in maintaining systems that are described as the “lifeblood” of the facility. “If we lose refrigerated water, we lose our cold rooms with hundreds of thousands of product in it,” highlighting the catastrophic consequences of failure. According to the Senior Principal Mechanical Engineer,
“Uptime is 100%, stuff can’t go down. It can [cost] into the hundreds of millions of dollars, depending on the scenario, never less than six figures.”
Zero Zone focus on redundancy ensures uninterrupted operations. For pharma, “the value of our research work far outweighs the cost of a redundant system.” With multiple chillers in place, facilities can seamlessly switch between units during maintenance or unexpected failures. Clients report significant uptime improvements with Zero Zone compared to competitors. “That’s why we bought [so many Zero Zone] systems,” pointing to the superior support and reliability they experienced.
Custom Engineering for Enhanced Reliability
“Working with cutting-edge technology for ten years I’ve learned that every installation has challenges, With Zero Zone they get worked out, and then I don’t hear anything from our operations staff after that.”
There has been a focus on improving reliability based on an improved understanding of the technical requirements and custom engineering. “They’ve done several modular approaches for us that have worked well, and those tend to work better since they are so discreet and less complex.”
“The first cost differential isn’t enough compared to the relationship”
Aligning with Pharmaceutical Partners’ Sustainability Goals
The Zero Zone commitment to sustainability aligns closely with the priorities of its pharmaceutical partners, many of whom aim to achieve net-zero carbon goals by 2030.
“We use all clean electricity, and we’re actively reducing our natural gas and water consumption.”
By addressing these challenges, Zero Zone demonstrates its willingness to innovate in response to environmental concerns.
“We use millions of gallons of water in the summer. Finding another solution could significantly reduce consumption.”
Furthermore, Zero Zone use of CO2 as a refrigerant supports broader sustainability goals, as it offers an environmentally friendly alternative to traditional refrigerants. This positions Zero Zone as a forward-thinking partner committed to helping clients meet both operational and environmental objectives.
Holistic Results and Outlook
Zero Zone partnership with its pharmaceutical clients exemplifies excellence in service, customization, reliability, and sustainability. By addressing specific industry challenges and delivering measurable outcomes, Zero Zone solidifies its role as a trusted partner in the pharmaceutical sector. As one client aptly summarized, “We spent a lot of time vetting chiller options, and I wouldn’t hesitate to get another Zero Zone.”
- Total Cost of Ownership: Customer initially spent $200k more on Zero Zone systems
suggesting at least an 11.1% lower total cost of ownership through reliability and reduced downtime. - Uptime: Customer reported significant reductions in downtime compared to competing systems, achieving near 100% operational availability.
- Service Response Time: Immediate support ensures issues are resolved swiftly, minimizing impact.
- Sustainability Goals: Customer noted Zero Zone contribution to achieving clean energy targets and reducing resource consumption.
Learn More About Zero Zone Industrial Refrigeration Systems
For more information on the solutions we offer, visit our products page. For more information on how Zero Zone can help you maximize the efficiency of your store, fill out a form on our contact us page.