Fenoprofen Calcium Manufacturing Plant Project Report 2025: Cost Analysis & ROI

Fenoprofen Calcium Manufacturing Plant Project Report by Procurement Resource thoroughly focuses on every detail that encompasses the cost of manufacturing. Our extensive cost model meticulously covers breaking down Fenoprofen Calcium plant capital cost around raw materials, labour, technology, and manufacturing expenses. This enables precise cost structure optimization and helps in identifying effective strategies to reduce the overall Fenoprofen Calcium manufacturing plant cost and the cash cost of manufacturing.

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Fenoprofen is a non-steroidal anti-inflammator y drug (NSAID) belonging to the propionic acid derivative class, which also includes ibuprofen and naproxen. It works by inhibiting the cyclooxygenase (COX) enzymes, which are responsible for the synthesis of prostaglandins, the chemical messengers that cause pain, fever, and inflammation. Fenoprofen is manufactured as a racemic mixture, and its calcium salt is the form generally used to produce the final pharmaceutical dosage. It is an established active pharmaceutical ingredient (API) for the management of mild to moderate pain and chronic inflammatory conditions.
 

Applications of Fenoprofen Calcium

The industrial application of Fenoprofen Calcium is exclusively for the manufacturing of pharmaceutical dosage forms (tablets and capsules) used to treat inflammatory disorders.

• Rheumatoid Arthritis: Fenoprofen Calcium is widely used for the long-term management of the signs and symptoms of rheumatoid arthritis, helping to reduce joint pain, swelling, and stiffness.
• Osteoarthritis: It is also used for the relief of pain and inflammation associated with osteoarthritis, a common degenerative joint disease.
• Mild to Moderate Pain: It is often indicated for the relief of mild to moderate pain and for the treatment of acute painful flares in chronic joint diseases.
   

Top 7 Global Manufacturers of Fenoprofen Calcium

The global market for Fenoprofen Calcium is supplied by a number of generic pharmaceutical API manufacturers. The originator was Eli Lilly (brand name Nalfon®). Leading global manufacturers now include:

• Teva Pharmaceutical Industries Ltd.
• Viatris (Mylan)
• Sun Pharmaceutical Industries Ltd.
• Aurobindo Pharma
• Cipla Inc.
• Dr Reddy's Laboratories
• IOL Chemicals and Pharmaceuticals Ltd. (Indian Organic Chemicals and Pharmaceuticals Limited)
   

Feedstock and Raw Material Dynamics for Fenoprofen Calcium Manufacturing

The production cost analysis for fenoprofen calcium is based on a complex, multi-step chemical synthesis to build the core (m-phenoxyphenyl)propionic acid structure.

• Aromatic Precursors: The key starting materials are aromatic compounds, such as 1-(3-hydroxyphenyl)ethan-1-one (m-hydroxyacetophenone) and bromobenzene. These are used to construct the central diphenoxy ether linkage of the molecule.
• Reducing and Activating Agents: The synthesis requires a variety of industrial reagents, including:
  • Sodium Borohydride (NaBH4): A key reducing agent used to convert the ketone intermediate into an alcohol.
  • Thionyl Chloride (SOCl2): A common chlorinating agent used to convert the alcohol intermediate into a reactive chloride.
• Cyanide Source: Sodium Cyanide (NaCN) is a crucial and highly hazardous reagent used in a nucleophilic substitution reaction to give the nitrile, which is the precursor to the final carboxylic acid group.
• Bases and Solvents: The process uses various bases, such as potassium carbonate (K2CO3), for hydrolysis, as well as a range of solvents like EtOH (ethanol).
• Calcium Carbonate: This is the salt-forming reagent used in the final step to convert the free acid into the stable Fenoprofen Calcium salt.
   

Market Drivers for Fenoprofen Calcium

The market for fenoprofen is a mature, niche segment of the massive NSAID market. Its demand is driven by the high prevalence of arthritis and its low cost.

• High Prevalence of Arthritic Conditions: The fundamental driver of the Fenoprofen Calcium market is the large and growing global population suffering from chronic inflammatory conditions like osteoarthritis and rheumatoid arthritis. These conditions require long-term pain and inflammation management.
• Low-Cost Generic Option: As a long-established, off-patent drug, fenoprofen is a very low-cost NSAID. This makes it an accessible and affordable option, particularly in price-sensitive healthcare systems and for patients with limited insurance coverage.
• Intense Competition (Major Market Restraint): The single largest factor limiting the market is the overwhelming competition from a vast number of other NSAIDs. Drugs like ibuprofen and naproxen dominate the market due to their massive over-the-counter (OTC) availability and widespread brand recognition.
• Cardiovascular and GI Safety Warnings: Like all non-selective NSAIDs, fenoprofen carries "black box" warnings regarding the increased risk of serious cardiovascular events (like heart attack and stroke) and gastrointestinal events (like bleeding and ulceration). This class-wide risk profile limits its use, particularly in high-risk patients.
   

CAPEX and OPEX in Fenoprofen Calcium Manufacturing

The Fenoprofen Calcium manufacturing plant cost refers to the high investment required for a cGMP-compliant facility designed to handle a multi-step synthesis with highly hazardous reagents.
 

CAPEX (Capital Expenditure)

The initial investment cost for a fenoprofen API plant is significant. The Fenoprofen Calcium plant capital cost includes:

• Land and Site Preparation: A suitable industrial site zoned for cGMP pharmaceutical chemical production involving hazardous materials.
• Building and Infrastructure (cGMP Compliant): Validated production blocks with high-containment facilities and specialised safety infrastructure for the handling of highly toxic reagents like NaCN and corrosive thionyl chloride.
• Chemical Reactors: A series of versatile, jacketed, and agitated glass-lined or stainless-steel reactors to accommodate the numerous synthesis steps.
• Purification and Isolation Equipment: Industrial crystallisation vessels, centrifuges, and controlled-environment vacuum dryers. Large-scale chromatography systems may be required for high-purity grades, representing a major investment cost.
   

OPEX (Operating Expenses)

Manufacturing or operating expenses for Fenoprofen Calcium are driven by the cost of its advanced intermediates and the stringent safety protocols required.

• Raw Material Costs: The largest component of OPEX, comprised of the cumulative costs of the various starting materials and speciality reagents, including 1-(3-hydroxyphenyl)ethan-1-one, bromobenzene, and NaCN.
• Safety and Waste Treatment Costs: Extremely high recurring costs are associated with the specialised infrastructure and protocols required for safely handling and neutralising highly toxic cyanide-containing waste streams. This is a primary factor in the cash cost of production.
• Energy Costs: Standard energy consumption for heating, cooling, agitation, and purification processes.
• Labour Costs: A skilled workforce of organic chemists and chemical engineers with expertise in complex, multi-step cGMP API manufacturing and hazardous material handling.
• Fixed Costs: It includes the significant depreciation and amortisation of the chemical plant and equipment.
   

Manufacturing Process

This report comprises a thorough value chain evaluation for Fenoprofen Calcium manufacturing and consists of an in-depth production cost analysis revolving around the industrial manufacturing process.

• Production from 1-(3-hydroxyphenyl)ethan-1-one: The manufacturing process of Fenoprofen Calcium begins with reacting 1-(3-hydroxyphenyl)ethan-1-one with bromobenzene to form a ketone intermediate. Then, this intermediate is reduced using sodium borohydride (NaBH4), which turns it into an alcohol intermediate. The alcohol is next chlorinated with thionyl chloride to form another intermediate compound. Further, this intermediate undergoes a nucleophilic substitution reaction with sodium cyanide (NaCN) to create a nitrile. Then, the obtained nitrile is treated with potassium carbonate in the presence of ethanol (EtOH) to form a final intermediate. Finally, the obtained intermediate is reacted with calcium carbonate in water to produce Fenoprofen Calcium as the desired product.
   

Properties of Fenoprofen Calcium

Fenoprofen is a chiral compound, and its calcium salt form, used in pharmaceuticals, is Fenoprofen Calcium Dihydrate.
 

Physical Properties

• Appearance: A white to off-white, crystalline powder.
• Odour: Odourless.
• Molecular Formula: C30H26CaO6·2H2O
• Molar Mass: 558.6 g/mol
• Melting Point: It does not have a sharp melting point, as it sinters and decomposes at high temperatures (above 240 degree Celsius).
• Boiling Point: Not applicable, as it decomposes upon heating at extreme temperatures.
• Density: Its density is approximately 1.3 g/cm³
• Flash Point: Not applicable, as it is a non-flammable solid.
   

Chemical Properties

• Solubility: The calcium salt is slightly soluble in water and soluble in ethanol.
• Structure: It is the calcium salt of fenoprofen. Fenoprofen Calcium is a propionic acid derivative, and its structure features a m-phenoxyphenyl group attached to the alpha-carbon of the propionic acid.
• Chirality: Fenoprofen Calcium contains one chiral centre. The commercial drug product is a racemic mixture, which is a 50/50 blend of its (R)- and (S)-enantiomers. The (S)-enantiomer is the biologically active form.
• Stability: The crystalline salt is stable under normal ambient storage conditions.
• Mechanism of Action: As a non-steroidal anti-inflammatory drug (NSAID), the chemical structure of fenoprofen allows it to act as a non-selective inhibitor of the cyclooxygenase (COX) enzymes, COX-1 and COX-2. It prevents the conversion of arachidonic acid into prostaglandins by blocking the active site of these enzymes. The reduction in prostaglandin synthesis is the primary mechanism responsible for its anti-inflammatory, analgesic, and antipyretic effects.
   

Fenoprofen Calcium Manufacturing Plant Report provides you with a detailed assessment of capital investment costs (CAPEX) and operational expenses (OPEX), generally measured as cost per metric ton (USD/MT). This approach ensures that your investment decisions are aligned with the latest industry standards and economic feasibility metrics, enhancing your manufacturing efficiency and financial planning.

Apart from that, this Fenoprofen Calcium manufacturing plant report also covers the leading technology providers that help you plan a robust plan of action related to Fenoprofen Calcium manufacturing plant and its production process(es), and also by helping you with an in-depth supplier database. This report provides exclusive insights into the best manufacturing practices for Fenoprofen Calcium and technology implementation costs. This report also covers operational cash flow, fixed and variable costs, and detailed break-even point analysis, ensuring that your manufacturing process is not only efficient but also economically viable in the competitive market landscape.

In addition to operational insights, the Fenoprofen Calcium manufacturing plant report also comprehensively focuses on lifecycle cost analysis, maintenance costs, and energy consumption costs, which are critical for maintaining long-term sustainability and profitability. Our manufacturing cost analysis extends to include regulatory compliance costs, inventory holding costs, and logistics and distribution costs, providing a holistic view of the potential expenses and savings.

We at Procurement Resource ensure that this report is not only cost-efficient, environmentally sustainable, and aligned with the latest technological advancements but also that you are equipped with all necessary tools to optimize supply chain operations, manage risks effectively, and achieve superior market positioning for Fenoprofen Calcium. 
 

Key Insights and Report Highlights

Key Questions Covered in our Fenoprofen Calcium Manufacturing Plant Report

• How can the cost of producing Fenoprofen Calcium be minimized, cash costs reduced, and manufacturing expenses managed efficiently to maximize overall efficiency?
• What is the estimated Fenoprofen Calcium manufacturing plant cost?
• What are the initial investment and capital expenditure requirements for setting up a Fenoprofen Calcium manufacturing plant, and how do these investments affect economic feasibility and ROI?
• How do we select and integrate technology providers to optimize the production process of Fenoprofen Calcium, and what are the associated implementation costs?
• How can operational cash flow be managed, and what strategies are recommended to balance fixed and variable costs during the operational phase of Fenoprofen Calcium manufacturing?
• How do market price fluctuations impact the profitability and cost per metric ton (USD/MT) for Fenoprofen Calcium, and what pricing strategy adjustments are necessary?
• What are the lifecycle costs and break-even points for Fenoprofen Calcium manufacturing, and which production efficiency metrics are critical for success?
• What strategies are in place to optimize the supply chain and manage inventory, ensuring regulatory compliance and minimizing energy consumption costs?
• How can labor efficiency be optimized, and what measures are in place to enhance quality control and minimize material waste?
• What are the logistics and distribution costs, what financial and environmental risks are associated with entering new markets, and how can these be mitigated?
• What are the costs and benefits associated with technology upgrades, modernization, and protecting intellectual property in Fenoprofen Calcium manufacturing?
• What types of insurance are required, and what are the comprehensive risk mitigation costs for Fenoprofen Calcium manufacturing?