A global manufacturer of drug delivery devices required the refurbishment and expansion of an existing 4,000m² GMP production facility to support new manufacturing requirements and increased processing capability.
The project needed to accommodate substantially heavier production equipment, improve operational efficiency and modernise building services, while maintaining ongoing operations within a live pharmaceutical environment.
Sustainability and carbon reduction were key objectives, requiring the team to maximise the value of the existing facility while reducing energy consumption and upgrading ageing infrastructure to meet future production demands.
The Solution
We delivered a carefully phased refurbishment and remodelling programme that allowed business-as-usual operations to continue throughout construction. Working within the constraints of the existing facility, we undertook structural modifications to accommodate new process equipment and reconfigured internal layouts to improve workflow and maximise available space.
The project included the introduction of a new mezzanine level and internal remodelling works, increasing the usable floor area by approximately 8%. Existing HVAC systems were assessed and reconfigured to improve performance and energy efficiency, incorporating measures such as waste heat recovery, air source heat pumps and dry cooling technologies. Thermal modelling was used to optimise plant sizing and identify opportunities to retain and reuse existing equipment where appropriate.
To support the upgraded manufacturing processes, new infrastructure was installed including chillers, vacuum systems, reverse osmosis water generation and building management systems. The result was a modernised GMP facility that increased operational capability, improved sustainability performance and provided the flexibility required for future production growth.
