We completed £ Multimillion D&B project to create a state-of-the art inhaler manufacturing cleanroom facility for Bespak, at their Holmes Chapel, UK, site.
Client Brief
Bespak required the expansion of its Holmes Chapel manufacturing facility to increase production capacity for next-generation low Global Warming Potential (GWP) pressurised Metered Dose Inhalers (pMDIs). With increasing global demand and growing pressure on the inhalation industry to reduce the carbon footprint of inhaler products, the project was a key part of supporting the transition towards lower-carbon respiratory therapies.
The project involved the design, refurbishment and expansion of an existing pharmaceutical manufacturing facility, including the construction of a new cGMP Grade D cleanroom. Delivered within a live operational environment, the facility needed to accommodate a high-speed aerosol mixing and filling line while maintaining uninterrupted production, achieving strict regulatory compliance and supporting ambitious sustainability targets.
The Solution
We delivered a fully integrated design and construction solution, acting as both Principal Designer and Principal Contractor throughout the project. Working within a live pharmaceutical manufacturing environment, we successfully expanded the facility and delivered a new cGMP Grade D cleanroom facility to support increased production of low-GWP pMDIs.
The cleanroom construction incorporated high-performance modular cleanroom systems and specialist architectural finishes designed to meet the stringent requirements of pharmaceutical manufacturing. Norwood's cleanroom solutions, including partitioning, glazing, walk-on ceilings and metal pan ceilings, were integrated throughout the facility to create compliant, adaptable and future-ready cleanroom environments. Additional features included breakout panels, window reveals and bespoke column encasements around existing structural steelwork.
Using Modern Methods of Construction, digital project delivery tools and low-waste building techniques, the project was completed three months ahead of programme and under budget while maintaining business-as-usual operations. The result is a state-of-the-art pharmaceutical cleanroom facility that increases manufacturing capacity, supports Bespak's sustainability objectives and strengthens the UK's position in the transition to lower-carbon inhalation therapies.
Key Products Used
- Norwood Mediline Cleanroom Partitions
- Norwood Cleanroom Glazing Systems
- Norwood Walk-On Ceilings
- Norwood Metal Pan Ceilings
- Breakout Panels
- Window Reveals
- Column Encasements
