The Background.

Our client, a UK-listed global specialty chemicals company, sought to double the production of their NiSAT product line at their Scotland facility.

NiSAT, a non-ionic synthetic associate thickener used in the paint industry as a thickening agent, required an expedited project execution due to market timing.Booth Welsh was engaged to provide a comprehensive solution to meet the client's requirements. An initial FEED study was carried out and this then evolved into a full EPCM solution, which was delivered successfully.

The Solution.

Booth Welsh undertook a fast-track design and build project, managing the entire project from the initial front-end engineering design (FEED) study through detailed design, construction, and final commissioning.Following successful completion of the FEED study, the project moved into a combined detailed engineering & construction phase. Driven by the market timing, a phased approach was taken to ensure construction could be commenced whilst detailed design was ongoing. This required design and construction to be aligned on a system-by-system basis.

This approach allowed for a streamlined and efficient execution, ensuring that the expanded facility could be commissioned in less than 12 months after the commencement of the initial FEED study.Booth Welsh assembled a multidisciplinary team to cover all major aspects of the project.The team's expertise included:

  • Project Management: Booth Welsh oversaw the entire project, ensuring effective coordination and timely execution of all project activities.
  • Process Engineering Design: Booth Welsh conducted detailed process engineering design, optimising the production process and improving efficiency.
  • Process Safety: The team performed a comprehensive Hazard and Operability Study (HAZOP), Layer of Protection Analysis (LOPA), and Safety Integrity Level (SIL) assessment to ensure the highest standards of process safety.
  • Mechanical Equipment Specification, Selection & Procurement: Booth Welsh handled the specification, selection, and procurement of various mechanical equipment, including pumps, vessels, agitators, and valves, ensuring optimal performance and reliability.
  • Instrument Engineering Design: The team designed the instrumentation systems, ensuring accurate measurement and control of critical process parameters.
  • Instrument Equipment Specification, Selection & Procurement: Booth Welsh sourced and procured process instrumentation and remote IO panels to support the expanded facility's operational requirements.
  • Control System Specification: The team developed a comprehensive control system specification, enabling efficient and effective control of the production process.
  • Electrical Engineering Design: Booth Welsh provided electrical engineering design services, including the specification, selection, and procurement of new Motor Control Centres (MCC), trace heating systems, and lighting.
  • Civil & Structural Design: The team designed a new mezzanine level and emergency escape staircase, optimizing the facility layout and ensuring compliance with safety regulations.
  • Construction Management: Booth Welsh managed the construction phase, establishing CDM site protocols, implementing a construction health and safety plan, conducting site inductions, and ensuring compliance with all necessary permits and regulations.

The Benefits.

New Production Capability: The establishment of the Concentrated Buffer and Flexible Manufacturing Facility provided the client with advanced production capabilities, enabling them to meet the growing demands of the biopharmaceutical industry. 

Increased Production Capacity: The upgraded facility significantly enhanced the client's production capacity, allowing for larger-scale operations and improved supply chain capabilities. 

Facility Designed for Future Expansion: Booth Welsh's solution was designed with future expansion in mind, providing the client with the flexibility to scale up their operations as needed, accommodating potential growth and market demands. 

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Improved Efficiency and Compliance: The new facility streamlined production processes, resulting in improved operational efficiency. Furthermore, adherence to industry standards and regulatory compliance was priority.