The Background.

The client selected Booth Welsh to support in enhancing the capabilities of their Liquid Media facility by installing a new Concentrated Buffer and Flexible Manufacturing Facility (FMF) to manufacture concentrated buffer solutions of varying compositions and carry out large volume acid / alkali titrations, within a Grade C clean room environment.

The project involved re-purposing the redundant plant room to establish a Grade C clean room facility, while also converting unused external space for acid/alkali storage.Booth Welsh was engaged after successfully conducting an initial concept study and were responsible for the detailed engineering and construction of the facility, as well as managing the site and subcontractors during the construction phase.

The Client

A market leader in manufacturing of liquid media, buffers and reagents used in the biopharmaceutical industry.

The Solution.

Booth Welsh implemented a comprehensive solution to meet the client's requirements and transform the Liquid Media facility into a cutting-edge Concentrated Buffer and Flexible Manufacturing Facility. The key components of the solution included:

Clean Room The existing redundant plant room was repurposed to create a Grade C clean room facility. New walls were installed to form three areas: a Grade C process area and two Grade D airlocks (MAL & PAL) for facility entry. Booth Welsh designed and installed clean room-compliant doors, ceilings, and flooring systems, ensuring adherence to industry standards. Additionally, a new air handling unit (AHU) was installed to provide sufficient air changes, maintain pressure cascades, and meet the Grade C requirements. Flexible Manufacturing Process To achieve the desired manufacturing capabilities, Booth Welsh designed and installed new process facilities. Two vessels were installed and equipped to hydrate large quantities of powder using water and various solutions for pH adjustment. Foundations and external containers were provided to house chemical intermediate bulk containers (IBCs). Pumps and piping were designed and installed to transfer the acid/alkali from the IBCs to the vessels. Moreover, pumps and weigh scale facilities were implemented for efficient transfer of the final product into smaller units for sale. A state-of-the-art dust extraction system was also installed to ensure a safe and controlled environment during processing. Electrical, Control, & Instrumentation Booth Welsh took charge of the complete design and installation of all electrical, control, and instrumentation aspects of the project. They provided a new process control system, human-machine interface (HMI), and control panel, all of which were designed, built, and tested at the Booth Welsh headquarters. Construction Management  Booth Welsh acted as the Principal Contractor, ensuring compliance with Construction (Design and Management) Regulations (CDM). They managed all aspects of the project on-site, including the permit-to-work system, which ensured controlled and safe execution of work.

The Benefits.

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.

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

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.