Snapshot

• Injectables Formulation Facility – Vials and Ampoules
• Built up Area = 7,537 sq.m

Project Brief

• Facility for Gonadotropins including Protein purification.
• Produces both Liquid and Lyophilized Injectables in Vials and Ampoules.
• Entire development comprises of Production block, Bio Lab (Animal House), Protein Purification section and ancillary areas like utility block, ETP area, Security cabin, fuel yard and Pump house.
• The project is approved by UK MHRA & ANVISA.

Snapshot

• Oral Solids & Liquids Dosage Formulation Facility
• Built up Area = 16,728 sq.m

Project Brief

• Greenfield project built on a 5-acre plot for Tablets, Capsules, Liquids (Multi-level manufacturing)
• Annual production capacity of 5 billion tablets and 10 million bottles.
• The plant is designed for minimum human intervention to prevent human error and includes cutting edge equipment such as the fully automated liquid manufacturing and packing lines, fully-fledged chemical and microbiology labs, separate air handling units to control environment conditions.
• Targeted approvals include WHO & EU GMP, PIC/s.

Snapshot

• IP Vaccine Facility at Hyderabad, India
• Built up Area – 3,700 Sq.m

Project Brief

• The facility is being planned for Inactivated Polio Vaccines
• Production Capacity shall be 20 Million dosages per annum.
• Fermentation Capacity: 2.0KL
• Controlled and restricted authorized access to the facility and storage areas
• Designed as per BSL-3 and GAP III requirement.
• Live areas room pressures are negative with respect to atmosphere.
• Dedicated Air Handling Units for Live and Non-Live areas with heaters in Exhaust and HEPA filters in return air.
• Decontamination procedures for the material and containers used in live manufacturing areas.
• Purified water and WFI pressurized circulation systems.
• Liquid waste from live areas will be directed to kill tank for further treatment

Snapshot

• Herbal Cosmetics Formulation Facility
• Built up Area = 4,646 sq.m

Project Brief

• Set up Plant for Herbal Product Range
• Cosmetic - Skin care and Hair care
• Phase wise project comprising total of 20 acres land.
• Standards need to maintained are GMP, FSSAI, FDA, HACCP.
• This was a unique project executed by Spectrum, as there were specific EHS & QUALITY issues to be followed right from the design stage. State of art facility for OSD formulation tablets/capsules, Liquid Syrup manufacturing.

Snapshot

• Ophthalmic & Liquid Injectable Formulation Facility
• Built up Area = 4,500 Sq.m

Project Brief

• Sterile Injectables (Ampoules, Vials & Pre-filled syringe) 
• Ophthalmic Formulation (Eye Drop)
• Warehouse for Storage of Raw material, packing material & finished goods.
•  First floor (New mezzanine floor created)
  •  Admin Office & technical area.
•  Second floor (New PEB structure created)
  • QC section
•  Third Floor (New PEB structure created)
  • QA & technical area.
     

Snapshot

• Oral Solid Dosage Formulation Facility
• Built up Area = 13,682 Sq.m

Project Brief

• The facilities is to be designed and engineered as per WHO, PIC/s, EU and US FDA.
• The manufacturing set up is on greenfield site to produce Tablets and Capsules.
• Annual Production Capacity – Tablet 2.3 Billion and Capsules 732 Million
• The Facility has below sections –
  • OSD Block
  • Utility Block
  • Electrical Panel Room
  • Boiler House
  • ETP
  • Pump House
  • Canteen

Snapshot

• Oncology Oral Solid Dosage and Liquid Injectable Formulation Facility
• Built up Area = 9,293 Sq.m

Project Brief

• The greenfield facility is planned for Oncology Finished Dosage Formulations in the form of Tablets, Capsules and Injectable.
• The facility is planned for following production capacities:
  •  Injectables (Liquids/Lyophilized): 3 Million vials per annum
  • Tablet: 36 Million per annum.
  • Capsules: 14 Million Capsules per annum.
• Ground Floor
  • Pilot plan for Tablet & Capsule  
  • Warehouse for Storage of Raw material, packing material & finished goods.
  •  Admin & Canteen area.
• Ground Mezzanine floor 
  • Technical area.
• First floor
  • Commercial production line for OSD & Lyophilized Injection section.
  • QC & QA Section
• Second floor
  • Admin & Technical area.

Snapshot

• Oncology Oral Solid Dosage and Liquid Injectable Formulation Facility
• Built up Area = 13,504 Sq.m

Project Brief

• The Facility is US FDA Approved
• The structures planned include Oral Solids Block, Injectable Block, R & D Block, Quality Control & Quality Assurance Block, Administration Block, Canteen, Utility Block, and other ancillaries like Security cabin, Pump rooms, ETP, etc.
• Pre-Engineered Metal Building construction for the Production Blocks viz. Oral Solids Block and Injectable Block for faster construction.
• Integrated granulation line from GEA.
• In the Injectable section, isolators for Solution Compounding, Sterile Filtrate Collection, Filling Line, Freeze Driers.
• Bag-in Bag-out filters for AHUs.
• Effluent deactivation system prior to discharge to the main ETP.

Snapshot

• Antigen (COVID) Vaccine Facility
• Built up Area = 3,736 Sq.m

Project Brief

• The facility is being planned for Covid-19 Antigen Vaccine
• Production Capacity shall be 50 Million dosages per annum
• Fermentation Capacity: 3.5KL
• Controlled and restricted authorized access to the facility and storage areas.
• Laminar Air Flow Units for Product Protection.
• Negative Pressure (Sink) for live areas intended for viral activities.
• Dedicated Air Handling Units for Live and Non-Live areas.
• Decontamination procedures (Steam sterilization) for the material and containers used in live manufacturing areas.
• Purified water and WFI pressurized circulation systems.
• Liquid waste from live areas will be directed to kill tank for further treatment.

Snapshot

• Injectable Formulation Facility
• Built up Area = 2,635 Sq.m

Project Brief

• Expansion of Microsphere injectable facility including Vial and Dual chamber line.
• Production facility for Injectable production facility with homogenization along with filling in vials and lyophilization, for Amphotericin products.
• The facility designed to comply with cGMP manufacturing standards of international regulatory bodies like WHO, EU FDA, Brazil ANVISA and US FDA and shall also conform to local statutory norms prevailing in India.

Snapshot

• Oral Solid Dosage Formulation Facility
• Built up Area = 14,870 Sq.m

Project Brief

• Tablet & Capsule facility expanded in 7 Phases.
• 8 Tablet lines, 1 Capsule line
• RH levels lesser than 30%.
• 1 line - Light Sensitive Products.
• Coating areas - Flameproof Construction.
• Facility is approved by US FDA.

Snapshot

• Oral Solid Dosage Formulation Facility
• Built up Area = 23,470 Sq.m

Project Brief

• Greenfield General OSD formulation facility.
• Production Capacity of 600 mil Tabs/annum & 180 Mil Capsules/annum.
• 2-storey Facility with Production & Warehouses planned at Level-1 and QC Lab, R&D Lab & Offices planned at Level-2.
• Vibrant Plot design with efficient space planning for Utility & Ancillary Blocks, Kitchen & Dining area, Waste Management Systems, Security & Parking lot.
• Facility design as per WHO, EU GMP, UK MHRA & PIC’s standards and guidelines.
• Adherence to current Good Manufacturing and Laboratory Practices.

Snapshot

• General Formulation Facility
• Built up Area = 63,197 Sq.m

Project Brief

• The facility is designed for Oral Liquid block (Ground +2); Oral Solid dosage block (Ground +3); Ointment Creams and Lotion block (Ground + 3); Central Warehouse with ASRS (Ground + 1 Floor) Utilities; Engineering office (Ground + 1).
• The plant manufactures various dosage forms like - 
  • Oral Solid Dosage
  • Injectables (Vials and Ampoules)
  • Creams: Tubes and Jars
  • Ointments
  • Lotions
  • Nasal Spray in Future
  • Separate manufacturing for Intermediates like Sugar Syrup, Opium Tincture, Camphorated Opium Tincture, Liquor ice Liqueur
• The Plant is design as per latest GMP norms and Thai FDA.

Snapshot

• Oncology : Oral Solid Dosage & Injectables Formulation Facility
• Built up Area = 32,000 Sq.m

Project Brief

• Greenfield facility planned to have dedicated blocks for Oncology Formulation.
• Formulation Block is planned for Oral Solid Section (OSD) & Future Provisions for Injectables
• The annual capacity of the OSD section is to produce 30 million Tablets and 14 million Capsule with expansion provision to triple the capacity.
• Injectable section for future provision for Installation of one fully automated Pre-filled Filled Syringe (PFS) line and one more vial line with Lyophilizer.
• Specific requirement for Hi-Potent facility like liquid decontamination system, Exhaust system for AHU’s, change procedure are considered in the facility design. Spectrum deputed its team for development of validation documentation and oversee the validation effort.
• “Contained at source” philosophy adopted for design of plant & selection of Equipment.
• Targeted regulatory compliance: US FDA Schedule M, EU-GMP, UK MHRA WHO

Snapshot

• Oncology API Manufacturing Facility
• Built up Area = 6,502 sq.m

Project Brief

• Oncology API facility OEL Band-5 (Potency between 0.1 to 1.0 micro-gm/m3/ 8 hrs. TWA)
• The facility includes following processing area.
• Cytotoxic intermediate processing, Hydrogenation Reaction section.
• Two clean room crystallization and powder processing zones.
• Required utilities, Q.C. and warehouse as part of production block.
• The facility has high pressure hydrogenation area within the plant, segregated from other areas with RCC walls & airlock.

Snapshot

• Oral Solids Dosage Formulation Facility
• Built up Area = 19,000 sq.m

Project Brief

• The entire development comprises of 33 Arcs of land with total built up area of 19,000 Sq.m
• The Facility set up for Tablets & Capsules.
•  Annual Production Capacity
  •  2.5 Billion Tablets output/annum.
  • 2 Vial Lines with 200 vials per min and 1 PFS line.
     
• RCC Structure Building construction for the buildings of Formulation Facility, Utility & PCC.
• Warehouse is planned for storage of 2,000 pallets.
• Spectrum was involved in developing User Requirement Specification and Procurement of all Production equipment and systems. Production equipment, Clean room panels, HVAC items, Electrical, Process water distribution systems.
• Plot plan developed for Future expansion purpose.
• US FDA approved.

Snapshot

• Oncology & General Oral Solid Dosage Formulation Facility
• Built up Area = 20,312 Sq.m

Project Brief

• The project comprises of two separate blocks for producing Oral Solid Dosage formulations for General and Oncology category of products.
• The planned annual capacity of the General products facility is about 2 billion units and that of Oncology products facility is about 70 million units.
• The facility has been set up in accordance with regulatory guidelines of US FDA and other local statutory norms for safety and building construction regulation.
• The Oncology facility have its dedicated Stores and Quality Control departments whereas the General products facility share these services with the other existing blocks.
• Spectrum on this project worked on design, engineering & co-ordination with a local design firm was responsible for Structural and Fire Safety designs for the buildings and support Novast in applying and getting required statutory approvals. 

Snapshot

• Vaccine Fill Finish Manufacturing Facility
• Built up Area = 12,800 sq.m

Project Brief

•  The Design & Engineering is done for the Vaccine production facility in Malaysia.
• Annual Production Capacity:
  •  Liquid Injection: 12.5 million vials per annum
  •  Lyophilized injections: 10 million vials per annum
  • Pre-filled syringes: 10 million syringes per annum  
• The proposed facility was planned, designed and engineered as per current cGMP standards of international regulatory authorities of EMEA, PICS as well as conform to all local regulatory requirements.

Snapshot

• Traditional and Allopathic Oral Liquid Dosage Formulation Facility
• Built up Area = 15,800 sq.m

Project Brief

• The facility is designed to setup Bottle, Sachet and Soft gel line.
• Also, Expansion of Oral Solid dosage Block was designed.
• The facility has Central Warehouse, Administration, QC and R&D Building.

Snapshot

• Nutraceutical Product Testing & R&D Lab
• Built up Area = 511 sq.m

Project Brief

• Spectrum has designed and engineered analytical laboratory with facility for microbial testing in China. This laboratory was designed to serve the nutritional industry. The main sections built in the center were.
  • Analytical Laboratory
  • Wet Chemistry Lab
  • Microbiology Lab
  • Stability Chambers' section
  • Offices for Chemists
  • Spectrum engineers were stationed at site for hooking up critical equipment such as autoclave, purified water systems, dishwasher dryers & stability chambers and completed the project in short span of six months.

Snapshot

• Large Volume Parentals (IV Solution) Formulation Facility
• Built up Area = 26,000 sq.m

Project Brief

The facility was set up to produce Polygelene in the form of Intravenous injection. Polygelene is used as Plasma substitute.

The installed capacity is 2.8 million bottles per annum. The facility was set up in accordance to Chinese regulatory standards.

The production area is about 1400 Sq.M and has separate zones for Manufacturing, Quality Control, Quality Assurance, Warehouse, Animal House, Utility, Service Area and Administration. The sterile areas and the other classified areas are constructed out of metal clean room panels. The solution preparation rooms were designed to handle solvents.

The key equipment installed include Solution Preparation vessels, Filtration units, Filtrate Collection vessels, Pre-Forming machines, Blow Molding machines, Wash-Fill-Seal machines, Super-heated Water Spray Sterilizers, Autoclaves, Purified Water Generation plant and Multi Column Distillation Units for generation of Water for Injection.

Snapshot

• Oral Solid & Liquid Dosage Formulation Facility
• Built up Area = 4,182 Sq.m

Project Brief

• The project is Design Engineered for manufacturing of following dosage forms -
  • Tablets: 219 Million per annum
  • Capsules: 36 Million per annum
  • Liquid Syrup: 4.8 Million per annum
• 2 Tablet lines, 1 Capsule line, 1 Liquid syrup .
• Facility is approved by GMP EU PIC/S & GDP.
• Facility is 3rd in Ukraine to receive GDP certification.

Snapshot

• Biosimilar mAb’s & GCSF Manufacturing and Fill Finish Facility
• Built up Area = 5,800 sq.m

Project Brief

• Microbial fermentation suit with 200 Litres Bioreactor.
• Mammalian cell culture fermentation with 1000 Litres Bioreactor.
• Fill Finish facility with Vial / PFS combo machine and Lyophilizer.
• Facility Designed as per BSL 1, suitable for Biosimilar mAbs Productions and GCSF .
• Utilities were designed for temperatures up to -12 Degree Celsius .
• The facility is designed and engineered as per  Russian FDA .

Snapshot

• Inhaler & Injectable Formulation Facility
• Built up Area = 5,684 sq.m

Project Brief

• The facility was set up for manufacturing of MDI & DPI
• The facility also comprises of Injectable & Oral Solid Dosage block.
• Dry type Chiller technology was used due to cold climatic conditions.
• Dual circuit External Brine and Internal Chilled water was installed to optimize CAPEX and OPEX.

Snapshot

• Oral Solid Dosage and Injectable Formulation Facility
• Built up Area = 14,400 sq.m

Project Brief

• The project is Design Engineered for manufacturing of products  like Antitubercular, antiviral, antineoplastic, antifungal medicines, sterile dosage forms, antibiotics.
• Annual Production Capacity -
  • Tablets: 72 Million per annum
  • Capsules: 396 Million per annum
  • Injectable: 40 Million per annum
  • DPI : 50 Million per annum
• Targeted approvals include WHO cGMP.

Snapshot

• Large Volume Parental Formulation Facility
• Built up Area = 3,100 sq.m

Project Brief

• Phase-I Built in a time span of 22 months.
• Phase-II Built in a time span of 14 months.
• Blood-substituting, antibacterial, antimycotic, haemostatic drugs and low-volume infusion therapy drugs.
• Polyethylene bottles from 50 to 500 ml – 20 Million/annum
• The facility was planned in accordance with cGMP requirements of WHO.
• Engineering was design of HVAC systems for sub-zero temperatures of up to (- 32 Degrees)

Snapshot

• Pharma Cluster Development
• Built up Area = 29,000 sq.m

Project Brief

• Facilities includes -
  • Repackaging for Oncology and Hormone products
  • Repackaging of Cephalosporin products
  • Manufacturing for General Oral solid dosage form
  • Central warehouse
  • Central Quality control laboratory
  • Administration & QA, Utility and HT yard
• Central warehouse is planned for storage of 10,000 pallets with self-supported ASRS .
• Pre-Engineered Metal Building construction for Oral solid dosage line  for faster construction.

Snapshot

• Oral Solids, Liquids, Creams & Ointments Formulation Facility
• Built up Area = 10,000 sq.m

Project Brief

• The plant is being set up in a plot of about 36,000 Sq.m with an overall built-up area of proposed facility of about 10,000 Sq.m. The facility will produce Pharmaceutical products under general category. The dosage forms and their annual production volumes include Tablets (180 Million), Capsules (45 Million), Liquid Syrups (6 Million) and Ointments/ Creams (3 Million) .
• Main block will house of Change Rooms, Production Area, Warehouse, Formulation Development Section, Quality Assurance, Quality Control, Administration Departments, Laundry and Technical area.

Snapshot

• Oral Liquid Formulation Facility
• Built up Area = 55,000 sq.m

Project Brief

• The facility has designed to comply with cGMP manufacturing standards of international regulatory bodies like WHO.
• Capacity Planning for all dosage forms based on Market Study reports and Category of Products proposed.
• Sizing of Production batches, recommending equipment capacities.
• Capacities and facility sizes were again reviewed based on the feasibility of accommodating these blocks in the land already available with Epharm.

Snapshot

• Multi-Specialty Hospital
• Built up Area = 13,476 sq.m
• No of Beds – 138 nos.

Project Brief

• Following main sections are planned for the facility.
  • Emergency care services
  • Ambulatory care services
  • Diagnostic and Therapeutic Services
  • In Patient Services
  • Clinical Support Services

Snapshot

• Oral Solids Dosage Formulation Facility
• Built up Area = 8,828 Sq.m

Project Brief

• The Facility is designed for manufacturing Oral Solid Dosage formulations under General category with plans to expand and set up facilities for the other pharmaceutical dosages in near future, in the industrial area at Dubai Science Park, Dubai
• The facility produces 195 million tablets per year & 10 million Capsules (Hard Gelatin) per year.
• The core areas are planned in Modular Panels. The Cooling system is designed considering the Distinct Cooling system.
• The facility is designed in compliance with requirements of the various local authorities like DEWA, DM, and DCDA, etc. and designed to meet cGMP requirements of regulatory bodies like US FDA, EU and GCC.

Snapshot

• Oncology : OSD & Injectables Formulation Facility (Design & Build)
• Built up Area = 6,802 sq.m

Project Brief

• The Greenfield oncology facility is designed to produce Tablets, Capsules, Freeze Dried and Liquid Injectable in Vials form.
• The Facility comprises of following:
  • Production Block
  • Admin Area & Canteen
  • Security Cabin
  • Electrical Substation / Gas Station
  • Energy Block & Water Storage tank
  • Scrap Yard
  • Roads & Parking Lots
  • Drainage system

Snapshot

• Oncology : Oral Solid & Injectable Formulation Facility
• Built up Area = 3,750 Sq.m

Project Brief

• The facility is designed to produce Oral Solids and Liquids and Freeze Dried Injectables.
• Injectables – 60 Vials/min line.
• Oral Solids – 30 kg/batch.
• Single pot processor technology is used for Granulation and Drying.
• Containment technology includes.
  • cRABS for Vial filling line & for Lyophilizer.
  • Isolators for Compounding and Dispensing.
• The facility is EU GMP approved.

Snapshot

• Oral Solid & Injectable Formulation Facility
• Built up Area = 10,687 sq.m

Project Brief

• The project is Design Engineered for manufacturing of  Tablets, Capsules, Sachets & Small Volume Parenteral.
• One Combi line for Vials and Ampoules.
• In-house Pilot Plant, QC & QA , R&D facilities
• Targeted approvals include WHO & GCC approvals.

Snapshot

• Oncology : Injectables Formulation Facility
• Built up Area = 10,000 sq.m

Project Brief

• The facility situated on a plot of approx. 10,000 sq m. can produce 1 million units of liquids and around 1.3 million units of lyophilized concentrates.
• Produces both Liquid & Lyophilized Injectables.
• AHUs with Bag-In Bag-Out type filter arrangement.
• Deactivation of potent liquid waste prior to discharge into the main ETP and filtering of exhaust air thru ULPA filters.
• Isolators - Dispensing of Actives and Solution Compounding for Injectables. Protective suites for Personnel Protection.
• The facility is approved by US FDA & Brazilian ANVISA

Snapshot

• General  &  Oncology : Oral Solids Dosage & Injectables Formulation Facility
• Built up Area 3,200 Sq. m.

Project Brief

• Green field 16acre plot
• R & D- G + 3 building with 0-10Kg batch size, Vial and Ampoule filling with Lyophilizer. Oncology OSD up to 5 Kg batch size.
• General block G +3, Vial, Ampoule and DPI injectable line. OSD with 60kg and 300 Kg granulation suit. Common QA + QC + Micro laboratory.
• Oncology Injectable block G + 3 building with Vial+ Lyophilizer, Combi PFS and Cartridge and DPI line.

Snapshot

• Injectables Formulation Facility
• Built up Area = 5,900 sq.m.

Project Brief

• Fill and Finish Plant to manufacture products of following dosage forms.
• Lyophilized (Freeze Dried) Injectable in Vials.
• Liquid Injectable in Vials.
• Liquid Injectable in Pre-Filled Syringes.
• Filling Line with 300 Vials/min.
• Facility  design comply to USFDA and EU requirements.

Snapshot

• Oral Solids, Liquids, Creams & Ointments Formulation Facility
• Built up Area = 26,022 sq.m.

Project Brief

• Built in a time span of 18 months produces Oral Solids, Liquids & Dry Powders.
• Multi-level manufacturing.
• 7 Tablet lines, 1 Line for Dry Powder filling and 1 Line for Liquid filling.
• Sugar transfer to 16 m level.
• Facility is approved by US FDA, UK MHRA, ANVISA, Health CANADA.

Snapshot

• Multiproduct API Manufacturing Facility
• Built up Area = 15,800 sq.m.

Project Brief

• Bar Coded Bin transfer system from warehouse to plant PTS with load cell for weighing.
• Dry material form ANFD is discharged in bin and then transferred to the required location.
• Vertical gravity flow to ensure material transfer from the centrifuge to dryer to milling and sieving followed by blending.
• Blended material is transferred through metal detector to packing line to fill the material in 25 Kg Bags.
• The PLC system was configured to carry out recipe management and material traceability through bar coding.

Snapshot

• Oncology API Manufacturing Facility
• Built up Area = 6,502 sq.m.

Project Brief

• Oncology API facility OEL Band-5 (Potency between 0.1 to 1.0 micro-gm/m3/ 8 hrs. TWA).
• The facility includes following processing area.
• Cytotoxic intermediate processing, Hydrogenation Reaction section.
• Two clean room crystallization and powder processing zones.
• Utilities, QC and warehouse as part of production block.
• The facility has high pressure hydrogenation area within the plant, segregated from other areas with RCC walls & airlock.

Snapshot

• Hi-Potent API Manufacturing Facility
• Built up Area = 2,000 sq.m.

Project Brief

• Capacity 10 to 25 kg per batch.
• Total number of rectors - 6 No's.
• NFD Isolators - 3 No's with 75 litres.
• Isolation for Product process and Micronization.
• Deactivation room provided.
• Utilities, QC and warehouse as part of production block.

Snapshot

• Multiproduct API Manufacturing Facility
• Built up Area = 6,040 sq.m.

Project Brief

• This was a Brownfield project comprising of API Intermediate suit, Intermediate Drying Area having two granulation suits and 5 powder processing units.
• Tank farm Area was design to handle critical storages.
• Plant Capacity: 98 KL
• Equipment: Reactors, ANFD, RVPD, BDCF, FBD

Snapshot

• Multiproduct API Manufacturing Facility
• Built up Area = 6,691 sq.m.

Project Brief

• This was a Greenfield project having plant reactor capacity of (30 KL, 2 reactors) and (10 KL, 2 reactors).
• The Phase 1 manufacturing output is (500 tons/annum), and Phase 2 manufacturing output is (1500 tons/annum).
• Below were some of the few process equipment 
  • ANFD – 7.5 Kl.
  • Spin Flash Drier – 200kg/hr.
  • Nauta Blender

Snapshot

• API Intermediate Manufacturing Facility
• Built up Area = 3,546 sq.m.

Project Brief

• This was a Greenfield project consisting of four sections.
• The facility was built to manufacture API Intermediate.
• The facility had typical process conditions like High pressure area & Distillation section.
• The facility also had Powder processing section (5-micron section).

Snapshot

• Oncology API Manufacturing Facility
• Built up Area = 2,100 sq.m.

Project Brief

• The facility comprises of three dedicated Modules.
• The facility comprises of special containment zone of PBOEL of 500 ng/cu. category.
• Isolators were used for charging and powder processing area.
• The facility is approved by US FDA
• Automation in process utility.
• Special arrangement of Kill tank for deactivation of toxic waste.

Snapshot

• API Intermediate Manufacturing Facility
• Built up Area = 4,182 sq.m.

Project Brief

• The facility was built up to produce 11 Products mapped on campaign basis.
• The facility comprises of following process reactions like Halogenations, Hydrolysis, Diazotisation and Hydrogenation reaction.
• Liquid product is separated by distillation unit operation.
• The entire facility is DCS controlled.
• We were also involved in HAZOP and Prestart up safety review.

Snapshot

• API Intermediate Manufacturing Facility
• Built up Area = 2,230 sq.m

Project Brief

• This facility is designed for producing Oncology APIs.
• The facility comprises of Cytotoxic & Non- Cytotoxic intermediate processing areas manufacturing Kilo Lab volume.
• Critical reactions like Hydrogenation reactions area were designed.
• Two clean room crystallization and powder processing zones for Cytotoxic.
• The facility has high pressure hydrogenation area within the plant, segregated from other areas with RCC walls & airlock.

Snapshot

• Specialty Chemicals Manufacturing Facility
• Built up Area = 8,679 sq.m

Project Brief

• This was a Greenfield Facility for manufacturing of Fluorochemicals & Specialty Chemicals
• The facility was built for (G+3) structure.
• Products manufactured at this site are Perchloroethylene and Trichloroethylene.

Snapshot

• Multiproduct API Manufacturing Facility
• Built up Area = 9,293 sq.m.

Project Brief

• This facility is greenfield facility spread over plot of 17 Acre. 
• The facility consists of Manufacturing block Warehouse, Utility block, Administrative, QA and QC Block, Effluent treatment plant, solvent store, and other ancillary structure.
• The Manufacturing block has manufacturing sections Consisting of Intermediate manufacturing and two dedicated powder processing facilities to manufacture two products simultaneously.
• The production block has 20 reactors ranging from 100 Lit to 5000 Lit. and other equipment required for producing API.
• The Effluent treatment facility was design for handling 100 KL per day of effluent with zero liquid discharge facility
• Warehouse was designed for future expansion with dedicated area for raw material, finished goods, Intermediate and Packing material storage area.
• The facility is designed for regulated market and is USFDA approvable.

Snapshot

• Multiproduct API & Kilo Lab Manufacturing Facility
• Built up Area = 1,672 sq.m.

Project Brief

• This was a Green field Facility in which Kilo lab and Pilot plant are in same building.
• The QC and Warehouse are in separate building.
• The facility is approved by US FDA.
• Various DMF Filed

Snapshot

• Project D - Biosimilar API Manufacturing Facility
• Built up Area = 2,150 sq.m.

Project Brief

• The production block has two Bioreactor (Fermenter) of 20 KL capacity each with seed fermenter train and harvester. Phase II was planned for downstream processing.
• This facility houses manufacturing section, personnel gowning areas, technical area for AHUs and routing of services.
• In addition to Production Block, Utility block was expanded to house additional chiller and air compressor. The plant was designed with a prime emphasis on product, personal & environmental safety.
• Layout was prepared to allow unidirectional movement of material and personnel and minimize potential mix-ups. The main manufacturing areas were maintained at negative pressure with respect to peripheral socially clean corridor.

Snapshot

• MR Vaccine Manufacturing Facility
• Built up Area = 4000 sq.m.

Project Brief

• Six modules for vaccine based on various technologies.
• The first module to manufacture MR (Measles – Rubella) vaccine based on chicken embryo fibroblast (CEF) cell culture and cell substrate (human diploid cells, MRC-5 cells) respectively on campaign basis.
• The facility is designed as cGMP compliant and of BSL 2 containment category.

Snapshot

• mAb’s Microbial and Fungal Fermentation Manufacturing Facility
• Built up Area = 400 sq.m.

Project Brief

• The New manufacturing block is developed to house following sections:
  • 5 KL microbial facility
  • Plan to use conventional cultures
  • Provision for using Recombinant cultures
  • Area contains Microbial Lab (Cell propagation), Seed and Fermentation area, Cell Lysis / Filtration area (Harvest), Extraction in solvent , In process QC, Material Day store (with Dispensing), Personnel entry and exit, Bio kill system, Central Warehouse, Utility Block, ETP, Solvent store area

Snapshot

• Vitamin D3 Manufacturing Facility
• Built up Area = 6,226 sq.m.

Project Brief

• Project in SEZ Area.
• Greenfield Facility.
• Fermentation and API Facility.
• Phase Wise Implementation.
• First Phase Completed in 12 Months.
• Second Phase completed in 9 months.

Snapshot

• Human Probiotic Facility
• Built up Area = 3,000 sq.m.
• Design-Build Project

Project Brief

• Phase 1.
  • Design & Build of Pilot Scale Facility.
  • The facility consists of 6*2 KL Fermenters and up stream processing equipment such as centrifuge, Blender and spray dyer.
• Phase 2.
  • The manufacturing block consists of Human Probiotic facility with 20KL fermentation capacity.
  • The main block consists of Manufacturing areas, warehouse, Change rooms & Service areas.

Snapshot

• Enzyme Facility for Animal Feed
• Built up Area = 3,000 sq.m.

Project Brief

• The facility was designed to meet GMP norms applicable for manufacturing animal feed enzymes.
• The facility consists of two manufacturing suit each having two fermenters of 10 KL capacity. One suit was dedicated for bacterial fermentation and other for fungal fermentation.
• The downstream processing equipment consist of centrifuge, reverse osmosis, and Spray drying and blending facility.
• The utility block consists of air compressor, chiller and cooling tower.

Snapshot

• Biotech API Facility
• Built up Area = 4,700 sq.m

Project Brief

• This green field Biotech API facility of Antigens, Industrial Enzymes & new biotech facility for API products.
• This facility shall be built as per the cGMP and Good Engineering practice and upon completion, shall follow Indian Schedule M, WHO, USFDA and EUGMP.
• The main block consists of Manufacturing areas, warehouse, Change rooms & Service areas. Manufacturing areas planned for 2 X 5KL Fermenters, Gowning areas, warehouse & supporting Service areas.

Snapshot

• Built to Suite Formulation Development Lab
• Built up Area = 10,223 Sq.m

Project Brief

• Formulation Development Lab, Analytical Development lab, Wet Chemistry Lab, Packaging R&D Lab, Pilot Plant for Tablet & Capsules. Ancillary Areas like, Offices, Cafeteria, Reading Room, Training Room, Recreation Room, Utilities Etc.
• Site was an under construction multi-storied building which was customised to suit clients’ requirements for floor loading, increased heights for clean room floors and cut-outs for some of double height equipment.
• Abbott has their own design and engineering standards which were followed in all design related work. further designs were reviewed by Abbott for any comments and suggestions.

Snapshot

• Formulation Development Lab
• Built up Area = 1,600 sq.m

Project Brief

• Set up by renovating a 30-year-old building.
• Main sections built were Analytical Lab, Wet Chemistry Lab, PBOEL 4 Sampling Facility, Stability Chambers section, Offices for Chemists & Scientists and Utility area.
• Laboratory equipped with 60 HPLCs and 4 Stability Chambers.
• Planned to accommodate 40 Scientists.
• Floor height was only 3.6 m and it was a challenge to accommodate HVAC and other services.
• Built as per specific EHS and Quality guidelines of J&J.

Snapshot

• CH Innovation Lab
• Built up Area = 300 sq.m
• Turnkey Design-Build Project

Project Brief

• Compact Space: Optimised utilisation of space by efficient circulation layout and positioning key areas on the either side of the corridor. Glass has been used extensively to maximise visibility and to have greater sense of compact spaces. Interior design of the space is vibrant, incorporating brand identity of the client in design features.
• Structural Strengthening: Since the Building Structure wasn’t designed for Heavy Equipment load which were to be placed in the Lab Areas. Extensive Structural Strengthening was undertaken.
• Equipment Placement: The Lab is situated on 7th Floor of the Building. The Existing Lifts were small and of lesser Load carrying capacity, Also the Door Openings etc. were smaller hence a lot of thinking went into making sure the Equipment were placed at their designated locations smoothly.

Snapshot

• Formulation Pilot Scale & R&D
• Built up Area = 3,000 sq.m
• Design-Build Project

Project Brief

• The Project is to set up the following blocks/Infrastructure in the plot premises.
  • R&D lab for Oral Solids, Semi Solids, Liquids, Ophthalmic & Injectables
  • Pilot Plant & Small-Scale commercial formulation facility for oral solids & semi solids
  • Basement floor at Level 1A
  • Admin Office, Common Area, FR&D, Canteen at Level 2.
  • R&D, Common Area and Service Area at Level – 3 Security Block
  • UG tank & Pump House
  • Parking area

Snapshot

• Formulation R&D and Lab
• Built up Area = 500 sq.m

Project Brief

• Executed on Design & Build basis
• Setting up Formulation Development R&D and Lab
• RMG, FBD, Tablet Machine, Coater were some of the major lab equipment
• Sample Manufacturing area
• Office and Canteen Area for new lab
• This was a fit-out project in the existing building of the corporate park
• The utility planning in the existing small area was the major challenge of the project

Snapshot

• Camphor Testing Lab & R&D
• Built up Area = 325 sq.m

Project Brief

• Project involved Setting up of following labs on Design –Build basis:
  • GMP & Non GMP QC Lab
  • R&D Lab Scope inclusive
    • Clean Room Modular Wall and Ceiling Panels
    • Lab Furniture Works
    • Gas Distribution System
    • Fume Hoods
    • Electrical & ELVS Works
    • HVAC Works
    • Fire Detection and Suppression Works

Snapshot

• Chemistry and Discovery Lab
• Built up Area = 9,825 sq.m

Project Brief

• Designed & Engineering for setting up discovery chemistry lab, wet chemistry lab, analytical lab.
• Each Floor planned to operate 110 Fume Hoods i.e., 330 Fume Hoods on Three floors.
• Major Challenge was that out of 110 Fume Hoods -40 Fume Hoods with operating height of 2.8 Mtr. and overall Fume Hood height of 3200 mm.
• Innovative idea implemented –Separate Exhaust enclosure with Spot extractors system designed/implemented for 60 nos. Rotavapor reaction units.

Snapshot

• Formulation Development Lab
• Built up Area = 1,850 sq.m

Project Brief

• Designed & Engineering for setting up following labs :
  • Analytical Laboratory
  • Formulation GMP lamp
  • Stability Chamber area
  • Offices and Related furniture
  • Microbiological lab
  • Ointment Formulation Lab
  • 60 nos. HPLC and 30 nos. resolution instruments The proposed facility is planned, designed, engineered and operated as per current GLP standards of International Regulatory Authorities like Local FDA, WHO, US FDA, EU GLP, and will confirm to all relevant local statutory/ regulatory and cGLP requirement

Snapshot

• Formulation Development Lab
• Built up Area = 8,565 sq.m

Project Brief

• Designed & Engineering for setting up following labs :
  • Analytical Development  lab
  • Product Development  Lab
  • Regulatory Affairs office
  • Administrative office
  • Warehouse Area
  • Stability Chambers
  • Canteen
  • Utility

Snapshot

• Yeast Product Manufacturing Facility
• Built up Area = 5,000 sq.m

Project Brief

• Brownfield expansion project for yeast manufacturing.
• Seed Fermenter was added, process sustainability project in terms of capacity enhancement.
• The facility is FSSAI certified.
• ZLD plant, with ETP the major process wherein new aeration tank was built and stand by evaporator.
• The client intends to expand extra block to add packaging line, filter press, cold room etc.
• AB Mauri is the  third largest yeast manufacturers in the world, Chiplun facility is the biggest yeast manufacturing facility in India.

Snapshot

• Vegan Milk A2 Protein Lab & R&D
• Built up Area = 310 sq.m
• Design-Build Project

Project Brief

• Vegan Milk A2 Protein R&D and Lab Facility.
• Lab Fermentation, Biological Lab and Analytical Lab were designed separately with separate AHU’s, which avoids the cross contamination.
• It is design and build turnkey contract in existing building.
• As it is planned in existing building, utility and Lab area was designed considering the existing height, space availability considering the GLP norms.

Snapshot

• Herbal Extraction & Formulation Facility
• Built up Area = 9,293 sq.m

Project Brief

• 7 Ayurvedic manufacturing suits & 6 packing lines.
• 5 Cosmetic manufacturing suits & 7 packing lines.
• Manufacturing facility for cream & lotion.
• WHO GMP compliance Ayurvedic section & cosmetic section upgradable to WHO GMP.
• Centralized warehouse at basement & QC lab on first floor.
• Effective CIP System & Process Automation.
• Specially Designed Storage System for Raw Material with Temperature & Humidity Control. Bulk Material Handling System Automation.
• Effective Dust Extraction System for Herb Pulverization Area.

Snapshot

• Herbal Extraction & Formulation Facility
• Built up Area = 10,223 sq.m

Project Brief

• This was an old Zandu facility acquired by Emami & was to be upgraded to meet GMP requirements as well as to enhance the production capacity.
• Herbal Extraction of Plants.
• Herbal Oral Solids.
• Herbal Cosmetics – Powders.
• Herbal Cosmetics – Oils.
• Fermentation.
• Processing Vessels.
• Reactors.
• Liquid Manufacturing.
• Filling & Packaging Lines.
• Utilities.

Snapshot

• Baby Food Nutraceuticals Pilot Scale Facility
• Built up Area = 1,672 sq.m

Project Brief

• Facility for Food Samples (Baby Nutrition).
• Separate design of Pathogen lab.
• Part of already operational plant. Designed and executed complete utilities specifically dedicated for this project.
• Cold Room and Incubation chambers.
• The facility has been set up in accordance with regulatory guidelines of US FDA and other local statutory norms for safety and building construction regulation.

Snapshot

• Milk Powder & Yogurt Mix Formulation Facility
• Built up Area = 1,858 sq.m

Project Brief

• Milk powder products
• Yogurt Mix formulation
• Facility Design, Utility and Clean room design as per GMP, FSSAI and HACCP norms Clean Room Modular Panels as per GMP standards.
• Specially Designed Storage System for Raw Material with Temperature & Humidity Control.
• Bulk Material Handling System Automation.
• Effective Dust Extraction System at the dumping and dispensing section.

Snapshot

• Cosmetics Formulation Facility
• Built up Area = 1,900 sq.m

Project Brief

• The project involves setting up Hair and Skin Care Facility, QC Lab, Micro area & Office space.
• The facility have four different set ups like Application Lab, Powder processing areas, Hair Oil Manufacturing area and Gummy area.
• The facility will be set up in accordance with cGMP guidelines and other local statutory norms.

Snapshot

• Baby Care Product Lab at Greater Noida
• Built up Area = 1,900 sq.m

Project Brief

• Dedicated areas for Baby Care Products Research and Development.
• Pilot Scale Production.
• Office Area and Canteen.

Snapshot

• Nutraceutical Facility for Animal Feed.
• Built up Area = 2,345 sq.m

Project Brief

• Nutritional supplement in powder form for Animals.
• Buhler Mixer Composite.
• 10 Tons / day production capacity.
• Pneumatic Conveying System, Silo System, Batching Hopper, Buhler Mixer, Discharge Assembly and Packaging.
• Effective CIP System & Process Automation.
• Specially Designed Storage System for Raw Material with Temperature & Humidity Control.
• Bulk Material Handling System Automation.

Snapshot

• Nutraceuticals Facility
• Built up Area = 2,600 sq.m

Project Brief

• The facility was set up in IT SEZ, Pune for manufacturing nutraceutical products by extracting marigold nutrients.
• Marigold Extraction Plant.
• Liquid-Liquid extractor and WFE technology.
• Zero Liquid Discharge ETP.
• Wax Fired Boiler.
• Maximum utilisation of plot.
• The plant is designed for minimum human intervention to prevent human error and includes cutting edge equipment such as the fully automated manufacturing and packing lines, fully-fledged RM and FG section, separate air handling units to control environment conditions.

Snapshot

• Nutraceuticals Formulation Facility
• Built up Area = 7,900 sq.m

Project Brief

• The project involves setting up two separate blocks for producing Oral Solid Dosage Formulation facility for Nutraceutical Product.
• The annual capacity of the Nutraceutical products in following dosages forms; Sachet: - 50 Million, Capsule: - 290 Million, and Tablet: - 120 Million.
• The facility set up is in accordance with regulatory guidelines of US FDA and other local statutory norms for safety and building construction regulation.

Snapshot

• Herbal Extraction and Formulation Facility
• Built up Area = 33,921 sq.m

Project Brief

• Aqueous extraction of herbs.
• Dosage forms: Tablets/ Granules, Pellets, Powder, Medicated oils, Gel and Ointment.
• The facility has the following sections: Raw material stores, Extraction plant for aqueous extraction of herbs and a formulation plant for Ayurvedic formulations, Utility block.
• The facility was upgraded to have men & material movement as per cGMP standards.

Snapshot

• Warehouse
• Built up Area = 17,700 sq.m

Project Brief

• Storage Capacity – 16,000 Pallets.
• Storage Height - 8.0 Mtr.
• Handling: Manual with High reach double deep stacker.
• Storage Condition- Temperature: NMT 25°C, Relative Humidity: NMT 60%.

Snapshot

• Central Warehouse
• Built up Area = 10,000 sq.m

Project Brief

• Base Pellets Size (mm): 10,000 Pellets within existing PEB structure (Warm Shell)
• Ambient Storage for Primary packing, Secondary packing, tertiary packing materials – 4500 pallets
• Raw materials Storage: APIs, Excipients - 2000 pallets
• Storage: Cold Room for API and Finished Goods - 700 Pallets
• New upcoming products storage 15 to 25 deg C – 1500 pallets
• FG Storage – 1500 Pallets
• Space for Approx. 20 nos deep freezers varying sizes of 25 deg C to 75 deg C

Snapshot

• Warehouse
• Built up Area = 4,000 sq.m

Project Brief

• Base Pallet Size (mm) : 1000W x 1200D x 150H (Including Clear leg. ht. of 100 mm.)
• Loaded Pallet Size (mm) : 1050W x 1200D x 1150 H
• Loaded Pallet wt. (kgs.UDL) : 500 kgs. max. (Including pallet self-wt.)
• Storage Capacity (Total No. Of Pallet) : 4760 nos.
• No. of robot : 1 No.
• System Height : 27.75 mtrs
• Clear building height : 29 mtrs

Snapshot

• Warehouse
• Built up Area = 264 sq.m

Project Brief

• Warehouse Dimension: 25.12L x 8.75W (In Mtrs)
• Base Pellet Size (mm): 1200W x 1200D x 150H (Including Clear leg. Ht of 100mm)
• Loaded Pellet Size (mm): 1200W x 1200D x 1050H
• Loaded Pellet Weight (Kgs. UDL): 1000 Kgs. Max (Including Pellet self-wt)
• Storage Capacity – 599 Pellets
• System Height: 13 Mtrs.
• Clear building height : 14 mtrs
• No. of Robot: 1 Nos
• No of Inbound & Outbound Pallets: 80 Pellets / Hr.
• Structure: Rack Supported Structure

Snapshot

• Warehouse
• Built up Area = 800 sq.m

Project Brief

• Storage Capacity – 2000 Pellets
• Storage Height – 16.0 Mtr.
• No. of Robot - 2 No.
• Temperature: NMT 25°C
• Relative Humidity: NMT 60%
• Nos of Inbound and outbound Pellets : 20 Pellets / hour
• Supplier: Godrej Efacec

Snapshot

• Warehouse
• Built up Area = 3,500 sq.m

Project Brief

• Storage Capacity – 9800 Pellets
• Storage Height – 19.0 Mtr.
• No. of Robot - 6 No.
• Storage Condition-
  • For 4000 Pallets- Temp: 21±3°C R.H -NMT 60%
  • For 5800 Pallets- Temp: NMT 30°C R.H - NMT 60%
  • Types of SKUs (Stock Keeping Units)-1700 Nos.
  • No. of Inbound and Outbound pallets: 120 pallets /hour.

Snapshot

• Warehouse
• Built up Area = 3,201 sq.m

Project Brief

• Storage Capacity – 10,000 Pellets
• Storage Height – 23.0 Mtr.
• No. of Robot - 4 No.
• No. of Inbound and outbound Pallets – 80 Pallets / hour
• Structure: Rack supported structure

Snapshot

• Multi-Specialty Hospital
• Built up Area = 27,880 sq.m

Project Brief

• Design and Detailed Engineering of four stories hospital of approx. 27,880 sq.m
• Undertook a special design for power redundancy and special lighting systems for design for OT, Critical are and ICU.
• Responsible for architectural review, MEPF, interiors, medical equipment planning, IT infra, OT, ICU, Critical area, HVAC, Clean room designs.