Innovation solutions for exacting requirements
The exacting demands of the manufacturing process had a major influence on the general layout and size of the structure at concept design stage, resulting in a number of innovative and unique solutions.
- Central location of main services plant rooms minimise lengths of services runs and spatial coordination issues.
- Walk-in ceiling voids allow access to services which, due to hygiene considerations, cannot be accessed from within the high cleanliness (Grade D) production areas .
- A single 3000 kg capacity lift with separate and interlocked doors provides transport of raw materials, new equipment and maintenance equipment, with one side opening to plant and services spaces and the other to access production areas. Two lift lobbies per floor are separately air-conditioned and service the dual purpose of an air lock so pressure regimes can be maintained throughout.
- Air-conditioning ducting for Grade D systems was fabricated under closely controlled conditions then cleaned before being sealed for transportation to site.
- Process and instrumentation diagrams for the air conditioning system were provided for each room to detail stringent air flow requirements and the effects of dust extraction on the air balance quantities.
Meeting international standards
The plant conforms to South African and European regulatory standards, allowing the client to receive international certification for the export of tablets, including:
- US FDA (United States Food and Drug Administration)
- UK MHRA (United Kingdom Medicines and Healthcare Regulatory Authority)
- WHO (World Health Organisation).
This has contributed to the plant already exceeding growth plans and a further similar plant is now being considered.
The design for WSP’s MEP services at Aspen Pharmacare won the South African Association of Consulting Engineers’ annual Design Award Competition for Design Excellence.