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Replacement of Contained Drain System for Pharmaceutical Plant

Front end engineering design support for installation of a new contained drain system for a large pharmaceutical company

Contained drain system required upgrade

The customer was a global pharmaceutical manufacturing and biopharmaceutical company developing innovative new medicine to treat chronic diseases. The company has manufacturing facilities in Ireland and the US and employees around 1200 people globally. The company’s Irish manufacturing plant had a contained drain system to control the flow into a tank. The focus of the system is to ensure that this waste doesn’t mix with any other waste stream. The products with powders washed out can’t get into the waste stream. The system is contained, where it has a collection sump at the bottom of the building with two 30 kilolitre holding tanks with change over spill waste disposal. The company was seeking to upgrade the contained drain system and required recommendations for best possible solutions.

FEED support with costed options to develop tender documents

Malone Group was engaged by the customer to provide front end engineering design (FEED) support for the upgrade project, specifying the type of system to be adopted that would be most effective for the customer. This included installing pipework to carry the waste product away with an overground sump storage system pumped to holding tanks.

Based on the analysis, there were options to put the holding tanks in different parts of the site. Our FEED study provided the customer with four options across the site with costs and detailed designs to produce tender documents for the Mechanical & Electrical (M&E) contractors. Pharmaceutical/ bio-pharma is a highly regulated industry so the design and installation of the system required utmost care and attention to detail.

On-time delivery of a fully operational contained drain system

As a result, after providing the initial FEED support, we also provided support at the construction, installation and validation stage of the process with commissioning support to ensure that a compliant and safe working solution was delivered to the customer. The new fully operational contained drain system was delivered on-schedule.