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New production plant for Laboratoria Smeets

Laboratoria Smeets - Belgien
Markt Life Sciences
Umfang
Land Belgien

Laboratoria Smeets, located close to Antwerp, is an innovative and ambitious contract manufacturer and packer of (para)pharmaceutical products, thereby focusing on powders. To enlarge their product offering, the company bought an existing process installation from a large pharmaceutical company and integrated the installation into a new and highly automated production plant. A complicated challenge for which they counted on Agidens Life Sciences.

EPCM approach delivers

Seeing that the project would have quite an impact on the staff and the overall day today organization of the company, Laboratoria Smeets decided to work with an EPCM contractor (taking care of Engineering, Procurement, Construction and Management). Jef Verplaetse, Managing Director of Laboratoria Smeets: “I felt it was important to limit the pressure on our internal resources and therefore decided to engage a party that could take care of every aspect involved. I needed a partner company that I could trust and that was able to manage the entire project.”

Agidens took charge of the entire refurbishment of the building in which the new plant was to be situated (including HVAC, fire protection, HV and LV electricial installations, plumbing, etc). Next to that, Agidens moved and reinstalled the process installation, while at the same time increasing its automation level significantly.

Challenges

EPCM projects are often complex, high cost and deadline driven. Agidens has the experience and know how to deal with the challenges involved. A standerdized project approach allows our teams to keep control of the budget and to deliver on time. Nevertheless, creative troubleshooting and a hands on mentality are necessary to tackle specific project related difficulties:

  • The complexitiy of the new plant was considerably higher than that of the existing Laboratoria Smeets plants.
  • Strict validation documentation was required by the client.
  • The existing building provided a limited space to integrate a large-scale process installation.
  • Agidens and Laboratoria Smeets set up a limited project team to keep decision making easy and communication lines short.

Deliverables

An existing building was completely refurbished and turned into a brand new state of the art production plant. Agidens took care of all aspects involved:

  • Civil construction (skids, walls, ceilings, floor treatment, etc.)
  • Supply of resources (HV and LV electricity, Water)
  • HVAC
  • Fire protection measures
  • Storage and transportation systems

The process installation consists of six large parts:

  • storage silo of 100m³ for the (bulk) storage of Polysoy
  • weighing unit to dose the exact amount of Polysoy required for the premix production
  • reactor to prepare the API solution (Active Pharmaceutical Ingredient)
  • mixer-dryer to apply the API to the Polysoy and to dry the final product
  • solvent regeneration system with cooling equipment
  • packaging line for packaging from 1kg up to 25kg validation documentation

Key benefits for the client

  • Agidens Life Sciences automated the plant as much as possible and made sure that the employees of Laboratoria Smeets can work under the best ergonomic conditions.
  • The plant hasn’t only been reassembled, Agidens also provided quite a number of innovations and improvements:
  • There is an immediate access to the information for batch documentation and traceability through a central data monitoring system (SCADA).
  • The maintenance cost is limited and includes preventive measures, such as additional differential pressure measurements on the filters, to avoid downtime as much as possible.
  • It is possible measure and log key process parameters such as the concentration of oxygen/reagents, the doses of liquids and powders.
  • There is an immediate access to the information for batch documentation and traceability through a central data monitoring system (SCADA).
  • The maintenance cost is limited and includes preventive measures, such as additional differential pressure measurements on the filters, to avoid downtime as much as possible.
  • It is possible measure and log key process parameters such as the concentration of oxygen/reagents, the doses of liquids and powders.