Fresenius Kabi's new Assembly Line
To cope with the rapid growth in the highly competitive pharmaceutical compounding and dispensing market, Fresenius Kabi Ltd commissioned Clean Modules Ltd to build a new high-efficiency aseptic services cleanroom production facility within Fresenius Kabi Ltd’s new combined site at Runcorn, Cheshire. Previously spread over three sites between Runcorn and Birchwood, Fresenius Kabi Ltd and Calea UK Ltd now enjoy the convenience of being under one roof and sharing one platform of operational excellence. The facility delivers the highest levels of workflow and energy efficiency at a keen installation cost and is the largest compounding and dispensing facility in the United Kingdom.
Fresenius Kabi Ltd is Europe’s leading healthcare company in the field of clinical nutrition and infusion therapy. Calea UK Ltd provides high technology clinical homecare to patients throughout the United Kingdom, distributing a range of products to support the care of critically ill patients both in hospital and at home, ranging from those suffering with Cystic Fibrosis to patients with intestinal failure and patients in intensive care. The new facility will guarantee patient safety in preparing medication and clinical nutrition using the latest in clean room technology.
The new aseptic services cleanroom production facility houses a Grade B Total Parenteral Nutrition (T.P.N.) compounding suite, a Grade B Batch compounding suite and a Grade B Fast compounding suite with a total of ten Laminar Air Flow cabinets and two 3-glove isolators. The compounding suites are supported by a 395m² assembly area, a 542m² packing and dispensing room and a 300m² Grade C support area. Besides the facilities for large-scale production, the new facility also houses a Prescription-
A 15% saving on usual installation costs was achieved by the use of Clean Modules Ltd’s modular cleanroom construction method. The modular cleanroom construction method also ensured that the build was completed within the agreed timetable of just eight months, from starting on site to the MHRA inspection. The use of System I composite cleanroom panels allowed Clean Modules Ltd to deliver a highly versatile and space-efficient facility that ensures Calea UK and Fresenius Kabi Ltd’s competitive position within the pharmaceutical compounding and dispensing market.
Production efficiency from the first few weeks was significantly ahead of expectation. This is particularly important, since demand is expected to grow significantly over the next four years and Fresenius Kabi Ltd want to fully utilise the space devoted to the new cleanrooms. The workflow of raw materials and the daily dispatch of individual orders (comprising from support equipment to cold stored individual prescriptions)
Additionally, in line with today’s rising energy costs and environmental policies, a 31% energy saving has been achieved through the careful design of the air handling plant and through the use of a novel re-circulating “piggyback”
Mr Guy Topping, International Compounding Manager for Fresenius Kabi Ltd said: “Fresenius Kabi is focussed on the growing demand for compounding services within the healthcare market and we understand the importance of uncompromising quality in the service that we offer. We enjoyed working with Clean Modules and by combining both companies’ experience and expertise we have created a facility that will provide the needed capacity in an efficient way. We are delighted with Clean Modules’ management of the project and are very proud of our new unit.”
Mr John F Robinson, Managing Director at Clean Modules Ltd said: ”By allowing us to challenge the initial design, the team at Calea (UK) Ltd and Fresenius Kabi Ltd, gave us a wonderful opportunity to develop a new high-efficiency cleanroom facility. Through an open and collaborative approach to the design phase we were able to use our skills in design, project management and construction to their fullest and deliver a facility that exceeds expectations.”
Clean Modules Ltd specialises in the Design, Construction and Project Management of Modular Cleanrooms, Mobile Cleanrooms and In-situ Cleanrooms. Clean Modules Ltd. has considerable expertise in Life Sciences such as Pharmaceutical, Healthcare, Hospital, and Biotechnology applications but also has experience with several other industries.
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