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Case studies

Pharmaceutical Manufacturing Facility Expansion

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Our client are a leading provider of advanced technologies to pharmaceutical and biotechnology industries. With over 80 years’ experience, they specialise in the early development, clinical supply and commercial manufacture of pharmaceutical, biologic and consumer health and beauty products.

5000m2

building extension

HVAC

provisions

14

months fast track 

project delivery

In order to meet the growing demand for development, delivery and supply, our client required the design, construction and commissioning of a facility for the manufacture and packaging of freeze dried tablets.

Our Solution

Bouygues Energies & Services were appointed as the turnkey design & build partner for this specialist freeze-dried tablet and packaging facility. Given our extensive experience working within the pharmaceutical industry, our unique, in-house, multidisciplinary teams were able to provide a design solution which matched the highly particular requirements of the client.

The project delivery included the construction of a new 5000m2 building extension, as well as state-of-the-art cleanrooms and utility systems, with specialist purified water and gas systems. We were also responsible for the integration of solution preparation systems, lyophilisation, a nitrogen filling tunnel and the freeze-drying and secondary packaging equipment. Our solution also included provision of HVAC services and cleanroom fit out, to ensure the necessary environmental parameters were met and maintained.

Client Benefits

A Single Point of Accountability
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical & electrical services, commissioning and validation to offer seamless engineering solutions to the challenges facing our client.

Compliance Delivered on a Fast Track Basis
Our solution encompassed a facility which adhered to regulatory compliance, supporting their coveted position within the industry, whilst meeting project time restraints.

Cutting Edge Facilities Promoting Business Growth
World class facilities will help cement our client’s place on the global market; with clients across the globe, an international standard manufacturing base will aid in the retention of their current portfolio and help with its future growth.

Our Commitments - Pharmaceuticals & Lifesciences

Our Commitments

De-risk Project Development

Accompanying you through the whole project development from concept stage to handover

 

Technical Expertise

Leveraging our engineering design and construction technique to accelerate and realise the vision of our clients 

 

Compliance Strategies Within Regulated Sectors

Ensuring MHRA and FDA regulations are met as required

 

 

Lean Operation

Ensuring greater long-term operational efficiency and productivity

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Case studies

Replicating the Red Planet

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ExoMars is an international co-operative of the European Space Agency (ESA), Roscosmos and NASA. The ExoMars Rover is an automated vehicle, engineered and built by Airbus Defence and Space for the ESA. It is intended that it will be launched into space in 2020, following a scout mission by an orbiter and probe in 2016. The mission: to find evidence of past or present life on Mars.

300

tonnes of specially selected sand

2000

LUX lighting system

9m

wide control room glazing

Client's Requirement

To support the Mars Rover venture, Airbus Defence and Space required a state-of-the-art testing area – the Mars Yard – to simulate Mars’ terrains and conditions on their main site in Stevenage, UK. They required an indoor terrain, about the size of a basketball court, filled with 300 tonnes of specifically selected sand, complete with rocky obstacles which would mimic the appearance of a Martian landscape.

Our Solution

Airbus Defence and Space appointed Bouygues Energies & Services as their turnkey Design & Build partner for the delivery of Mars Yard. By working in close collaboration with the client, we were able to make every provision to ensure the facility replicated the Mars environment.

We ensured that the environment was highly controllable through the installation of ventilation and air conditioning, to maintain a temperature between 18 and 25 degrees. We also installed an external AHU with a high quality fabric air distribution duct to distribute air uniformly, without disturbing the fine sand terrain; and an ultra bright 2000 lux lighting system, to simulate typical light levels on Mars. The indoor floor surface was designed to a reddish-brown colour, in imitation of the Red Planet, and this was complemented by a large mural of the Martian landscape.

Our service included the construction of a unique, open grid ceiling, allowing suspension of services and a target grid system for the Mars Rover, as well as the installation of an elevated secure control room, built with 9m wide glazing and all necessary power and IT. This allowed a full view of the terrain area, enabling analysis of ExoMars behaviour such as drilling, roving and overall manoeuvrability.

Client Benefits

A single point of contact to boost performance
Working within a live operational site, we provided detailed design, architectural, procurement, construction, mechanical & electrical services and commissioning to deliver a one-of-a-kind world class facility.

Minimising environmental impact
By utilising existing building services, adapting them to new scope and layout, we minimised the financial and environmental impact that would have accompanied a Greenfield development.

User friendly and adaptable
The fully-fitted, elevated control room, built with the integrity of the environment in mind, will allow observation of the Mars Rover, without hindering or altering test results. Furthermore, the ability to alter environmental conditions means that the facility is highly adaptable to suit all manners of testing for the Mars Rover.

Cutting edge facility
The innovative project provides Airbus Defence and Space with a showpiece facility that will help develop the Mars Rover’s autonomous navigation, cementing their position in the aerospace field.

 

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Case studies

Additive Layer Manufacturing Facility

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Our client are one of the world’s largest, independent, first tier suppliers to the global aviation industry. Drawing upon over 100 years of aerospace experience, considerable knowledge and superior manufacturing technologies, our client supplies high-value, integrated assemblies in both metallic and composite materials.

21 

degrees (+/-1) control

<40%

RH

BMS

system

Client's Requirement

Our client required the construction of a controlled environment, advanced manufacturing area for their additive layer manufacturing (ALM) solutions. ALM is a process where components are created layer by layer, enabling complex structures to be produced directly from 3D CAD models; a game-changing development for the aerospace manufacturing industry.

Our Solution

Bouygues Energies & Services were appointed as the turnkey design & build partner for this project. Through a collaborative approach to the design, we delivered a ‘box within a box’ construction solution, using composite walls and ceilings. This met the client's requirement of an area built within the existing building, which would still remain independent from the building’s structure. All floors were levelled and finished to the standard of new areas, ensuring succinct amalgamation of the old areas with the new.

Our in-house design teams designed a full HVAC system to control humidity and temperature within the manufacturing area, managed by a networked BMS system. The design solution incorporated provision of close control temperature and humidity within the 21 degrees (+/- 2) and <40% RH.

Working within the live operational site, our team installed lighting levels, gases and compressed air in order to meet specific client equipment requirements. We tested and commissioned the facility before handover to ensure that high standards had been maintained throughout the project for prime client usability.

Client Benefits

A single point of accountability
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical & electrical services, and commissioning to offer seamless engineering solutions to the challenges facing our client.

Cutting edge facility
The ALM process is the next step in efficient aircraft manufacture and the completion of this facility provides our client with the correct environment to utilise ALM, manufacturing ‘first of their kind’, additive layer aircraft components.

Innovative manufacturing capabilities
ALM capability will mean that lead times will be reduced, manufacturing will be more efficient and more innovative products can be created, improving prospects for both our client and theirs.

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Case studies

Critically Controlled Cleanroom Facility

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Our client required a bespoke facility, which would be purpose-built and highly controlled to ISO class 8 accreditation. All operations would need to maintain strict BioBurden control parameters, as well as be aware of the molecular and particulate contamination risks.

Steel

design

Class 8

ISO accreditation 

BioBurden

control parameters

Our Solution

Following previous experience of working in collaboration with our client, Bouygues Energies & Services were appointed as the turnkey design & build partner for this project.

Our track record of delivery for cutting-edge technology and mission critical projects enabled us to present a detailed solution that met the client's specialist requirements. By collaborating with their project management executives, our own team were able to fully identify and understand the requirements of the project and therefore offer a fully prescribed solution.

The full-height, stainless steel design comprised of a changing room, airlock, equipment support and preparation areas. In order to meet the paramount environmental demands, a molecular carbon filtration system and temperature and humidity controls were core aspects of the design.

Client Benefits

A single point of accountability
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical & electrical services, commissioning and validation to offer seamless engineering solutions to the challenges facing our client.

Validated results
By delivering the project to strict regulatory standards, the facility is validated under the ISO classifications, allowing our client meet their own customer expectations.

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Case studies

National industry Biotechnology Facility 1

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The Centre for Process Innovation (CPI) helps its clients develop their products and processes from early and mid-stage development, with minimal risk and guided understanding of relevant cost contribution. To achieve this proof of scale testing, they required facilities which could accommodate a diverse range of biomass feedstocks and comprise of state of the art handling and preparation equipment.

downstream processing technologies 

10,000L

fermentation capability

DCS

control system

CPI appointed Bouygues Energies & Services as a principal contractor to design and build its pilot and demonstrator industrial biotechnology facility at Wilton Centre, Redcar. CPI required the detailed design, construction and commissioning of the bioprocessing facility, biolaboratories, cleanrooms, biotechnology processing equipment and clean/critical utility systems.

Our Solution

Bouygues Energies & Services’ in-house process engineering division are already responsible for the selection and integration of leading advanced laboratory technologies (HPGLC, GCMS, LCMS) and test instruments (NIR). Our consulting team were therefore well equipped to develop a conceptual and detailed design, based on CPI’s unique user requirements of creating highly flexible facilities and engineering systems that would help its clients de-risk their process development.

We designed and built bespoke and novel downstream processing equipment, such as oscillatory baffle flow reactors and high shear homogenisers. We ensured the facility was also supported by an advanced DCS control system for semi-automatic/fully automatic operation.

Client Benefits

A single point of contact to boost performance
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical & electrical services, and commissioning to offer seamless engineering solutions to the challenges facing our client.

Efficiency delivered
A fast track delivery of world-class facilities, meeting budget constraints,  maximising the client's future profitability.

Financial savings passed on to clients
10, 10-750 and 10-10,000 litre scale fermentation vessels complement proof-of-concept testing and production at scale, enabling CPI’s clients to demonstrate processes, prior to expensive capital investment into full scale projects.

Knowledge exchange
The state of the art DCS systems are utilised for process controls and data capture for scale up, enabling worldwide interfacing and knowledge exchange with universities.

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Case studies

King's College London

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King's College London and Bouygues Energies & Services have a longstanding relationship, dating back to 1999. Working with such a prestigious university is a great source of pride for our team and we continue to work hard every day to ensure we bring the best service possible. 

£250,000

reduction in mechanical and electrical costs from our cost-saving drive

£1.1m

peak annual savings

The university landscape continues to evolve. Whilst enhancing and improving their estate, KCL wanted to ensure energy and sustainability were at the top of the agenda. 

To do this, we partnered with KCL and launched a large scale efficiency review, assessing all aspects of service delivery to offer more efficient and effective ways of working. 

Our Solution

We introduced new approaches to asset management, using both Condition Based Monitoring and Failure Mode Effects Analysis, to drive a more holistic approach to equipment maintenance. We measured and analysed the performance of systems to evolve the calendar-based maintenance programme (SFG20) and introduced a more bespoke model. This model was created from best practices within energy-focused maintenance, business-focused maintenance and risk-based maintenance.

The new approach assessed plant performance, identifying that plant performing different roles were being serviced the same. New individual equipment profiles were created and maintenance plans were changed accordingly, improving efficiency of service maintenance. 

Following a staff consultation, 14 maintenance engineers that exclusively serviced the KCL estate are now also assigned to other Bouygues Energies & Services clients in the locality. This has removed the cost of having engineers on site during unnecessary times whilst also upskilling the team, creating huge cost savings for KCL. 

 

Benefits to Client

£1.1m in savings the following year 

This significant saving was achieved through a mixture of simple changes and fundamental strategy alterations across four areas; mechanical and electrical maintenance, soft facilities management services, energy savings and the innovative use of lifecycle funds. Crucially, these savings are now being reinvested in student services. 

Reduction in staff costs and development of specialist skills

Staff costs were reduced as a result of maintenance engineers also being assigned to other Bouygues Energies & Services clients. This also allowed staff to develop and introduce more specialist and non-intrusive skills, which were beyond the industry standard SFG20 approach. This involves identifying plant performance whilst running, eliminating the need to shut down and cause disruption to KCL, this approach goes beyond ISO 55000.

New methodology is continually tested and adjusted

This ensures that maintenance is in line with the equipment's criticality, and KCL is not placed at an unacceptable risk. 

 

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Case studies

The Biorenewables Development Centre

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The Green Chemistry Centre of Excellence (GCCE) based at the University of York, is at the forefront of innovation in the Biorenewable sector. The GCCE consider sustainable chemical research their priority, looking to transform waste food into a renewable source of high value chemicals, materials and fuel.

7

world class technologies

1

month to 1 week reduction in processing time

next-generation DNA technologies

The GCCE have proven at laboratory scale that microwave treatment process of sustainable feedstock can be developed to convert bio-waste into sustainable products, replacing the conventional use of fossil-based chemicals.

To enhance and develop these novel processes, the Biorenewables Development Centre (BDC) was established in collaboration with GCCE, with the intention of creating a facility of open access, scalable processing capabilities. This facility would utilise plant derived materials as sustainable feedstocks for the production of high value, biorenewable chemicals.

Our Solution

The University of York appointed Bouygues Energies & Services as their scale-up partner for the turnkey Design & Build solution of their open access pilot scale facility: Biorenewables Development Centre. Involved from early design stage, we developed a strategic masterplan to provide a highly flexible processing facility. This would allow the client to achieve world class standards of excellence for biorefining technologies and would be relevant to industrial application.

Working within an existing live operational environment, our solution encompassed the integration and commissioning of novel extraction and processing technologies such as Microwave Technologies, Spinning Cone Separation, Supercritical CO2 Extraction and Ammonia Fibre Expansion. Our specialist team also assisted the client in the optimisation of the biorefinery facility, by including an upstream biomass feedstock Pellet Handling System and a biofermentation train. Our solution will offer clients a reduction in processing time from weeks to hours.

Benefits to the Client

A Single Point of Contact to Boost Performance
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical and electrical services, and commissioning to offer seamless engineering solutions to the challenges facing our client.

Stepping Up the Scale
Science and vision accelerated from laboratory scale, to a highly technical industrial solution.

Academic Endorsement
Scale up supports academic and research partners in performing novel extraction and purification processes, transforming feedstock into biorenewable chemicals, materials and fuel.

Increased Efficiency
The development of a biorefinery train reduces processing time from weeks to hours, speeding up the entire process and increasing the practicality of biorenewable production procedures.

Contributing Towards a Bioeconomy
Our delivery contributes to the realisation of the BDC’s own vision; to bridge the gap between academia and industry. The facility can be used to develop greener processes and products, and to show organisations how they can achieve the same.

Our Commitments - Pharmaceuticals & Lifesciences

Our Commitments

De-risk Project Development

Accompanying you through the whole project development from concept stage to handover

 

Technical Expertise

Leveraging our engineering design and construction technique to accelerate and realise the vision of our clients 

 

Compliance Strategies Within Regulated Sectors

Ensuring MHRA and FDA regulations are met as required

 

 

Lean Operation

Ensuring greater long-term operational efficiency and productivity

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Case studies

Large Scale Fermentation Facility

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Over the last decade, the development of new technologies has opened a vista for manufacturing companies to answer the current and future market trends. One such company is Croda; creating, producing and selling speciality chemicals, whilst maintaining their commitment to sustainable innovation.

30,000L

stainless steel fermenter

2,000L

seed fermenter

30,000L

glass-lined fermenter

New technologies, alongside a mix of natural, raw materials; combined with creative chemistry, have enabled Croda to offer excellent solutions for their clients and the delivery of a large scale fermentation facility would further promote this aim.

Our Solution

Involved from an early design stage, Bouygues Energies & Services were appointed as the Design & Build partner to provide a distinctive process engineering solution, utilising our unique, in-house, multidisciplinary design and project delivery capabilities.

Our solution offered some of Europe’s largest fermentation and downstream processing footprint capabilities at 30,000 litre manufacturing scale, by incorporating highly innovative plant hardware such as conventional stainless steel and glass lined systems. Included in our design was a DCS control system to enable fully automated manufacturing strategies, supported with bespoke recipe management, process control, condition monitoring and trending facilities.

The new biotechnology facility was to be integrated within an existing production area, adjacent to a live and fully operational manufacturing process. This required exemplary project management skills, planning and coordination, to keep the existing production areas live during the commissioning and construction of the new, state of the art facility.

Benefits to the Client

A Single Point of Contact to Boost Performance
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical & electrical services, commissioning and validation to offer seamless engineering solutions to the challenges facing our client.

Optimised Usability
Clean in place (CIM) and steam in place (SIM) provisions, for effective system sterilisation, minimising disruption through disassembly and increasing practicality for the client. 

Meeting Future Market Requirements
At 30,000 litre manufacturing scale, the facility will be capable of producing personal care products, utilising marine and thermophilic organisms will enable Croda to offer excellent solutions for their clients.

Our Commitments - Pharmaceuticals & Lifesciences

Our Commitments

De-risk Project Development

Accompanying you through the whole project development from concept stage to handover

 

Technical Expertise

Leveraging our engineering design and construction technique to accelerate and realise the vision of our clients 

 

Compliance Strategies Within Regulated Sectors

Ensuring MHRA and FDA regulations are met as required

 

 

Lean Operation

Ensuring greater long-term operational efficiency and productivity

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Case studies

Biochemical Manufacturing Plant

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Our client are a process technology licensing company, founded as a spin-out from Imperial College London. They strive to develop leading manufacturing technologies by using a combination of traditional chemistry and biochemistry approaches, to meet customer requirements for lactic acid and polylactic acid (PLA) production.

7

separate equipment skids

ATEX 

rated conditions

Scale-up

capabilities

Our client’s aims are to enable partners to produce high value, renewable chemicals and ingredients, using feedstock of low value waste and industrial by-product streams. Our clieent therefore required the construction of a pilot plant, which would enable scale up of the laboratory process for proof-of- concept and would also improve manufacturing flexibility to maximise and optimise investment return.

Our Solution

Bouygues Energies & Services developed an innovative Design & Build solution for the pilot plant, based on modular process. Comprising of seven separate equipment skids, this design allowed for portability and also ease of expansion if necessary. The modular skids and vessels were prefabricated, prewired and pretested within our prefabrication facility in Knowlsey, Liverpool.

Based on our design and specifications, the pilot plant enabled a predictive scale up, to proof different stages of the process including; esterification, evaporation, bioreactors and distillation under ATEX rated conditions. As a result, the facility is designed and built to accommodate a wide variety of feedstock and produce bio-based chemicals, meeting client project proposals.

Benefits to the Client

A single point of accountability
Providing detailed design, architectural, procurement, construction, installation, process engineering, mechanical and electrical services, and commissioning to offer seamless engineering solutions to the challenges facing our client.

Quality at speed
An ultra fast track delivery, meeting project specifications and target costs while delivering world-class standard facilities, therefore minimising expense to the client. 

Meeting industry demands
The versatility of the facility accommodates rapidly growing industry requirements such as automotive, personal care and aerospace, across high volume applications. This offers the client longevity for their facilities; they are able to expand as the client's portfolio expands.

Our Commitments - Pharmaceuticals & Lifesciences

Our Commitments

De-risk Project Development

Accompanying you through the whole project development from concept stage to handover

 

Technical Expertise

Leveraging our engineering design and construction technique to accelerate and realise the vision of our clients 

 

Compliance Strategies Within Regulated Sectors

Ensuring MHRA and FDA regulations are met as required

 

 

Lean Operation

Ensuring greater long-term operational efficiency and productivity

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Case studies

Semi-Industrial Algae Photobioreactor

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In an economy that is increasingly concerned with sustainability, the development of sustainable and natural ingredients is vital to the long term objectives of pharmaceutical, nutraceutical and cosmetic industries.

500L

photobioreactor

1kg

dry weight of algal product

1

of the largest in Europe

In response to these objectives, scientists and academics from Plymouth Marine Laboratory (PML), University College London and Protein Technologies were interested in developing micro-algae, which could then be converted into raw materials for pharmaceutical, nutraceutical and cosmetic industry use.

PML and Protein Technologies therefore required the unique Design & Build of a semi-industrial scale photobioreactor. First of its kind, the photobioreactor needed to be modular in design, with integrated feed tanks, control and monitoring systems.

Our Solution

The project delivery strategy included the design and build of fully tested, preassembled and prewired photobioreactor units, which would be mounted on a skid frame to enable ease of transport and deployment in diverse applications across the world.

Our process engineering teams performed detailed process design calculations based on the physical and chemical parameters for growing microalgae. This ensured optimised conditions could be achieved within the photobioreactor, promoting algal growth.

Deviating from the conventional, coiled photobioreactor construction, we developed a straight, single tube photobioreactor. This original and innovative design provided better flow control access to each of the individual growth tubes, making it more robust and resilient than a conventional photobioreactor.

Following approval by the academic partners, we prepared 3D visualisations and fabrication drawings for manufacturing at our off-site prefabrication facility in Knowlsey, Liverpool.

Benefits to the Client

Groundbreaking research capabilities
The project boasts an understanding of the processes involved with producing sustainable materials, increasing awareness of UK research and demonstrating the application of such research into the manufacturing of commercial products.

Longevity through forward thinking
The 500 litre photobioreactor is the largest in Europe, producing one kilo (dry weight) of algal product. The unique modular design also means that the photobioreactor can be increased, to accommodate even larger scale growth runs, potentially up to industrial scale.

Client experience as a priority
The quality of the design ensures quick and easy clean down between experimental runs, improving usability.