Plant Expansion including new Reactor, Filter Dryer plus support systems
(£5m Detailed Design incl process modelling)

Veterinary Pharmaceutical Plant, Southern Italy

The Problem
The existing pharmaceutical plant output could not match projected sales. An expansion based on the

provision of a new Reactor, new Filter Dryer, new processing vessels, new solvent recovery plant and
modifications to the USP water system was required.

The Solution
BPE were engaged to provide the detailed design on behalf of the client. Based on an integrated
team format, BPE provided the detailed process, instrument and control design documents for key elements of the expansion. Deliverables included P&IDs, major equipment specifications, shutdown system specifications plus control diagrams, batch recipes and phase diagrams.

This automated batch process required the careful integration of the new systems into the existing
and BPE were responsible for the generation of the documentation required for the re-programming
of the DCS. This included the modifications to the existing batch control as well as new data for the
new equipment. All work was completed in accordance with the GAMP framework for compliance.

Using proprietary process simulation packages, BPE modelled the proposed methanol recovery scheme to assess its feasibility and range of operation. This work provided the material balance and equipment data for the detailed design of the plant.

The expansion to the USP water system presented a particular challenge but based on a fundamental review of concepts BPE was able to recommend practical GMP compliant solutions that maintained the quality of the water