Process Plus provided Architectural services to define the location of a new facility for a Major Chemical company to produce and distribute alcohol-based hand care products. Architecture services included programming and validating integral space requirements and room classifications. These documents were then used by building mechanical to define the building utility equipment. Structural engineering through Process Plus was provided and developed a basis of design based on the architectural floor plan, building mechanical information and equipment arrangements that supported the process design.
Process and Packaging Engineering groups were charged by the client to ignore how they work today, and develop these systems based on the latest technology and practices in the industry.

Process Engineering and Packaging Engineering worked with the client to understand their goals regarding production output for the new site. PFDs were developed for the proposed process and packaging, driving client concurrence to define the requirements. The PFDs were used to develop P&IDs that were utilized by Process Design to develop a preliminary equipment arrangement. Options related to the level of automation for the packaging lines were proposed and once output and package configurations were understood, initial layouts were developed. Mechanical, Process and Packaging Engineering developed equipment list and equipment load requirements utilized by Electrical Engineering to develop electrical power requirements and associated plant infrastructure.

Through the design process it was determined that the client wanted to automatically convey finished product to the distribution building on-site. Process Plus designed an overhead conveyance system with end of the line case packing and palletizing in an 40,000 square foot addition to the adjacent distribution warehouse to streamline the production process. Structural, Electrical, Architectural, Instrumentation & Controls and Automation disciplines all supported this effort.

Automation group developed and implemented a 21 CFR Part 11 compliant batching automation system, allowing for paperless batch records and control of Production Processes.
Validation group developed and worked with the client to execute the Building Validation Master Plan, Commissioning and Qualification / Validation protocols.
Process Plus teamed with a third-party General Contractor to provide a “fast-track” design and construction schedule to ensure facility was operational by Q2 2022..

Value Provided:

  • From the unloading of raw materials to the load out of finished products, Plus Group provided comprehensive engineering, design, controls integration, automation, validation and construction management services.
  • Process Plus was tasked with evaluating the clients’ current practices, understanding their goals for production output, level of automation and cGMP compliance goals when developing this facility and process design.
  • Process Plus has extensive experience in designing projects for highly regulated industries. Our depth of personnel with experience in cGMP productions, hazardous material processing and validation of facility, process and packaging functions were invaluable to the client.
  • Process, Packaging and Automation engineering groups were asked by the client to ignore how they do things today and bring current industry standards and design into the design of the new process and facility.