Filling & Packaging Line Renovation

Merck Animal Health Location: Elkhorn, Nebraska Square Footage: 10,000 Construction Cost: $13,000,000

Project Description:

Drivers for this retrofit project were to double vial filling capacity, minimize capital costs, and develop phasing plans for the installation of the new filling equipment while maintaining production operations within the aseptic core.

The project consisted of developing a basis of design through detailed design to increase throughput while minimizing shutdown of the facility. The project included renovation of an existing sterile core and installation of high-speed vial filling equipment, depyrogenation tunnel, capping equipment and associated airlocking. Established flows into and out of an existing lyophilizer corridor had to be maintained, with the new filling suite access incorporated as well.

Aseptic core renovation in preparation for new equipment installation included the relocation of an existing filling line and decommissioning of a second filling suite. This second filling suite was then renovated to accommodate new capping equipment. Vaporous hydrogen peroxide (VHP) systems were designed for decontamination of non-product contact materials entering the new high-speed filling suite.

Drivers for this retrofit project were to double vial filling capacity, minimize capital costs, and develop phasing plans for the installation of the new filling equipment while maintaining production operations within the aseptic core. Programming the space, planning phased implementation, specification
of process equipment, estimating utility loads, developing mechanical and utility system concepts to support the production increase, and coordination with CRB Builders as a Design/Build Project were services that were included.
back to top