Bringing Ideas to Reality: Developing Novel Agarose Bead Preparation Systems
Summary
Our team was responsible for engineering and building a large-scale agarose bead preparation system from the initial concept. We understood our customers’ requirements and translated them into an effective engineering solution. At the end of this collaboration, we provided a production facility that met our client’s needs.
Scope/Task
Supporting a global developer, manufacturer, and supplier of agarose beads that helps the life science industry purify target chemicals. The client sought Briggs of Burton’s expertise to scale up their production capabilities for a novel process involving the manufacturing of specialised beads, which would be sold to life science and pharmaceutical producers for them to use in drug purification.
Challenges
- Designing and engineering a system to handle large volumes of beads susceptible to shear, while maintaining precise control over the process
- Optimising process flow through the production operations to ensure efficiency and effectiveness
- Managing several contractors and supporting them with field services such as pipework and wiring etc.
Solution
We developed User Requirement Specification (URS), Basis of Design, and Process Flow Diagrams (PFDs) to guide the project. Detailed plant configuration and equipment sizing were completed, with Piping and Instrumentation Diagrams (P&IDs) and 3D models used to ensure accuracy. Additionally, 3D models provide stakeholder engagement and prevent clashes between contractors such as civil, Structural, and Architectural (CSA) consultants and building contractors. The system was engineered to scale up existing lab-based processes to large-scale production, incorporating features to efficiently manage the production of beads. It included a number of bespoke Briggs UK manufactured stainless steel modules and systems that included: Heating and cooling vessels with agitators, mobile vessels, wash columns, and integrated utility systems.
Our team managed the entire project lifecycle, including procurement, equipment manufacturing, and installation. We provided testing including Factory Acceptance Testing (FAT), Software Testing, and Site Acceptance Testing (SAT) to ensure that the large-scale system met all performance and quality standards before final delivery.
Result
Our engineers successfully scaled up the production process, transforming a small-scale concept into a fully operational system capable of producing beads in greater quantities. The new system enabled Purolite to support life science and pharmaceutical producers, to produce high-quality agarose beads that support in drug purification. The project was completed on time and within budget, demonstrating our capability to handle complex engineering challenges with an adaptable approach.
