Process Engineering Solutions for Life Sciences – From Concept to Reality
The project involved a feasibility study, complete process and system redesign, and successful construction of a bespoke, pre-assembled pharmaceutical process system for a pharmaceutical company at their facilities in the UK and Europe. The system plays a crucial role in the pharmaceutical manufacturing process, specifically for producing antiretroviral medications e.g. human immunodeficiency virus (HIV) drugs. Briggs of Burton’s expertise made it possible to develop a bespoke approach, showcasing the success of customised solutions in meeting specialised customer requirements.
Scope/Task
The client, a leading biopharmaceutical company, sought our expertise in developing a novel system to support their proprietary processes used in drug formulation, addressing a need for a solution that was not available commercially.
Challenges
- Tailoring a solution that did not yet exist in the market
- Validating theoretical concepts
- Identifying potential risks and mitigation strategies for full-scale production
Solution
The project began with a Front-End Engineering Design (FEED) study to explore the feasibility of developing a novel solution designed to improve the drying, cleaning and preparation of pharmaceutical-grade drug processing aids. This involved working closely with the customer’s engineers to explore and refine the process requirements. We analysed key aspects such as temperature controls, cleaning processes, and system transformations.
To validate the theoretical design, our team built a small-scale demonstrator unit at the client’s facility. This prototype was built according to the specifications and 3D models developed during the feasibility study. It served as a test to verify the principles of the proposed system, ensuring optimal performance and efficiency.
After successful trials and validation, we proceeded to the full-scale commercial system. The final design was installed at the client’s site, followed by rigorous Pre-Delivery Inspection (PDI) procedures to ensure compliance with quality standards. The system underwent our standard engineering pharmaceutical qualification process and commissioning to guarantee a seamless operation.
Result
The project shows how collaborative process engineering can address complex and unique challenges. The process significantly improved the client’s manufacturing capabilities for its drugs. It streamlined cleaning processes, leading to improved drug formulation efficiency. The final solution met the customer’s specific needs, providing them with a reliable and tailored process for their niche application, and helping them to pursue their commitment to innovation, sustainability and patient wellbeing.
