About This Project

Thermo Fisher Scientific’s state-of-the-art sterile drug manufacturing facility is a 24,000 square metre beacon of innovation, not only as a testament to advanced engineering but also a crucial hub for the production of life-saving vaccines and therapies.

Equipped with a high-speed, fully automated aseptic fill-finish line, it caters to both small and large molecules, supporting the development and commercial manufacturing of critical healthcare solutions.

Producing over 30 million sterile doses a month, the facility not only bolsters global health initiatives but also employs more than 300 individuals, contributing significantly to the local economy.

The Challenge

The journey to operational excellence was paved with challenges, from partial demolition and reconstruction of existing structures to managing congested services.

The facility’s large steel water tank, essential for supplying the hydrant and sprinkler system, along with the incorporation of clean rooms, cold rooms, and an ESFR design for the storage system, demanded innovative solutions to ensure safety and compliance without compromising on efficiency.

The Active Fire Solution

To respond to these challenges, Active Fire implemented a customised integrated modular cabinet system to house all the fire protection equipment, alongside a PPVC pump module complete with a diesel tank.

This approach not only streamlined the installation process but also ensured a high level of reliability and adaptability for the facility’s fire safety infrastructure.

The Result

The adoption of Design for Manufacture and Assembly (DfMA) practices played a pivotal role in the project’s success, leading to a 30% reduction in costs by minimising material waste and optimising manufacturing processes.

The construction timeline was significantly accelerated, with schedules shortened by 60% due to improved team coordination and the efficiency of plug-and-play installations.

Quality assurance saw a remarkable improvement, with enhanced checks leading to a 95% reduction in installation errors and rework.

This meticulous attention to detail resulted in higher-quality fire protection systems, bolstering reliability and performance.

Moreover, the project’s commitment to sustainability was evidenced by a 30% decrease in environmental impact, underpinned by robust urban mining and recycling practices.

Overall, the significantly decreased project risks and lifecycle costs helped increase project ROI by 35%, enhance the asset value and provide Thermo Fisher Scientific a competitive advantage in the market.