Oral solid dosage and packaging facility
Merck's expansion in China was its largest OSD facility outside Europe
About this project
Merck is a leading science and technology company in healthcare, life science and performance materials. The company expanded its footprint in China to grow the business in this vibrant economy.
This new oral solid dosage (OSD) manufacturing and packaging facility in Nantong was the company's largest outside of Europe.
The solution
PM Group provided full engineering, procurement and construction management (EPCM) for Phase 2 of the new oral solid dosage (OSD) manufacturing and packaging facility.
The scope of the Phase 2 project was to provide additional bulk tableting production and packaging equipment. At the same time modifications to the utilities needed to be made.
To meet the Phase 2 production capacity, the administration building was extended and the canteen was completely refitted and enlarged.
Construction around a live facility
The Phase 1 development involved the creation of a production train for registration batches. A key challenge for Phase 2 was how to work around this live GMP facility. Regulatory authority audits on Phase 1 continued throughout the construction period. Shut downs were minimised by the installation of a 'clean room within a clean room'.
This protected the live GMP facility and allowed the maximum level of production to continue during the build. With the HVAC modifications in place, we were able to guarantee regulatory compliance.
Health and safety innovation
Environmental Health & Safety was the central focus for both Merck and PM Group.
A key issue in this area was the safe installation of equipment on a very busy site without affecting the schedule.
"Our solution was to install a permanent three story lifting platform. This helped avoid a clash with site traffic and assisted in the safe management of the facility once in the operational phase.”
John Duggan
Director of Pharmaceuticals, Asia
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