The Challenge/ Complete an upgrade of major air handling units within a live manufacturing environment serving production critical areas within the GlaxoSmithKline Boronia site, including GMP Grade C Blow Fill Seal Filling Suites, as well as Manufacturing Rooms and general support areas.

Our Solution/ Project delivery was a very fast-track program and was further challenged by significant existing site constraints. To keep all existing pharmaceutical manufacturing processes uninterrupted, which would otherwise have resulted in significant loss of production costs, a new roof top plant room was built to accommodate the new mechanical plant including air handling plant and central boiler plant. All new works were designed and planned to be undertaken while keeping all existing services fully operational. The majority of commissioning tasks on the new systems were completed prior to cut-over. The cut-over process, including final ductwork connections, air balancing, final commissioning, automatic controls tuning and verification, had to be completed over a three day period during GSK plant shutdown which required a high degree of planning. The end result was a completed project that delivered outstanding results. Other than the marked minimisation of production downtime, the upgrade has also made significant improvements to energy efficiency, maintenance accessibility, room pressure and condition stability and also allows for future expansion of mechanical systems.


  • Shortlisted for 2016 AIRAH Awards in the Best HVAC&R Retrofit or Upgrade Award category

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