Major redevelopment of world-leading pharma facility

When the Scottish subsidiary of global pharmaceutical giant decided the time was right for a multi-million pound redevelopment of the manufacturing area in its Dundee facility, it chose Denca to deliver the transformation of its system.

Investment in the future

As a market leader, at the forefront of animal healthcare innovation, manufacturing and distribution, this latest overhaul of their premises marks a substantial investment in improving the production process, offering greater flexibility within the system and also providing a degree of future proofing.

As a key element of the project, Denca Controls was awarded a contract, worth £500,000, to supply a complete control system, validated to demanding pharmaceutical standards, to fully automate the new manufacturing facilities. Denca’s scope of supply included hardware and software design, commissioning and validation support, plus control panel manufacture, E/I installation and instrument calibrations.

Ambitious plans

This was a large-scale project. A number of new manufacturing suites were built across two separate sections using client-specified product designations for ‘internal’ and ‘external’ applications, with the aim of maximising efficiency and also flexibility within a standardised system.

Each state-of-the-art manufacturing section is designed to operate hygienically and be able to be cleaned in place (CIP). Amongst the new hardware, each manufacturing area has a new vessel – one of 6,000 litres and the other 10,000 litres capacity – as well as new air compressors, dryers, filters and air receivers. The facility is serviced by a new purified water generation, which is to be continuously circulated around the building and accessed at a number of different points. Its will be constantly monitored for quality and critical parameters.

State-of-the-art solutions

Denca was able to provide and integrate the very latest automation controls along with new up-to-date hardware, supporting our client’s pioneering position within the animal healthcare sector and their drive to continually push forward,

The control system is based around a single Siemens S7-300 PLC with remote I/O modules and four operator stations, each containing a Siemens TP1200 Comfort Panel HMI. In addition, there are several package plants contained within the control arrangement, together with 11 user points.

Denca also specified, supplied and installed monitoring equipment and instrumentation, and integrated 10 control valves, 113 pneumatically operated block valves, 22 inverter controlled motors and five direct online controlled motors.

The complete project was delivered by Denca using our own, in-house staff and resources demonstrating our capability to deliver effectively at the highest level.

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