Design & Engineering

At KeyPlants, we have extensive experience in developing our clients’ ideas and plans into a GMP-compliant facility design. Our  expert process architects and process engineers can take your project from feasibility studies and site master planning, through conceptual and basic engineering, to a fully-detailed construction documentation package. 

The Basic Engineering work will be based on the developed and agreed Concept Design. The main purpose of Basic Engineering is to refine the execution strategy, further develop the facility, process design and scope. This is supported by the development of design and execution documents, along with plans and specifications. In this way, we can estimate cost and time to project completion, to meet the requirements for the capital investment project application at your Board of Directors or Investment Committee.

Basic Design focus areas:

• Project planning towards business drivers and stakeholders’ requirements 
• Develop the Process design based on the selected concept 
• Refine utility energy consumption, energy capacities and future need for expansion 
• Develop building design and site 
• Further develop the execution plan and time schedule 
• Permitting 
• Automation design 
• Commissioning and Validation Planning 
• Site Planning 
• Initiate Construction Planning

We liaise with local engineering firms regarding compliance with local rules and regulations, and of course with our clients, taking on board their unique product knowledge; whilst maintaining full transparency in the design development.

Focus areas during basic design are site planning, layouts, defining technology and cost and schedule for the execution of the project. 

We provide worldwide experience, combined with over 20 years of hands-on expertise.

Our design expertise includes:

• Building Information Management Design (BIM) 
• Clean room design 
• HVAC 
• Mechanical Engineering 
• Electrical Engineering 
• Sustainability 
• Structural engineering 
• Life Safety

For modular projects, we execute the complete design. For conventional projects, we manage and work with partners in order to optimise the project team and provide added value. 

Proper site master planning is one of the most important factors in maximising return on capital investment and ensuring the long-term viability of a site.

When evaluating the feasability of a new project or site, or the refurbishment of an existing site/building, KeyPlants can provide valuable expertise to predict capital and manufacturing costs. We can support you in planning capital expenditures that will contribute to long-term financial success and maximise shareholder value.

Working in close collaboration with all stakeholders, we take critical issues such as site location, infrastructure, logistics and expandability into consideration. We also include the evaluation of energy, water usage, security, building location and layout, as well as production processes, Good Manufacturing Practice (GMP), material flow, warehousing, and personnel requirements, to create several concept options.

This results in an enhanced long-term site plan through the inclusion of multiple scheme scenarios. These contribute maximum cost effectivity and sustainability for our clients.
 

At KeyPlants, we offer process simulation and process optimisation studies for your batch or continuous processes. Process simulation is a computer model representing a unit operation, a process train, or an entire manufacturing plant.

As it’s a database model, you can quickly study process alternatives before risking capital expenditures. Proposals of optimised debottlenecking solutions for prioritised future plant requirements can be incorporated into the initial design, to achieve process flexibility and minimise overall capital cost.

Process Simulation can add value throughout the lifecycle of your new facility, from master planning debottlenecking and even day-to-day operations on existing site and operations.

We work with dynamic event-based plant simulation software tools that enable us, through efficient modelling efforts, to generate process operation timelines (Gantt charts) and resource histograms. When the model is developed, we have the expertise and experience to perform 'what-if' debottlenecking studies for the optimisation of complete trains, or equipment utilisation and the design of support systems. 

Protecting employees from exposure to dangerous agents and ensuring a correct GMP environment for the product during the manufacturing process, often requires the use of a combination of isolation technologies, proper air classifications, room and isolator pressurisation schemes, and personal protective equipment.

When making a Containment Study, we will help you define the strategy and select the technology solution you need to protect personnel, the product, and the environment, as required for your production.

First, we will define the overall requirements and justifications in a Containment Strategy, and assess the available technologies that may be employed according to the specific requirement. The strategy will be based on your operations and the Operator Exposure Limit (OEL) for your product.

At KeyPlants, SAFETY comes first. A plant failure that leads to personnel injuries, equipment and facility damage, or environmental implications, must always be prevented.

During the design development, our engineers can perform a safety risk analysis to identify all potential causes of failure, through a rigorous and systematic assessment of your facility, in order to find any weak points in your design.

We have the experience, and proven procedures in place, to perform an efficient risk analysis to identify the necessary measures needed to avoid, or mitigate, potential risks. Performing a safety study during the design phase will always pay off.