BES, the specialists in design and construction of technically complex environments, was the principal contractor on a recently completed new multi-million-pound state of the art inhaler manufacturing facility for Bespak, at its Holmes Chapel, UK, site.
Bespak a specialist global contract development and manufacturing organisation (CDMO) solely focused on the inhaled and nasal drug delivery industry – has expanded its production capacity following a significant upgrade to its existing facilities and the completion of a pristine new current good manufacturing practice (CGMP) Grade D cleanroom environment. The new premises house an additional high-speed commercial aerosol mixing and filling line, providing Bespak customers with access to greater manufacturing capacity for new low global warming potential (GWP) pressurised metered dose inhalers (pMDI), a response to increasing worldwide demand.
Pharmaceutical companies have been working to replace propellants used in pMDIs for several years. Regulations around the use of environmentally damaging propellants have been tightening, and this is reducing the production and consumption of the high GWP hydrofluorocarbons (HFCs) currently used in pMDIs. Consequently, low GWP pMDI manufacturing is in high demand, yet still in short supply, so this additional investment and expansion by Bespak will help support its customers in their transition to the use of greener propellants, helping plug the shortage of such facilities.
A fast-track turnkey design and build project led by BES involved the design, build and fit out of an extension to house a new filling line as well as a newly built sophisticated clean room to house bespoke mixing and filling equipment. BES developed a fully integrated digital Building Information Model (BIM) to aid project visualisation prior to starting and for reference throughout; reducing errors and speeding up the whole process. BES’s multidisciplinary team made very good progress in a challenging confined environment; such was the progress, Bespak gained access during the final completion phases, enabling staff training and prompt testing to begin. BES provided structural, architectural, mechanical, electrical, and process services, involving full filling line integration including purified water, process air, drainage, heating and cooling systems. A modular cleanroom system comprising partitions, glazing and ceilings was installed to deliver adaptable flexible space. The advantage of this Norwood system is that it allows spaces to adapt and change in the future without costly refurbishment.
Adam Brierley, BES project manager, commented: “The nature of our work is complex and demands close collaboration to succeed and without exception this project delivered on all counts. Working collaboratively with many contractors and suppliers – across the project we were coordinating c500 operatives and c50 subcontractors. Such close partnerships meant there were several benefits for the client, not least on timescales, enabling client access earlier than planned whilst the final construction stages were ongoing.”
Darren Hodkinson, Chief Operating Officer, at Bespak commented; “We are committed to leading the transition to low GWP propellants in pMDIs, and our expanded facilities will allow us to provide customers with an agile pathway to commercialisation at our Holmes Chapel site. The close collaboration with BES enabled a smooth and effective working relationship delivering certain phases ahead of schedule, enabling our site operations teams to start their preparation to go live on the line earlier than originally planned. Our customers will benefit from our drive to shorten timelines while maintaining excellence, facilitated in this case by our strong collaboration with BES.”
The fast-track nature and close collaboration of all involved in this project has been demonstrated by early completion of each stage of this complex design and build project. Bespak will start commercial production during 2025.
