Project Overview
A pharmaceutical client needed to expand its production capacity by implementing three new tablet coating systems to support company growth. However, the initial construction management (CM) design and budget made the expansion unfeasible, leaving critical equipment purchased but unused. The client turned to Horgan to salvage the project and develop a viable solution that would integrate the new equipment efficiently within an active production facility.
Key Achievements
Advisory & Planning
- Integrated Project Delivery (IPD) Approach: Horgan assembled a collaborative team consisting of the client, architect, engineer, manufacturing representatives, subcontractors, and vendors.
- Budget & Feasibility Analysis: Horgan reevaluated the project scope, providing cost-effective solutions to make the expansion financially viable.
- Fast-Track Project Development: A practical design, project estimate, and streamlined implementation strategy were developed to ensure feasibility and efficiency.
- Regulatory & Compliance Planning: Ensured adherence to pharmaceutical manufacturing standards, cleanroom requirements, and industry regulations.
- Vendor Coordination: Managed collaboration between stakeholders to align timelines and ensure smooth execution.
Construction
- Occupied Facility Execution: Work was performed in an operational, clean production facility, requiring strict coordination to avoid disruptions to ongoing manufacturing.
- Structural Engineering & Modifications: Designed and constructed a structural steel mezzanine to accommodate the new continuous coating systems.
- Cleanroom & Environmental Controls: Built controlled production spaces with proper ventilation, boiling, and cooling systems to meet manufacturing requirements.
- MEP (Mechanical, Electrical, and Plumbing) Upgrades: Infrastructure was modified to support the technical and operational needs of the tablet coating equipment.
- Risk Mitigation & Safety Measures: Implemented strategic planning to minimize risks while maintaining compliance with industry safety standards.
This is the first time that I know what is being done at this scale; people are talking about this at universities for years with input from pharma companies. Thomas Engineering has been making this machine for 20 years, and nobody has done this in the past in the pharma world. For us, the biggest impact would be speed to the market, with processing time from 39 days to about 8 days from a powered Granulation/ Blending/ Compression/ Coating. This process from start to finish is about 1 hour of process time in the past, it was weeks.”
– Director of Operations, Tablet Coating Facility
Outcome
Project Completed Within Budget: Through strategic planning and cost optimization, the expansion was delivered within the allocated budget.
100% Intended Design Execution: The final implementation fully supported the client’s production growth strategy, ensuring seamless equipment integration and increased manufacturing capacity.
By combining expert advisory, meticulous planning, and seamless execution, Horgan successfully transformed an unfeasible project into a fully operational, high-performing pharmaceutical production facility.
12-Month Turnaround: From Horgan’s onboarding to substantial completion, the project was executed efficiently within a year.
