Design, Construct, Validate and Maintain

Final product packing area

DSM Nutritional Products (DSM) is a leading global supplier of nutritional and speciality ingredients to food, beverage and dietary supplement manufacturers. The company creates, manufactures and markets innovative products and services, which are used in a wide range of nutritional and nutraceutical applications.

Background to the project

The existing Panthenol Packing Area within the DSM plant at Dalry required upgrading to meet DSM zoning requirements and improved Good Manufacturing Practice (GMP). GMP improvements include cleanliness, personnel and material flows and contamination control. This involved the full strip out of the existing packing area, to be replaced with the construction of a new packing room. The existing packing room was also extended to accommodate packing materials.

The project was split into two phases to minimise the duration of the shutdown of the packing area. The works outwith the packing room were undertaken in Phase One. These works included a new mezzanine floor to accommodate the extension of the packing room and a new external canopy. Phase Two of the project involved upgrading the existing packing room and therefore closing down production. It was important that the facility was complete and in production at the end of the shut down period. The entire facility was striped back to the perimeter walls.

Scope of the project

Two new packing areas and a palletising area were constructed to accommodate the new filling/palletising machines. Due to access limitation the machines were brought onto site midway through the construction period to allow the rooms to be completed. The filling areas were classified to Class ISO 14644-1 Class 8.

Two filling machines and a palletiser were supplied. The Bulk fill is capable of filling quantities from 20kg to 1000 kg, accurate to +/- 150kg into drums or IBCs. A HEPA zone is located above the filling head to reduce contamination entering the product. 

All machines are controlled by HMIs with batch data transferring to a central PC. The client can remotely access the data and print off the batch reports. The PC can be remotely accessed for maintenance.

Machines conform to the essential requirements of British and European standards and are CE marked supplied with an EC declaration of conformity or incorporation.

The scope of works also included the following:

  • Full strip out of existing packing area
  • Upgrade of changing areas
  • Steelwork and building work to create extension to packing area
  • Design and build of two filling rooms including air lock
  • Design and build of one palletising room
  • Design, installation and commission of two filling machines
  • Design, installation and commission of one palletising machine
  • FAT, SAT and Validation of process systems

Timescales

The project was completed on time and to budget.