Sterile Products Plant for AstraZeneca at Macclesfield Campus

Sterile Products Plant for AstraZeneca at Macclesfield Campus

Client Requirement:

AstraZeneca required a new 5,000m² sterile products plant (SPP6) at their Macclesfield campus to produce life saving medicine. The project followed a Principal Contractor Alliance model with a target cost and pain/gain share agreement. The facility needed advanced equipment such as freeze dryers, autoclaves, washers, and filling isolation technology, along with adherence to the BES/BGEN BIM Implementation under the UK BIM Framework.

Our Solution:

BGEN was appointed as Principal Contractor, tasked with taking the design to BSRIA Stage 5 for construction. Our scope covered architectural, mechanical, HVAC, and electrical design, installation, and commissioning.

The new facility was constructed over three floors with each floor dedicated to specific elements. The building houses process rooms, ancillary, technical deck for service distribution and plant deck for air handling; all strategically located to ensure ease of maintenance and compliance to cGMP standard. With the ground floor areas divided into four categories to minimise contamination.

As the building was an open shell, we had the responsibility to construct each individual room using a pharmaceutical-grade partitioning system allowing future-proofing and scalable opportunities, complemented by the installation of air handling units, BMS, EMS systems to monitor and control environmental conditions along with safety systems including fire suppression, lighting and access control. Furthermore, we also installed the fume cupboards, laminar airflow booths, and cabinets ready for AstraZeneca to produce the life saving medicine.

Pre-fabrication was used to speed up on-site installation and early validation. Despite COVID-19 challenges, strict safety measures, including social distancing and PPE measures were successfully implemented to keep the project on track.

Client Benefits:

• Single point of contact to ensure client collaboration and management to ensure timely delivery.

• BGEN delivered a cutting-edge sterile products plant, meeting AstraZeneca’s requirements for sterility, efficiency, and sustainability.

• Advanced air handling and environmental systems ensure a controlled production environment, while pre-fabrication helps streamline construction.

• Despite pandemic challenges, the project was completed safely and on schedule.

• The project also supports community initiatives, reflecting BGEN’s commitment to social responsibility.

Additional information

Project Timescale:

The Contract specified the following key dates for completion:

• Start of Shell Construction April 2020

• Start of Shell fit out January 2021

• Fit Out Completion Sept 2023

Awards:

• During the construction phase BGEN and members of the construction team were awarded individual awards for displaying the highest competency for health and safety . This was recognised by Astra Zeneca during the AZ internal AZCAS awards ceremonies held on campus.

• In September 2024 the project won a prestigious building excellence regional award from the Local Authority Building Control Team (Cheshire East Council ) in the “Best non-residential new build category”.