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Renovation of a Solid Dose Manufacturing Facility

Optimizing process flows, segregation, and maintainability.
  • Newly renovated warehouse space showing aisle and shelving units - Gannett Fleming.

    Renovations create a clean, secure environment for storing intermediate bulk material.

  • Renovation of a packaging area with an exposed ceiling and construction equipment - Gannett Fleming.

    Construction of a new tertiary packaging area separates clean filling operations from the warehouse.

  • Construction worker builds a cement block wall to create a new transition area within the plant - Gannett Fleming.

    Workers construct a new transition zone to improve clean-to-dirty material and personnel flow.

  • Large room used as a staging area for new ductwork and air handlers during construction - Gannett Fleming.

    New ductwork and air handlers installed throughout the facility improve efficiency and air quality.

  • Fork lift sitting under stainless steel hydrogen off-gas capture hood - Gannett Fleming.

    A dedicated fork truck charging station with hydrogen off-gas capture hood protects air quality.

  • View of the large dust collection equipment located on the exterior of the building-Gannett Fleming

    New dust collection system maintains a safe, clean environment while improving energy efficiency.

McNeil Consumer Pharmaceuticals

Lancaster, Pennsylvania

Our Role
Architecture, Program Management, Construction Management, Electrical, Structural, Mechanical, Plumbing, Commissioning, Qualification, Validation.

100,000 sq. feet
Construction Cost
$5 million
7 months
  • Increased productivity by improving process flows
  • Mitigated compliance risks by addressing segregation and maintainability issues
  • Minimized disruption to production during construction
  • Reduced potential contamination during packaging operation.

A Fortune 500 company, McNeil Consumer Pharmaceuticals produces a wide range of over-the-counter medicines trusted by people around the globe. The company’s Lancaster, Pennsylvania, facility was in need of renovations to improve efficiency and address compliance risks. 

Throughout a seven-month period that included a six-week production outage for the construction, Gannett Fleming worked with the company to provide an architectural and engineering solution that optimized process flows and addressed gaps with segregation and maintainability.

What We Did

From feasibility study through project completion, Gannett Fleming delivered architectural and engineering solutions on time and on budget to transform 100,000 square feet of manufacturing, administrative, and warehouse spaces within the facility. Services included project/program management; electrical, plumbing, fire protection, structural, HVAC engineering, and commissioning; and qualification and validation. 

By optimizing the flow of people, products, and materials through the manufacturing, packaging, and warehouse areas, the project team reduced the facility’s risk of non-compliance. Modifications also minimized potential contaminants during packaging operations.

Key Features

  • Redesign of gowning, zoning, and material transfer areas reduces potential contamination
  • Improvements to heating, ventilating, and air conditioning systems increase product/material segregation, as well as worker safety and comfort
  • Upgrades to building automation systems provide increased operational control and monitoring
  • Modifications to the water system ensure water supply meets United States Pharmacopoeia (USP) purification standards
  • Repair or replacement of floors, walls, and doors improves facility function and appearance.