Construction and Assembly Management

Project reference: New construction of an active ingredient production facility

Planning a new production facility is complex and poses a number of challenges. This was also the case for a German manufacturer of biopharmaceutical active ingredients at its Austrian site, which had to master the construction of a new 8-storey production building, as well as additional storage, logistics and QA buildings. onoff was commissioned to supply and implement the complete EI&C assembly and instrumentation of the production facilities, as well as to implement a reporting system (CNS) and environmental monitoring system (EMS). The figures show just how complex this task was: onoff took over the construction and installation management of all trades with around 40 subcontractors and suppliers.

Project goals

Central monitoring of the production, laboratory and storage areas with an EMS monitoring system
Complete instrumentation, installation, commissioning and qualification of the automation for auxiliary systems (utilities)
Planning, engineering, delivery, installation and commissioning including qualification of the EMS monitoring systems

Modular automation system

Complete EMSR assembly and instrumentation

Project management and production support

Technical realization

Supply and manufacture of 400 RIO cabinets for Utilities and 3 EMS monitoring systems as well as 20 RIO cabinets
Delivery, assembly and cabling of 1,000 field devices for the automation of the EMS system and 3,640 field devices for the automation of utilities
Creation of circuit diagrams for the 3 EMS systems
Project planning for Experion application (EPKS), IQ implementation of EPKS automation
Creation, commissioning and qualification of 3 EMS monitoring systems with PCS 7
Creation, commissioning and qualification of the automation for the utilities area together with Honeywell automation system EPKS
Installation of a central notification system (CNS) for faults and safety instructions for employees on site

Project summary

Thanks to the smooth coordination of assembly and commissioning by the companies involved, the project objective was achieved without any significant delays in the individual trades.

Thanks to the modular automation system implemented by onoff, the customer is able to realize a highly flexible production of active ingredients for several products with short changeover times. As a result, production can react quickly to the respective customer and market requirements within a short period of time.