Modular Solutions
Modularization
Modularization is a rational way to simplify and streamline the construction of a building or fabrication of equipment.
Modularization enables us to move the majority of the construction works from site to a dedicated fabrication workshop where the modules a prefabricated.
The success of prefabrication lies within the adoption of a manufacturing philosophy rather than a traditional construction philosophy.
Prefabrication in a dedicated workshop allows for much better control of the working environment which gives a much higher construction cleanliness.
Furthermore, the rational and industrial approach optimizes the material flow and use of resources which gives a very high predictability in delivery time and quality.
Pharmadule Morimatsu is applying the modularization concept not only to entire manufacturing facilities but also to process modules, production rooms, pipe racks, facility modules, clean room panels etc.
The modularization approach;
- Increases predictability
- Enhances safety
- Increases flexibility
- Optimizes the delivery time
MODULAR DRIVERS
TIME TO MARKET
Modular off-site construction gives you a unique opportunity to reduce the delivery time for your manufacturing facility. The possibility to compress the schedule by working with different activities in parallel can save 3-12 months compared to conventional construction (depending on project).
Shorter time to market
This approach gives your investment a faster return on investment and a higher net present value.
You can also use the shorter delivery time to defer your investment decision giving you more time for process development thus avoiding changes due to process modifications, and still meeting your market demand and return on your investment.
For us it's a matter of pride to be able to deliver faster than others - continuing to deliver the values that Pharmadule has been recognized for over the years.
PREDICTABILITY
Building your new manufacturing plant in a fabrication workshop gives you an unmatched predictability.
Our well-proven delivery model, based on our modular concept and off-site construction under controlled conditions, will ensure the success of your project.
Predictability is key for a successful project
High predictability ensures that you get your new pharmaceutical manufacturing facility up and running on time. It ensures your critical process systems perform as specified and that you are able to deliver on your commitment to patients.
Every capital project is a business-critical decision and the ability to predict the outcome is of utmost importance.
For us predictability means you get what you expect and when you expect it.
OFF-SITE FABRICATION
Modular fabrication minimizes risks. Our staff has extensive experience from the pharmaceutical industry. They are highly trained in pharmaceutical engineering and perform the fabrication indoors under controlled conditions with rational and effective working procedures in an assembly line manner under controlled industrial conditions.
While the manufacturing facility is fabricated in the workshop, the site preparations and foundation works on site are finished and municipal services put in place. When the modular plant arrives, it is quickly assembled, commissioned and validated.
75-80% of your facility is finalized in our workshop. This means that the work is carried out in a safe and controlled environment, away from the weather challenges and not depending on local resources thus reducing the project risk.
Our approach to integrated qualification leverages our efforts in the workshop to a maximum, drastically reducing time spent on-site.
Our modular concept has been recognized to provide our clients with:
- Faster project delivery
- Lower risk
- Predictable implementation
- Greater flexibility
WORKSHOP INSTALLATION
- After the modular steel frames have been blasted and painted, a concrete floor is poured to create a solid floor that absorbs loads and is comfortable to work on.
- Then installation of piping and HVAC duct works starts, followed by other installations.
- Wall panels are mounted and doors, windows and ceiling are installed.
- Process- and utility equipment are installed and systems can be test run in the workshop.
WORKSHOP INSTALLATION
- After the modular steel frames have been blasted and painted, a concrete floor is poured to create a solid floor that absorbs loads and is comfortable to work on.
- Then installation of piping and HVAC duct works starts, followed by other installations.
- Wall panels are mounted and doors, windows and ceiling are installed.
- Process- and utility equipment are installed and systems can be test run in the workshop.
WORKSHOP INSTALLATION
- After the modular steel frames have been blasted and painted, a concrete floor is poured to create a solid floor that absorbs loads and is comfortable to work on.
- Then installation of piping and HVAC duct works starts, followed by other installations.
- Wall panels are mounted and doors, windows and ceiling are installed.
- Process- and utility equipment are installed and systems can be test run in the workshop.
WORKSHOP INSTALLATION
- After the modular steel frames have been blasted and painted, a concrete floor is poured to create a solid floor that absorbs loads and is comfortable to work on.
- Then installation of piping and HVAC duct works starts, followed by other installations.
- Wall panels are mounted and doors, windows and ceiling are installed.
- Process- and utility equipment are installed and systems can be test run in the workshop.
WORKSHOP INSTALLATION
- After the modular steel frames have been blasted and painted, a concrete floor is poured to create a solid floor that absorbs loads and is comfortable to work on.
- Then installation of piping and HVAC duct works starts, followed by other installations.
- Wall panels are mounted and doors, windows and ceiling are installed.
- Process- and utility equipment are installed and systems can be test run in the workshop.
The modular concept - step by step
Based on the experience from delivering more than 80 facilities - the Modular Way - Pharmadule has a well developed delivery process to ensure the results you expect - On Time and On Budget.
PROCESS MODULES
The modular concept has not only been adopted to modular facilities, but also to process systems in the Life Sciences and Consumer Goods industries.
We provide complete process solutions, the modular way, from bioreactors and fermenters, through media/buffer preparation, harvest and purification, all the way to formulation, bio waste, and CIP systems.
Morimatsu’s “Extreme Modularization“ further maximizes off-site construction and help to reduce the site installation from weeks to days and sometimes just hours. The use of advanced technology and digital platforms, like virtual reality, 4D simulation, 3D scanning etc. have allowed us to facilitate faster site installation with benchmark projects that have accomplished record completion in our industry.
As one of the very few modular suppliers in the world, the strong combination of Pharmadule and Morimatsu offers a delivery of your total process modular solution from skids and process modules to highly integrated modular facilities for multiple industries.
INDOOR MODULES
In the dynamic landscape of pharmaceutical production, finding solutions that balance efficiency, compliance, and cost-effectiveness is crucial. Indoor modules offer a practical and streamlined approach tailored specifically to the needs of the pharmaceutical industry.
Indoor modules are a suitable option to rapidly build a new or expand an existing GMP facility. Pharmadule's indoor modules are installed inside a building, directly on the floor, recessed into the floor or on a support structure to create a installation space below.
Indoor modules provide a controlled environment that ensures the integrity of your processes. These modules are designed to meet stringent cleanliness standards, minimizing the risk of contamination and ensuring product quality and safety.
READ MORE
Dive deeper into our modular concept and explore the wide range of process systems we offer. Download brochures here: Resource Center
