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;
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.
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.
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:
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.
In Detailed Design, all detailed specifications, shop drawings and installation drawings needed for fabrication and documentation of the facility are developed based on the approved Basic Design.
We finalize the 3D model (Building Information Modelling) with a single point of entry for all data for objects. Our integrated Enterprise Resource Planning (ERP) system allows full digital flow of engineering data throughout the project from start to end.
Fabrication of the modular building is performed indoors in the fabrication workshop. The fabrication follows rational and effective working procedures in an assembly line manner under controlled industrial conditions. Our staff has extensive experience from fabrication of pharmaceutical plants and are highly trained in pharmaceutical engineering.
Process- and utility equipment, piping and other important systems are readily installed in the modules. Since the modules are open frames installation can easily be done and equipment and material don't have to be maneuvered through doors
Once the installation is completed the modules are prepared for shipping. Loose items are marked and packed separately. Spool pieces are bar code marked and shipped within the modules. Equipment is braced to avoid movement during transportation. Each module is shrink wrapped and covered by a tarpaulin. Shipping is normally done by truck and boat.
The modules arrive well protected to the site and are assembled on the prepared foundation. The complete building can be set in 1-14 days depending on size.
At the site, the modular units are interconnected and hooked-up to electrical power, water mains, sewage system and utilities.
The commissioning and qualification activities start as soon as the modules has been set to ensure your facility will be up and running according to schedule.
Commissioning and qualification are carried out according to a Commissioning and Qualification Master Plan to secure that the systems work within defined system boundaries and in the final operating environment.
When the project is completed we make a walk-through and final inspection together with the client and the as-built final documentation is handed over in the Turn Over Package (TOP).
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.
Large scale formulation system for large volume parenteral solutions.
Custom designed and built purification system.
Large scale buffer preparation system with multiple tanks.
Transfer panels to be mounted through the wall for easy access of utilities in the cleanroom area.
Large, modular process installation for preparation of various shampoos, hair conditioners and other personal care products.