Pharmaceutical and Biopharmaceutical Modular Concept

Modularization lies at the core of Pharmadule Morimatsu’s replicable and well-proven delivery model. It is based on an off-site modular build concept that helps ensure consistent delivery of high quality facilities regardless of final location.

‘Prefabrication’ is sometimes confused with temporary or portable facilities. Its true application is part of a rational approach to industrialization that modularizes design and uses off-site pre-build to simplify and streamline workflows.

This rationale rejects the traditional artisan approach to construction in favour of a modern manufacturing methodology. This method carries three key advantages:

• It increases predictability over cost, schedule and quality
• It reduces delivery time
• It minimizes work at the final site, thus minimizing any disturbances on ongoing manufacturing

Modular Facilities
The Modular Concept has two main pillars: modularization and off-site fabrication;

Modularization
Modularization depends on thorough analysis of the various elements and uses of a building and expressing the outcomes in a ‘building block” design approach in which each principal element is manifested as a sub-unit that can be pre-manufactured and ‘plugged in on site to integrate into the overall project.

Thus Pharmadule has analyzed the needs of its customers to perfect basic designs for a series of commonly required modules. These include process modules, production rooms, pipe racks, facility modules, clean room panels etc.

Each module is capable of being specified or adapted to individual needs and preferences, in the same way as modern cars are built to individual customer specification so that vehicles are rarely identical.

Off-Site Fabrication
Also like cars, construction and personalization takes place in the factory, not on site. This is a much more cost-effective and controlled way of approaching the process that guarantees consistent high quality and on-time delivery.

Modular fabrication minimizes risks. Our staff applies extensive experience from the pharma industry and their high degree of training in pharmaceutical engineering to perform the fabrication indoors under controlled and ideal conditions, following rational and effective working procedures.

While excavations, foundations and services are being established on-site, 75 to 80 per cent of the actual construction, including all the most demanding high-tech and quality controlled aspects, are taking place in the Pharmadule factory.

When modules arrive onsite, they can be quickly installed and connected; integrated into an overall master design that already exists in 3D form.

Our approach to integrated qualification leverages our efforts in the workshop to a maximum, drastically reducing time spent on-site.

This means that the work is carried out in a safe controlled environment, away from the weather hazards and independent of third-party services or local resources thus drastically reducing project uncertainties and risk.

For more information about Pharmadule Morimatsu’s modular concept, please contact Pharmadule Morimatsu directly.