Turnkey MEPF & Solar for Consern Pharma — Ludhiana — HVAC, Electrical, Plumbing, Fire Fighting, Low Voltage, Solar

Scope

• HVAC
• Electrical
• Plumbing
• Fire Fighting
• Low Voltage
• Solar

• In execution — turnkey MEPF + solar: HVAC, electrical, plumbing & public health, fire fighting, ELV and solar PV, under one execution team
• Multi-storey pharmaceutical facility, handed over floor by floor
• Client: Consern Pharma Limited — WHO-GMP certified formulations manufacturer with a DSIR-certified R&D facility; in pharmaceuticals since 1996, manufacturing since 2001 (consernpharma.com)
• Written progress and area-wise handover reporting to the client throughout

Engineering challenge

• Consern Pharma Limited, in its own account on consernpharma.com, began in 1996 as a pharmaceutical marketing company, set up its own manufacturing in 2001 and has since grown across psychiatry, neurology, cardiac, diabetic and skin-health segments. It reports WHO-GMP certified manufacturing, a DSIR-certified R&D facility, 547-plus formulations and three patents, a presence in ten-plus countries, and says more than 8,950 doctors trust its products.
• Its portfolio is led by a neuro-psychiatry (CNS) range — anti-anxiety, anti-depressant, mood-stabiliser, anti-migraine and cognitive products — alongside de-addiction, diabetic and cardiac care, a skin-care and dermocosmetics division, and nutraceuticals it lists as upcoming; it also offers contract manufacturing, distribution and R&D partnerships. The project is its multi-storey facility in Ludhiana: two blocks and a gatehouse inside one compound, as the render at the top of this page shows.
• A formulations plant is built around its air. Classified manufacturing areas need controlled temperature and humidity, filtered air at defined air-change rates and a pressure cascade from clean to less-clean rooms, so that dust from one product cannot reach another. The HVAC is a process system with a validation record, not comfort cooling, and it decides the size of the plant rooms, the shafts and the roof.
• Power has to hold the process. Air-handling units, compressors, granulation, coating and packing lines, quality-control instruments and the records they generate cannot see an interruption, so the distribution is planned around continuity, with standby and uninterruptible cover where the process demands it.
• Fire and water are layered risks in a pharma building. Raw-material and solvent stores, process floors, packaging and finished-goods warehousing each need their own detection and protection logic, and plumbing & public health has to keep potable water, process water, drainage and effluent on separate routes through a building where every penetration of a cleanroom wall is a controlled, sealed detail.
• Six trades, one team, in step with the civil works. HVAC, electrical, plumbing & public health, fire fighting, ELV and the solar PV plant are being delivered by Secured Engineers as a single turnkey package, phased so that each floor reaches handover standard in sequence as the civil works release it — with written progress and area-wise handover reporting to the client throughout.

Our solution

• HVAC: the air-handling and conditioning for the production floors and their supporting areas, with the classified zones’ filtration, air-change and pressure regime set out before the ductwork is routed.
• Electrical: the power distribution and the floor-wise feeds to process equipment, plant and lighting, planned around the continuity a pharmaceutical process demands.
• Plumbing & public health: water supply, drainage and effluent routing, with process and domestic streams kept apart.
• Fire fighting: the detection and fire-protection installation across stores, process floors and warehousing, designed for the materials each area holds.
• ELV: the low-voltage systems — detection and alarm, surveillance, access and data — cabled on routes coordinated with the power.
• Solar: a solar PV plant on the facility, tied into the electrical distribution it supplies, so that part of the plant’s daytime load is met on site.
• Floor-by-floor handover with the client, the civil contractor and the project management team; continuous quality inspections and safety monitoring; written area-wise reporting.

Approvals

Work of this scope typically runs through the following statutory approvals, which we manage end to end:

• CEIG approval — HT installations, DG sets and solar
• Fire NOC — the state process
• DISCOM net-metering

Outcome

• In execution. Floors are being completed and accepted in sequence, and integrated MEPF and solar infrastructure is being delivered across the facility, with written progress and area-wise handover reporting to the client throughout.
• Capacities — including the solar plant’s size — equipment makes, test and commissioning records and approvals are added to this record at handover; nothing is claimed ahead of that.

Lessons and engineering considerations

• Design the HVAC from the room classification outward. The grade of each area fixes its air changes, filtration and pressure relationship to its neighbours, and the air-handling plant, ducts and shafts are sized backwards from that schedule, not from floor area.
• Pressure cascades are commissioned, not drawn. Door undercuts, leakage, the order in which air-handling units start and the balancing of every return path decide whether the cascade on paper exists in the building — allow the time to measure and re-balance.
• Separate process power from building power, on the schedules and in the panels. A pharma plant’s critical loads — air handling, compressed air, quality control — need their own distribution and their own continuity provisions, visible to the operator, rather than being mixed into general lighting and power.
• Every penetration of a cleanroom wall is a detail to seal and sign off. Ducts, pipes, cable containment and sprinkler drops through classified walls are planned together, formed once, and sealed to the standard the wall is built to.
• Phase the MEP with the civil floor cycle. On a multi-storey plant handed over floor by floor, containment and first fix follow the slab cycle, plant rooms and risers go in before the finishes, and each floor is tested and accepted as a unit, so that no single floor holds the whole building.
• Put the solar plant into the roof and load study on day one. A pharma roof is contested by air-handling units, exhausts and tanks; the PV array needs its own clear area, cable route and a point of connection in the distribution that is designed, not found.