Project Aqua Pure — Final Integrated Proposal
D3/D4 master planning • ISPM all-in-one blow–fill • PIC/S engineering, validation and regulatory strategy
One coordinated vision—from site master plan to validated sterile production.
This visual proposal consolidates all available client drawings into a consistent concept for a modern IV manufacturing campus. It connects architecture, process, clean utilities, terminal sterilization, inspection, packing, warehousing and the 12-package engineering delivery framework.
Executive Overview & Campus Alternatives
Complete Project Overview Image Board
Large-format CEO presentation integrating the campus, PW/WFI, compounding, ISPM all-in-one blow–fill, terminal sterilization, inspection, packing and finished-goods logistics.
D3 Campus & External Architecture
Alternative master-plan expression showing complete site arrival, building massing, logistics and utility interfaces.
D3 Internal Manufacturing Features
Cleanroom circulation, production suites, compounding, sterile processing and warehouse environment.
D4 Campus & External Architecture
Preferred campus vision integrating administration, controlled logistics, utilities and finished-goods movement.
D4 Internal Manufacturing Features
Integrated personnel entry, compounding, ISPM filling, autoclaves, inspection, packing and high-bay storage.
ISPM, Compounding, Sterilization & Inspection
All-in-One Injection, Blow & Fill Line
Coordinated machine envelope, injection, blowing, sterile filling, sealing, discharge and service-side access.
Manufacturing & Holding — Twin 15T
Twin vessels, 3 m access platform, hygienic manifold, CIP/SIP strategy and utility interfaces.
Pass-Through Autoclave Suite
Loading and unloading logic, sterilizer carts, cooling, technical access and monitored clean/dirty separation.
Automatic Visual Inspection — 24,000 BPH
Infeed, inspection stations, camera-light systems, reject/recheck logic, HMI and electrical service access.
PW/WFI, Storage and Finished-Goods Automation
PW/WFI Generation & Distribution
Raw-water intake, pretreatment, RO/PW generation, WFI distillation, hygienic distribution and CIP integration.
10T & 20T Horizontal WFI Storage
Comparative tank arrangements, sanitary connections, instrumentation, drainability and maintenance access.
Integrated Inspection, Packing & Dispatch
Label and inspection, pillow/carton packing, robotic handling, weight verification, sealing and case dispatch.
Continue to the 12 Master Engineering, Validation & Regulatory Packages
Issued-for-Construction (IFC) Master Drawing Suites
Click Any Discipline Drawing Below12 Master Engineering, Validation & Regulatory Packages
Click Any Package Card Below To View Full SpecsPersonnel Change Room Architecture & Visual Renders
Grade D Outer PAL & Hand Wash Station
Sensor-activated hands-free wash basin, HEPA warm-air hand dryer, and Step-Over Bench (SOB 1). Sinks are restricted to Grade D only as per EU Annex 1.
Grade B/C Interlocked Gowning Airlock
Step-over bench (SOB 2 & 3), continuous filament sterile jumpsuit gowning, electromagnetic door interlocks with LED status lights, and sensor IPA hand rub.
CNC Outer Locker
Street clothing & outdoor shoe removal. Hairnet application.
Grade D Outer PAL
Step-over bench 1. Hand wash, HEPA dryer, Grade D coat & shoes. Sensor IPA rub.
Grade C Intermediate
Step-over bench 2. Non-linting jumpsuit, hood, goggles, clean boots & nitrile gloves. (No sinks).
Grade B Sterile PAL
Step-over bench 3. Sterile jumpsuit, sterile over-boots, sterile surgical gloves & IPA spray purge.
EU GMP Annex 1 & WHO TRS Compliance Rules
- No Sinks in Grade C/B: Hand washing sinks and HEPA dryers are strictly limited to Grade D PAL. Sinks forbidden in C & B changing rooms to prevent microbial contamination.
- Door Interlocks & Purge Timer: Electromagnetic interlocks prevent opening outer and inner doors simultaneously. 30–45s air flush cycle.
- Unidirectional Exit PAL: Separate Exit Personnel Airlock with reverse de-gowning sequence prevents cross-contamination.
195,050 sq. ft.
24,000 BPH
≥ 400 BPM
3,564 Pallets
Facility Scope & Capabilities
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Site Location: Butt Chemicals Pvt Ltd Campus (31.457280° N, 74.301440° E).
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ISBM Technology: Injection Stretch Blow Molding (ISBM) & Blow-Fill-Seal all-in-one production line.
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High-Speed Robotics: EFORT ER210-2700 6-axis industrial robot for automated carton palletizing.
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Pyrogen-Free Water System: Multi-effect distillation with 10-Ton & 20-Ton WFI storage tanks.
Key Cleanroom Zoning
Master Plan Comparison: AQI-D3 vs AQI-D4
Option AQI-D3 Architectural Layout
190,780 sq. ft. Total Footprint • 77,680 sq. ft. Production • Dual-train expanded shell layout.
Option AQI-D4 Architectural Layout
138,335 sq. ft. Total Footprint (-27.5% CAPEX) • High-density 3,564 Pallet Warehouse (+200% capacity).
Option AQI-D3 (Expanded Shell)
190,780 sq. ft. Total- Production Area: 77,680 sq. ft.
- Packing Hall: 21,400 sq. ft.
- Finished Goods Storage: 52,420 sq. ft.
- Pallet Capacity: 1,188 Pallets
- Best For: Multi-line future production expansions.
Option AQI-D4 (Compact & High Density)
138,335 sq. ft. Total (-27.5%)- Production Area: 36,275 sq. ft.
- Packing Hall: 10,000 sq. ft.
- Finished Goods Storage: 52,780 sq. ft.
- Pallet Capacity: 3,564 Pallets (+200%)
- Best For: Optimal CAPEX and high-volume buffer storage.
Equipment Bill of Quantities (BOQ)
| Tag | Equipment Name | Specification / Capacity | Qty | Cleanroom Zone | Utility Connections |
|---|
Central Engineering Utilities
Electrical Power
380V, 50Hz, 3-Phase 5-Wire System connected to control cabinets.
Compressed Air
DN15 connection, 6 – 8 bar operating pressure for solenoid valves.
Industrial Steam
3 – 8 bar operating pressure; requires dedicated condensate discharge.
Raw & Pure Water
DN50 raw inlet at 2–4 bar; SS316L loop distribution for PW & WFI.