Berenyi, a South Carolina-based industrial and commercial design-build firm, has concluded the construction and retrofitting of Symrise's Goose Creek, SC facility with a cutting-edge cleanroom environment.
This milestone achievement marks the completion of Symrise's inaugural fully automated filling station in North America, setting a new standard in automated cleanroom technology.
Berenyi's solution incorporated a system of positive air differential pressure control
Commencing construction in fall 2022 following the multi-year design phase initiated under Symrise's 2020 contract award, Berenyi's state-of-the-art facility was finalised in spring 2023.
The project's success is attributed to meticulous planning, advanced engineering methodologies, and strategic design implementations.
Using automation in a filling station
Symrise's newly established fully automated filling line operates within a pristine cleanroom environment to ensure product quality.
The facility's HVAC infrastructure utilises multiple fan coil units integrated into common return plenums over fill rooms
The sophisticated filling station supports a number of diverse packaging formats. Beyond mere filling operations, the system seamlessly handles palletising, labelling, and strapping of finished products without requiring human intervention.
Presently equipped with dedicated lines for filling drums, pails and IBC containers the facility boasts high capabilities and a unique design to facilitate future expansion, including potential incorporation of an additional filling line.
Ensuring cleanroom integrity
Maintaining the cleanroom environment while managing hazardous liquids and vapours posed significant technical challenges. Berenyi's solution incorporated a system of positive air differential pressure control, utilising interlocked high-speed roll-up doors and localised vapour extraction systems during the filling process.
The modular cleanroom's design incorporates cGMP-compliant, pharma-grade seamless wall panels, and robust metal paneling
In addition, HEPA filtration installed over the point of fill provides the cleanest possible air in the most relevant areas.
These measures ensure continuous positive pressurisation during operations, safeguarding against external contaminants and maintaining the facility's ISO Class 8 cleanliness standards.
HVAC system function
The facility's HVAC infrastructure, a cornerstone of its operational integrity, utilises multiple fan coil units integrated into common return plenums over fill rooms. Hybrid ducted systems manage material airlocks, optimising airflow dynamics to sustain positive pressure despite minimal makeup air requirements. This setup coordinates seamlessly with conveyor systems and interlocked doors, ensuring consistent environmental control throughout production cycles.
Hazardous vapour extraction
Integral to the facility's operational safety, localised extraction systems capture hazardous vapours emitted during filling processes. These systems, seamlessly integrated into the filling line's control framework, engage automatically during operations and deactivate upon completion.
Hazardous vapours are expelled through a filtered ducted system to exterior stacks, mitigating environmental impact.
Mezzanine structure support
Berenyi's design includes a purpose-built mezzanine platform supporting critical infrastructure such as HVAC equipment, electrical distribution systems, and the fire suppression system.
Hazardous vapours are expelled through a filtered ducted system to exterior stacks, mitigating environmental impact
This elevated structure optimises spatial efficiency while facilitating future maintenance access, enhancing operational resilience and longevity.
Additional strategic design elements
The modular cleanroom's design incorporates cGMP-compliant, pharma-grade seamless wall panels, and robust metal paneling capable of withstanding rigorous cleaning protocols, thereby ensuring a sterile environment conducive to pharmaceutical-grade manufacturing standards.
Additional features include ESD epoxy flooring with 4” flash coving, automatic doors and remote-controlled HEPA fan filter modules
Additional features include ESD epoxy flooring with 4” flash coving, automatic doors and remote-controlled HEPA fan filter modules.
Under slab plumbing
An innovative under-slab plumbing system was meticulously engineered to manage potential spills, featuring a network of pipes and drainage configurations integrated beneath the facility's existing slab. This system, designed with sealed connections, precise slope gradients, and durable materials, directs any spilled contaminants to a designated sump pit at the unloading station. An automated level switch activates a process wastewater pump, expelling waste to the designated treatment facility for safe disposal if a spill was to ever occur.
Aesthetic performance
While located within a conventional warehouse, the cleanroom facility complex incorporates the latest technology and modular cleanroom assembly methods. The overall fill room complex is a beautiful complex to see in person.
Expert insights and future prospects
Berenyi partnered with cleanroom contractor Ultrapure Technology to design and build the cleanroom suites.
Ultrapure Technology’s Cleanroom Projects Manager, David Lynch remembers: “Despite being a very complex cleanroom suite, the consistent collaboration between: Symrise, Berenyi and Ultrapure, (among others,) resulted in an extremely high quality, high performing project.”
HEPA filtration installed over the point of fill provides the cleanest possible air in the most relevant areas
Jordan Behringer, Managing Partner at Berenyi, emphasises the project's role in advancing design-build technology and setting new benchmarks in industrial automation and cleanliness. Collaborating with Symrise on this groundbreaking initiative underscores Berenyi's commitment to innovation and excellence in the manufacturing sector.
Conclusion
The completion of Symrise's fully automated cleanroom filling station by Berenyi, Inc. represents a monumental leap forward in industrial automation and cleanroom technology within North America. This state-of-the-art facility establishes a precedent for quality and efficiency in the global manufacturing landscape. As technological advancements continue to evolve and market demands grow, Berenyi looks forward to future collaborations that uphold these high standards of innovation and client satisfaction.